WO2016185445A2 - A silicone rubber fabric and a method of laser cutting thin pliable sheets to produce the fabric - Google Patents

Abstract

A laser cutting process is provided to manufacture intricate and complicated designs into thin pliable silicon rubber sheets that have been modified for aesthetic and olfactory properties and successfully demonstrated for integration as a component part of a product or for standalone use in the fashion, accessories and fragrance design industries. The manufacturing process depends on many interdependent factors including but not limited to the power output of the laser cutter, the cutting speed, the distance of the focal point of the laser beam of the laser cutter relative to the thin pliable sheet being cut, and the air pressure differential across the thin pliable sheet in the cutting chamber of the laser cutting machine. These laser-cut thin pliable sheets of silicone rubber can constitute a fabric.

Description

A SILICONE RUBBER FABRIC AND

A METHOD OF LASER CUTTING THIN PLIABLE SHEETS TO PRODUCE THE FABRIC

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from United States Provisional Patent Application No. 62/164,167 filed on May 20, 2015, which is incorporated herein by reference in its entirety.

FIELD

[0002] This specification relates to methods of laser cutting thin pliable sheets, and in particular to methods of laser cutting thin pliable sheets to produce a fabric.

BACKGROUND

[0003] Cutting fine features, with low tolerances, in materials can be challenging. The challenge is amplified when the material to be cut has low mechanical strength, as may be the case for thin pliable materials having a thickness of equal to or less than about 5 mm. Examples of pliable materials include elastomers such as rubber and the like. One possible cutting method is laser cutting, where the work piece is supported by a flat rigid work surface and a laser beam passes over the work piece and melts, burns, evaporates and/or otherwise ablates the work piece along predetermined cut lines.

[0004] However, laser cutting thin pliable sheets can be particularly difficult because the work piece can be subject to melting, burning, and/or heat distortion during the cutting process. Whether a thin pliable sheet can withstand laser cutting can depend on a number of inter-dependent parameters, such as the laser power and the speed of the cut. The techniques for laser cutting thin pliable sheets remain underdeveloped because it can be challenging to optimize the multitude of inter-dependent laser cutting parameters to achieve high quality cuts. In addition, many lower grade pliable materials such as rubber include chlorine-containing compounds which are released as chlorine gas or other noxious chlorine- containing byproducts during the laser cutting process. Some of these chlorine-containing byproducts have been shown to be carcinogenic, which has prompted workplace safety laws to restrict laser cutting of these lower grade pliable materials.

[0005] Moreover, laser cutting components for the fashion and accessories industry is

underdeveloped as these techniques or material specifications have not been applied at a commercial level. The laser machining industry does not report fashion as a vertical, and industry research shows although the industry will achieve a high category annual growth rate across all vertical industries the fashion industry is not counted among them. In addition, integrating laser-cut components into fashion and accessory design requires fabrication techniques that can be non-standard, and need to be successfully demonstrated in and optimized for commercial production.

[0006] In the areas of fashion materials and personal ornamentation, here is a need for new materials that can be safely used by a wide variety of people with different skin types and sensitivities. In addition, new materials are needed which are hypoallergenic, and are flexile in the sense of having properties and form factors that can be custom-specified according to fashion, design, and branding requirements. Many traditional materials lack this flexibility and also can have a tendency to exacerbate sensitivities in people who use and/or wear them. For example, many people are allergic to one or more of the metals commonly used in the manufacture of fashion accessories and apparel. In other cases, a person's biochemistry may be such that his/her perspiration quickly tarnishes an item made from various common metals and/or alloys. Some fabrics including leather contain chemicals that are irritants.

SUMMARY

[0007] The present specification provides a laser cutting process to manufacture intricate and complicated designs into thin pliable silicon rubber sheets that have been modified for aesthetic and olfactory properties and successfully demonstrated for integration as a component part of a product or for standalone use in the fashion, accessories and fragrance design industries. The manufacturing process depends on many interdependent factors including but not limited to the power output of the laser cutter, the cutting speed, the distance of the focal point of the laser beam of the laser cutter relative to the thin pliable sheet being cut, and the air pressure differential across the thin pliable sheet in the cutting chamber of the laser cutting machine.

[0008] Laser cutting medical and food grade silicone rubbers do not create hazardous gaseous byproducts because these rubbers do not contain chlorine. In addition, accessories, apparel or devices comprising finely laser-cut thin pliable sheets of medical grade silicone rubber can avoid many limitations of traditional materials because they can be biocompatible, hypoaller genie, moisture- resistant, and have lower density than metals, plastics and leathers commonly used for fashion accessories. Furthermore, these laser-cut thin pliable sheets of medical grade silicone rubber are flexible fashion materials because then can be fragrance- and/or color-matched according to design and branding specifications. Moreover, these laser-cut thin pliable sheets of silicone rubber constitute a fabric.

