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method of making chain mail

enmesh helices of different materials and dissolve one material
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Chain mail is an interesting type of fabric, having both strength and flexibility. The problem is its difficult to make.

Here's a simple way to make chain mail that would make mass production easy.

Step 1. make rings of two different materials. One material is strong, the other is soluble or having a low melting point (e.g. gallium).

Step 2. Stick rings in an alternating stack.

Step 3. Cut the ring stack axially

Step 4. Skew the ring stack so that one end of the first ring is adjacent one end of the next ring and so on. Attach the ends together (e.g. fuse with heat). This makes an alternating material helix.

Step 5. Stretch the helices.

Step 6. Enmesh helices (e.g. wind one helix through the next).

Step 7. Dissolve or melt the soluble material.

Step 8. Chain mail is formed.

See illustrations.

Could be used for very small chain links to make a smooth fabric. Could also be used to make 3 dimensional chain mail.

xaviergisz, Aug 31 2019

illustrations https://imgur.com/gallery/SW8NBRD
[xaviergisz, Aug 31 2019]

Chain matrix [xaviergisz, Aug 31 2019]

Welded chain mail glove (< $90) https://www.amazon..../dp/B000NNT2GW?th=1
[scad mientist, Aug 31 2019]

[link]






       3 dimensional chain mail would provide great protection against being stabbed through time.
pertinax, Aug 31 2019
  

       Sounds like you end up with all unclosed rings. There will continue to be a market for handmade chain mail, just because of that.
notexactly, Aug 31 2019
  

       I suspect that there are already automated methods of creating welded chain mail. Otherwise a butchers glove would cost much more than $90. [link] That looks like a good one made in Germany "with hermetically sealed micro plasma welds." There are a lot of cheaper ones as well, but I didn't look at them all to see if any of those were also welded.
scad mientist, Aug 31 2019
  

       Knitting machines are quite cleverly complex. Adding a weld at the right time seems trivial. But if your process mechatronics is simpler, you're onto a winner.
wjt, Aug 31 2019
  
      
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