Making the head has been a frustrating process of pursuing a line of creation only to end up at a dead end. Well not precisely a dead end. Each line of creation leads to a whole new branch of possibility but not necessarily the solution to my problem which is how to make flat plastic bend into a hemisphere. I made some terrific stuff like this flat hexagonal sheet made from recycled water bottles slightly heated and reformed. Made with a reverse vacuum forming technique. I thought of using a geodesic dome plan to make my patterns but the head is not a regular dome shape but is more elongated along one side. Moving slowly forward. More tests.
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