[0009] In this specification, elements may be described as "configured to" perform one or more functions or "configured for" such functions. In general, an element that is configured to perform or configured for performing a function is enabled to perform the function, or is suitable for performing the function, or is adapted to perform the function, or is operable to perform the function, or is otherwise capable of performing the function.

[0010] It is understood that for the purpose of this specification, language of "at least one of X, Y, and Z" and "one or more of X, Y and Z" can be construed as X only, Y only, Z only, or any combination of two or more items X, Y, and Z (e.g., XYZ, XY, YZ, ZZ, and the like). Similar logic can be applied for two or more items in any occurrence of "at least one ..." and "one or more..." language.

[0011] An aspect of the present specification provides a method of laser cutting a thin pliable sheet, the method comprising: securing the thin pliable sheet to a cutting bed by creating an air pressure differential between a first surface of the thin pliable sheet facing the cutting bed and a second surface of the thin pliable sheet opposite the first surface, the second surface facing away from the cutting bed; adjusting a power of a laser to a cutting range of about 45 W to about 80 W, the laser generating a laser beam; directing the laser beam onto the second surface of the thin pliable sheet; adjusting a position of the cutting bed to maintain the first surface at a focal point of the laser beam, the first surface maintained at the focal point to within a predetermined tolerance; and moving the laser beam relative to the thin pliable sheet along a predetermined cut pattern at a cutting speed in a speed range of about 5 mm/s to about 20 mm/s.

[0012] The method can further comprise: reducing the cutting speed in zones near portions of the predetermined cut pattern that specify a corner that is about 90o or sharper; and when the cutting speed is reduced, reducing the power of the laser to a reduced cutting range of about 40% to about 60% of the cutting range.

[0013] The air pressure differential can fall in a range of about 28 KPa to about 90 KPa.

[0014] During the moving, the air pressure differential can create air flow past the thin pliable sheet.

[0015] The zones can comprise a length along the predetermine cut pattern spanning 1 cm before and 1 cm after an apex of the corner.

[0016] The predetermined tolerance can comprises about half a thickness of the thin pliable sheet.

[0017] The method can further comprise: preparing the thin pliable sheet for cutting by covering with masking tape at least a portion of the second surface.

[0018] A diameter of the laser beam at the focal point can be less than or equal to about 1.5 mm. [0019] The thin pliable sheet can have a thickness equal to or less than about 5 mm. [0020] The thin pliable sheet can have a thickness equal to or less than about 2 mm. [0021] The laser beam can have a cutting kerf of less than or equal to about 2 mm. [0022] The laser beam can be configured to cut the thin pliable sheet at a minimum feature size of less than or equal to about 1.75 mm.

[0023] The method can further comprise: cutting a shape out of the thin pliable sheet by moving the laser beam along internal portions of the predetermined cut pattern inside of the shape before the laser beam moves along a peripheral portion of the predetermined cut pattern, the peripheral portion tracing a perimeter of the shape.

[0024] The thin pliable sheet can comprise a silicone rubber comprising one of food grade silicone rubber and medical grade silicone rubber.

[0025] The thin pliable sheet can further comprise one or more of a human-detectable fragrance and a human-visible dye, added to the silicone rubber.

[0026] The laser can be configured to pulse.

[0027] The laser can be configured to pulse in a frequency range of about 70 pulses per inch of cutting to about 110 pulses per inch of cutting.

[0028] The laser can have an average output power of about 65 W.

[0029] The speed can be in a range of about 6 mm/s to about 10 mm/s.

[0030] According to another aspect of the present specification there is provided a fabric comprising: a thin pliable sheet comprising a silicone rubber, the silicone rubber comprising one of food grade silicone rubber and medical grade silicone rubber, the thin pliable sheet having a thickness of less than or equal to about 5 mm, the thin pliable sheet laser cut according to the method of claim 1 to comprise a minimum feature size of less than or equal to about 2 mm.

[0031] The fabric can further comprise a human-detectable fragrance added to the silicone rubber before the laser cutting. [0032] The human-detectable fragrance can be added to a liquid precursor of the thin pliable sheet, the human-detectable fragrance added at a concentration of about 10 grams of human-detectable fragrance per about 500 grams of the silicone rubber.

[0033] The fabric can further comprise a human-visible dye added to the silicone rubber before the laser cutting, the human-visible dye added to a liquid precursor of the thin pliable sheet.

[0034] The fabric can further comprise another thin pliable sheet secured to the thin pliable sheet using Sil-Poxy Silicone Adhesive, the other thin pliable sheet comprising rubber.

[0035] The fabric can further comprise another fabric secured to the thin pliable sheet using a shoe glue, the other fabric comprising one or more of silk, cotton, wool, denim, and a stretch fabric.

[0036] The fabric can further comprise another fabric secured to the thin pliable sheet using a shoe glue and by sewing, the other fabric comprising one or more of silk, cotton, wool, denim, and a stretch fabric.

[0037] The fabric can further comprise another fabric secured to the thin pliable sheet by sewing performed by a Singer Stitch machine operating one of a 110/18 needle and a 80/12 needle and using one of a polyester thread and a nylon thread, the other fabric comprising one or more of silk, cotton, wool, denim, and a stretch fabric.

[0038] The fabric can further comprise another fabric secured to the thin pliable sheet by hand sewing, the hand sewing comprising: laser cutting a plurality of stitch holes in the thin pliable sheet, each stitch hole having a diameter of about 1 mm, each stitch hole spaced at least about 2 mm from its nearest neighboring stitch holes; and passing a thread through the other fabric and through two or more of the stitch holes. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] For a better understanding of the various implementations described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings in which:

[0040] Fig. 1 shows a flow chart summarizing a method of laser cutting a thin pliable sheet, according to non-limiting implementations.

[0041] Figs. 2a shows a schematic representation of a cut pattern, according to non-limiting implementations .

[0042] Fig. 2b shows a magnified region of the cut pattern of Fig. 2a.

[0043] Fig. 2c shows a top perspective view of a laser cut thin pliable sheet, laser cut according to the cut pattern of Fig. 2a.

[0044] Figs. 3a and 3b depict example cut patterns for ornamental objects, according to non-limiting implementations .

[0045] Fig. 4 depicts an exemplary method of determining operational parameters for laser cutting a given cut pattern in a thin pliable sheet of a given material and thickness, according to non-limiting implementations .

[0046] Fig. 5 shows a schematic representation of a cutting head of a laser cutting machine, according to non-limiting implementations.

[0047] Fig. 6 shows a schematic representation of a cutting head of a laser cutting machine, according to non-limiting implementations.

[0048] Figs. 7 and 8 show respectively two portions of a material properties table for silicone rubber. [0049] Fig. 9 shows a table depicting results of an extraction test of a sample of a silicone rubber thin pliable sheet.

[0050] Fig. 10 shows a photograph of the sample tested to produce the results shown in Fig. 9.

[0051] Figs. 11a and 1 lb show respectively top plan and side view photographs of an example silicone rubber fabric (shown in light color) glued to a wool fabric (shown in dark color), according to non-limiting implementations.

[0052] Figs. 12a and 12b show respectively top plan and side view photographs of an example silicone rubber fabric (shown in light color) glued and sewn to a stretch fabric (shown in dark color), according to non-limiting implementations.

[0053] Figs. 13a and 13b show photographs of an example silicone rubber fabric (shown in light color) sewn to a denim fabric 1310 (shown in dark color), according to non-limiting implementations.

[0054] Figs. 14a and 14b show photographs of an example silicone rubber fabric sewn to a thin pliable rubber sheet, according to non-limiting implementations.

[0055] Fig. 15a shows a top view photograph of an example silicon rubber fabric with laser cut stitch holes, according to non-limiting implementations.

[0056] Fig. 15b shows a top view photograph of the silicon rubber fabric of Fig. 15a hand stitched to another fabric, according to non-limiting implementations.

[0057] Fig. 16 shows an example silicone rubber fabric incorporated into a leather shoe as the tongue and instep of the shoe, according to non-limiting implementations.

[0058] Fig. 17 shows the pattern for the fabric of Fig. 16. [0059] Fig. 18 shows an example silicone rubber fabric used to form a front pocket of a hoodie, according to non-limiting implementations.

[0060] Fig. 19 shows an example silicone rubber fabric used to form the full back panel of a dress, according to non-limiting implementations.

[0061] Fig. 20 shows an example silicone rubber fabric incorporated as an insert into a denim jacket using heavy denim stitching, according to non-limiting implementations.

[0062] Fig. 21 shows an example silicone rubber fabric incorporated as a trim into a bikini top, according to non-limiting implementations.

[0063] Fig. 22 shows an example silicone rubber fabric incorporated into the ankle strap of a high- heel sandal, according to non-limiting implementations.

DETAILED DESCRIPTION

[0064] The described implementations in the present specification are intended to be examples and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the specification, which is defined solely by the claims appended hereto. In some laser cutting machines, the work piece to be cut is secured to a cutting bed. In case of a flexible work piece, such as a thin pliable sheet, this cutting bed can be rigid to support the work piece in a flat orientation. In some implementations, a thin pliable sheet can be any pliable sheet material having a thickness of equal to or less than about 5 mm. In other implementations, the thin pliable sheet can have a thickness of equal to or less than about 2 mm.

[0065] In some laser cutting machines, the cutting bed comprises a mesh or honeycomb structure which can allow for applying a suction pressure through the cutting bed to the sheet-shaped work piece. This suction pressure can be used to secure the work piece to the cutting bed. In other laser cutting machines, instead of and/or in addition to applying suction, i.e. reducing pressure, at one surface of the thin pliable sheet, an overpressure of air can be applied to the opposite surface of the thing pliable sheet facing away from the cutting bed. This overpressure can also exert a force to press and secure the thin pliable sheet to the cutting bed. Generally, then, to secure the thin pliable sheet to the cutting bed an air pressure differential can be created between a first surface of the thin pliable sheet facing the cutting bed and a second surface of the thin pliable sheet opposite the first face and facing away from the cutting bed. It is also contemplated that the gas used to create the overpressure need not be limited to air, and any other suitable gas or mixture of gases can be used, including but not limited to nitrogen, C0₂, argon, and other inert gases.

[0066] In some implementations, the laser cutting machine can be a table-top laser cutting machine with a laser peak pulsed output power of about 100 W, or 50-60 W not pulsed. The laser beam used to cut the work piece can be generated by any suitable source including, but not limited to, a C0₂ laser, a neodymium laser, a yttrium-aluminum-garnet laser, or a fiber laser. The power and/or intensity output of the laser beam can be controlled, which in turn can control the amount of power transferred to the work piece and the resulting cutting temperature in the work piece. The laser beam can be passed through optics for directing the beam and/or for collimating and/or focusing the beam. These optics can include, but are not limited to a focus lens. In case of a C0₂ laser, the effective power output of the laser may decrease as the laser ages.

[0067] In cases where the laser has a fixed frequency, the amount of power output by the laser can be controlled by adjusting the intensity of the laser beam. In the case of pulsed lasers with a fixed frequency, the average power output of the laser can be controlled by adjusting the pulsing frequency (i.e. the duty cycle) as well as adjusting the laser beam intensity.

[0068] The laser cutting machine can move the laser beam relative to the work piece according to a predetermined design which specifies the cut pattern along which the work piece is to be cut. The laser cutting machine can move the laser beam, the work piece, or both. The design can also specify when the beam is to be turned on and/or off. In some machines the laser beam can be pulsed, and the frequency of the pulsing and/or the duty cycle can be adjusted.

[0069] Fig. 1 shows an example implementation of a method 100 for laser cutting a thin pliable sheet. In step 105, the thin pliable sheet can be secured to the cutting bed of a laser cutting machine by creating an air pressure differential between the first surface of the thin pliable sheet facing the cutting bed and the second surface of the thin pliable sheet opposite the first surface, the second surface facing away from the cutting bed.

[0070] In some implementations, the pressure differential can be created by applying an overpressure in the cutting chamber and against the second surface of the thin pliable sheet. The pressure against the second surface can be in the range of about 130 KPa to 190 KPa. In some implementations, the pressure differential can be in the range of about 28 KPa to about 90 KPa. This pressure differential can also create air flow (or other gaseous flow) past the thin pliable sheet as it is being laser cut. This air flow can cool the thin pliable sheet and allow it to harden more quickly during and after the laser cutting. This in turn can reduce the likelihood of damage to the thin pliable sheet by thermal deformation or burning. In addition, the air flow can clear any gaseous byproducts of the laser cutting out of the cutting chamber, thereby reducing the likelihood of these products contaminating the thin pliable sheet.

[0071] A pressure differential that is too high can cause the thin pliable sheet to deform; for example, a thin pliable sheet under high suction applied through or overpressure applied over a honeycomb cutting bed may assume an undulating surface following the honeycomb shape of the cutting bed. A pressure differential that is too low may be insufficient to secure the thin pliable sheet to the cutting bed, allowing excessive movement of the thin pliable sheet during the laser cutting process. Such excessive movement can interfere with an accurate cut, as the thin pliable sheet can move

unpredictably relative to the laser beam. The pressure differential can be adjusted to account for parameters including but not limited to the nature of the material being cut, the thickness of the thin pliable sheet, and the structure of the cutting bed.

[0072] The pressure differential can also be adjusted based on the area of the thin pliable sheet and the area of the shape to be laser cut from the sheet. For example, in the case of suction, since suction pressure is measured as force per unit area, a given suction pressure secures a sheet of larger area with a larger force. As such, a relatively smaller suction pressure may be sufficient to secure sheets and shapes of larger area. [0073] In step 110, the power of the laser can be adjusted to a cutting range of about 45 W to about 80 W in the case of continuous laser beams. The higher the laser power, the more energy it will transfer to the thin pliable sheet, and the higher the cutting temperature will be. Adjusting the laser power can allow for adjusting the cutting temperature and reducing the likelihood of excessive cutting

temperatures burning, melting, or otherwise thermally damaging the thin pliable sheet. On the other hand, a cutting temperature that is too low can result in unsuccessful or incomplete cuts, and/or in the cutting process taking longer than necessary.

[0074] The amount of power transferred by the laser to the thin pliable sheet also depends on the cutting speed: the faster the cutting speed, the lower the energy transferred to any given region of the thin pliable sheet. As such, for a given cut pattern and a given thin pliable sheet, the laser power and the cutting speed can be adjusted together to produce a cutting temperature that can produce high quality laser cuts. For laser types whose effective power output declines over time, e.g. C0₂ lasers, the nominal power setting can be adjusted for the age of the laser to maintain a consistent effective power output.

[0075] In some implementations, the focus of the laser beam can also affect the cutting temperature, the heat distribution in the thin pliable sheet, and quality of the laser cut. A laser beam tightly focused at or near the surface of the thin pliable sheet can deliver more power to a smaller area and create a higher localized cutting temperature. A less tightly focused laser beam, in turn, can create lower and less localized cutting temperatures. In addition, a more tightly focused laser beam can also have a smaller cutting kerf (described in greater detail below) and can cut finer features in the thin pliable sheet.

[0076] In some implementations, the laser beam can be pulsed. When the laser beam is pulsed, the average power output of the laser can be about 65 W. The pulsing can be in the frequency range of about 70 pulses per inch of cutting to about 110 pulses per inch of cutting. The pulsing can allow for reducing the cutting temperature when using a higher power laser. Reducing the pulsing frequency can allow for less laser energy to be delivered to the thin pliable sheet per unit time, and can reduce the rate of heating of the thin pliable sheet by the laser beam. In many materials, a greater peak pulse "ON" power will result in quicker vaporization of the work piece material and a cleaner cut with less heat being imparted to the work piece material near the cut. In other words, high peak pulse power can result in reduced damage to the Heat Affected Zone in the work piece.

[0077] In step 115, the laser beam is directed onto the thin pliable sheet to commence the laser cutting. The laser beam is directed onto the second surface of the thin pliable sheet, i.e. the surface that faces the laser beam and faces away from the cutting bed.

[0078] In step 120, the position of the cutting bed can be adjusted to maintain the first surface of the thin pliable sheet at the focal point of the laser beam. The first surface can be maintained at the focal point to within a predetermined tolerance. In some implementations, the predetermined tolerance can comprises about half a thickness of the thin pliable sheet. In other implementations, the predetermined tolerance can comprise about the thickness of the thin pliable sheet. In yet other implementations, the predetermined tolerance can comprise about one quarter of the thickness of the thin pliable sheet.

[0079] While the above description discusses maintaining the first surface at the focal point, in other implementations, the cutting bed can be adjusted to maintain any other part of the thin pliable sheet at the focal point of the laser beam. For example, the second surface of the thin pliable sheet can be maintained at the focal point, or the mid-point between the first surface and the second surface can be maintained at the focal point.

[0080] Maintaining the laser beam' s focal point consistently at a predetermined portion of the thin pliable sheet can increase the likelihood of producing laser cuts of consistent and high quality. If the cutting bed of the laser cutting machine, or the thickness of the thin pliable sheet, happen to be uneven, the cutting bed can be adjusted continuously during the laser cutting process to maintain the predetermined portion of the thin pliable sheet (e.g. the first surface) at the focal point of the laser beam. In some implementations, adaptive optics can be used to move the focal point of the laser bream instead of and/or in addition to adjusting the cutting bed.

[0081] In step 125, the laser beam can be moved relative to the thin pliable sheet along a

predetermined cut pattern at a speed in the range of about 5 mm/s to about 20 mm/s. In some implementations, the laser beam can be moved relative to the thin pliable sheet along a predetermined cut pattern at a speed in the range of about 6 mm/s to about 10 mm/s. A speed that is too low can cause overheating, thermal distortion, melting, and/or combustion of the thin pliable sheet. A speed that is too low can also unnecessarily lengthen the cutting process. A speed that is too high can fail to cut through the thin pliable sheet, or can create a cut line with a surface roughness that is too high. In some implementations, the speed can be different in different portions of the pattern. The speed can be adjusted to account for factors including, but not limited to, the nature of the material being cut, the thickness of the sheet, the cutting temperature, and the cut pattern.

[0082] While Fig. 1 shows a particular order of steps in method 100, it is also contemplated that the steps of method 100 can be performed in any other suitable order.

[0083] Hence, an implementation of method 100 for laser cutting a thin pliable sheet can comprise: securing the thin pliable sheet to the cutting bed by creating the air pressure differential between the first surface of the thin pliable sheet facing the cutting bed and the second surface of the thin pliable sheet opposite the first surface, the second surface facing away from the cutting bed; adjusting the power of the laser to the cutting range of about 45 W to about 80 W; directing the laser beam onto the thin pliable sheet; adjusting the position of the cutting bed to maintain the first surface at the focal point of the laser beam, the first surface maintained at the focal point to within the predetermined tolerance; and moving the laser beam relative to the thin pliable sheet along the predetermined cut pattern at the speed in the range of about 5 mm/s to about 20 mm/s.

[0084] In some implementations, method 100 can further comprise reducing the cutting speed in zones near portions of the predetermined cut pattern that specify a corner that is about 90° or sharper, and when the cutting speed is reduced, reducing the power of the laser to a reduced cutting range of about 40% to about 60% of the cutting range.

[0085] In some implementations, the speed is reduced near corners that are about 75° or shaper. In other implementations, the speed is reduced near corners that are about 60° or shaper. These corners can comprise sharp vertexes, such as a vertex of a square or equilateral triangle. The corners can also comprise curved corners. [0086] In some implementations, the speed reduction near these corners can be a reduction of the cutting speed by about 20%, by about 40%, or by about 60%. It is also contemplated that the speed reduction can be by an amount different than 20%, 40%, and 60%. The speed reduction can allow for obtaining more cleanly cut corners. In the case of vertexes, the reduced speed can allow for cutting more sharply-defined vertexes. As the cutting speed is reduced, the laser power can also be reduced to prevent overheating the thin pliable sheet being cut.

[0087] The zones near the corner can comprise a length along the predetermine cut pattern spanning 1 cm before and 1 cm after an apex of the corner. In other implementations, the zones can comprise a length along the predetermine cut pattern spanning 0.5 cm before and 0.5 cm after an apex of the corner, or a length along the predetermine cut pattern spanning 2 cm before and 2 cm after an apex of the corner. In some implementations, the apex can comprise a point along the corner in the cut pattern before which point the slopes of tangents to the cut pattern have a different sign than the slopes of the tangents to the cut pattern after the apex. In other words, the apex of a corner can be the point on the cut pattern of that corner where the slopes of the tangent lines to the cut pattern change sign.

[0088] In some implementations, the thin pliable sheet can undergo preparation before commencing laser cutting. The preparation can include the step of covering, entirely or partially, one or more surfaces of the thin pliable sheet with a masking tape suitable for use in the laser cutting process. The covered surfaces can comprise one or more of the first surface and the second surface. In some implementations, masking tape can be used to cover a portion of the second surface of the thin pliable sheet that is exposed to the laser beam.

[0089] The masking tape can protect the surface of the thin pliable sheet from sparks and other high temperature debris that can be created as a by-product of the laser cutting. Such debris can scorch, burn, or otherwise damage or deface the surface of the thin pliable sheet. A suitable masking tape can be of a type that detaches from the thin pliable sheet without leaving a residue. The masking tape can also be selected to resist burning during the laser cutting. Applying one or more layers of masking tape to one or more surface(s) of the thin pliable sheet can add mechanical stiffness to the thin pliable sheet to enhance the sheet's ability to remain flat under the air pressure differential and to minimize the sheet's deformation during the laser cutting process. [0090] In some implementations, the thin pliable sheet can have a thickness of equal to or less than about 5 mm. In other implementations, the thin pliable sheet can have a thickness of equal to or less than about 3 mm. In yet other implementations, the thin pliable sheet can have a thickness of equal to or less than about 2 mm. In some implementations, the thin pliable sheet can be a laminate of different layers of the same or different materials.

[0091] In some implementations, the thin pliable sheet can comprise a composite material. The thin pliable sheet can comprise any material that is pliable because of the pliability of the material and/or because of the thinness of the sheet. In some implementations, the thin pliable sheet can comprise an elastomeric material. The thin pliable sheet can comprise material including, but not limited to, silicone rubber comprising food grade silicone rubber or medical grade silicone rubber. Silicone rubber can be hypoallergenic and safe and durable for being worn against the human skin.

[0092] In some implementations, the silicone rubber thin pliable sheet can further comprise one or more of a human-detectable fragrance and a human-visible dye/color, added to the silicone rubber.

[0093] As discussed above, the laser cutting device can comprise a focus lens that focuses the beam at the focal point. This lens can allow for cutting fine and very precise designs. Each lens has a predefined focal point. In some implementations, the cutting bed of the laser cutting device can be adjusted to remain at the focal point. The cutting bed of a laser cutting device can be adjusted and depending on what is being cut, it can be adjusted to below or above the focal point. Adjusting the cutting bed above or below the focal point can result in dispersed energy when contacting the thin pliable sheet. This can reduce precision as the cross-section of the laser beam is larger at the point of contact with the thin pliable sheet.

[0094] Every laser cutting machine can require its own adjustments because over time due to wear and tear of the machine, different areas of the cutting bed might have different heights and this must be accounted for prior to initiating the cutting process. In the case of silicone rubber, the dispersed laser energy that is not powerful enough to cut the material, may alter the chemical composition of the silicone rubber, due to the addition of energy to break atomic and molecular bonds within the atomic structure of the material. It may also change the hardness of the silicone rubber. All of these alternations can result in unintended and/or inconsistent laser cutting results.

[0095] Figure 2a shows an example shape 205 to be cut out of a larger thin pliable sheet 245. The shape 205 is defined by cut pattern 200. In laser cutting shape 205, a laser beam travels along cut pattern 200 to cut shape 205 out of thin pliable sheet 245. Cut pattern 200 can have a peripheral portion 210, which traces along the outer perimeter of shape 205. Cutting along peripheral portion 210 would detach shape 205 from thin pliable sheet 245. Cut pattern 200 can also have one or more internal portions 215, which are situated inside shape 205. Cutting along internal portions 215 would not detach shape 205 from thin pliable sheet 245. Cutting along internal portions 215 of cut pattern 200 can, however, release cutout portions 240.

[0096] In some implementations, when cutting shape 205 out of thin pliable sheet 245, the laser beam can cut along internal portions 215 of the cut pattern 200 inside of shape 205 before cutting along peripheral portion 210 of cut pattern 200. This allows shape 205 to remain attached to sheet 200 as long as possible during the cutting process. This, in turn, can have the advantage of keeping available more of the material of thin pliable sheet 245 to act as a heat sink for as long as possible. Having such a larger heat sink can reduce the likelihood of shape 205 undergoing excessive thermal distortion during the cutting process. A further advantage can be that thin pliable sheet 245 has a larger area than shape 205, allowing for a larger air pressure differential force to secure the material being cut to the cutting bed. This higher air pressure securing force can reduce the likelihood of shape 205 moving excessively relative to the cutting bed during the laser cutting. The higher air pressure securing force can also reduce the air pressure differential necessary to secure shape 205 during the cut.

[0097] In some implementations, the cutting can start at or near the centre of the cut pattern and move outwards towards the outer perimeter of the cut pattern. The centre of the cut pattern can comprise the midpoint of two diagonal lines inside an imaginary rectangle surrounding the design of the cut pattern. Alternatively and/or in addition, the center can comprise the center of a circum-circle, circum- quadrangle, or minimum bounding circle of the cut pattern, and/or the center of mass of the planar shape defined by the outer perimeter of the cut pattern. [0098] To reduce localized heating of a given region of shape 205, the laser beam can skip from a first region 220 to a second region 225, to allow first region 220 to cool while the beam cuts along the cut pattern 200 within second region 225. In case of regions that have relatively more closely-spaced and/or more numerous details to be cut, for example first region 220, the laser beam can skip away to a second region 225 and return to first region 220 multiple times to allow first region 220 to cool each time before continuing cutting in first region 220. This can allow for cutting to continue in second region 225 while first region 220 cools. The selected regions can be of any size or location so long as they are sufficiently spaced apart to allow for the thin pliable sheet in a region to cool sufficiently while the laser beam is cutting in another region.

[0099] Figure 2b shows a magnified region of Figure 2a. Length 230 can represent the minimum feature size of shape 205. Minimum feature size can be the width of the narrowest strip of the thin pliable sheet that can be achieved by laser cutting two parallel lines, shown as parallel lines 250 and 255 in Figure 2b. The minimum feature size can be influenced by the material composition of the thin pliable sheet, the sheet thickness, the laser power, and the cutting speed. In some implementations, the minimum feature size can be less than or equal to about 2 mm. In other implementations, the minimum feature size can be less than or equal to about 1.75 mm.

[00100] Length 235 can represent the width of the narrowest slit with parallel sides that can be cut into thin pliable sheet 245. Length 235 is theoretically bounded at the lower limit by the cutting kerf of the laser beam; however, the narrowest parallel slit may in practice be larger than the kerf, as the kerf alone can be too narrow to define a sufficiently distinct open slit. The kerf can be influenced by the diameter of the laser beam, the laser power, the cutting speed, and the nature of the material being cut. In some implementations, the kerf can be less than or equal to about 2 mm. In other implementations, the kerf can be less than or equal to about 1 mm. Regarding the diameter of the laser beam, in some implementations, the diameter of the laser beam at its focal point can be less than or equal to about 1.5 mm. In yet other implementations, the diameter of the laser beam at its focal point can be less than or equal to about 1 mm.

[00101] Fig. 2c shows a top perspective view of shape 205 cut out of thin pliable sheet 245 (shown in Fig. 2a). [00102] The laser cutting methods described herein can find applications including, but not limited to, creating stand-alone fashion items, fashion accessories, fabrics for apparel and other uses, ornamental objects, and medical devices. Figures 3a and 3b show example cut patterns for ornamental objects: Figure 3a shows a cut pattern for an object that can be worn as a bracelet. Figure 3b shows a cut pattern for a necklace. Examples of other uses are described in detail below.

[00103] In some implementations, laser cutting parameters of cutting temperature (controlled partly by laser power), cutting speed, and the suction pressure securing the thin pliable sheet to the rigid backing can be different depending on factors including, but not limited to, the nature of the material of the thin pliable sheet, the thickness of the thin pliable sheet, and density and minimum feature size of the cut pattern. Figure 4 shows an example method 400 for determining operational parameters for laser cutting a given cut pattern in a thin pliable sheet of a given material and thickness.

[00104] In step 405, an assessment can be made as to whether the cutting temperature is lower than the thin pliable sheet's combustion temperature. If the determination in 405 is negative, then method 400 can move to step 410 where the intensity and/or power of the laser beam can be reduced in order to reduce the cutting temperature. Method 400 can then return to step 405 to assess whether the cutting temperature has been reduced to below the combustion temperature.

[00105] If the assessment in step 405 is affirmative, method 400 can move to step 415, where an assessment can be made as to whether the thin pliable sheet is excessively thermally distorting during the cut. If this determination is affirmative, method 400 can move to step 420 where the speed of motion of the laser beam relative to the thin pliable sheet can be increased. Then method 400 can return to step 415 to reassess for excessive thermal distortion. A level of distortion can be deemed excessive if it prevents the laser cutting machine from reproducing the cut pattern in the thin pliable sheet within predetermined tolerances.

[00106] If the assessment in step 415 is negative, then method 400 can move to step 425 where an assessment can be made whether the quality of the cuts being made by the laser beam is acceptable. The cuts can be assessed for smoothness. The cuts can also be assessed for whether they have edges that are flush with the surface of the sheet. If the determination at step 425 is negative, then method 400 can move to step 430, where the speed of motion of the laser beam can be reduced. Then method 400 can return to step 415 to repeat the determinations of thermal distortion and cut quality.

[00107] If the assessment in step 425 is affirmative, method 400 can move to 435 where a

determination can be made as to whether the thin pliable sheet is distorting excessively under the suction pressure. If the determination in step 435 is affirmative, then method 400 can move to step 440 where the suction pressure can be reduced. Then method 400 can return to step 435 for a

redetermination of distortion under suction pressure. A level of distortion can be deemed excessive if it prevents the laser cutting machine from reproducing the cut pattern in the thin pliable sheet within predetermined tolerances.

[00108] If the assessment in step 435 is negative, then method 400 can move to step 445 where an assessment can be made as to whether movement of the thin pliable sheet relative to the backing is sufficiently small to allow for an accurate cut that reproduces the cut pattern in the thin pliable sheet within predetermined tolerances. If the determination in step 445 is negative, then method 400 can move to step 450, where the suction pressure can be increased. Then method 400 can return to step 435 where assessment for excessive distortion and movement are repeated. When the determination at step 445 is affirmative, method 400 can then move to step 455 where parameters of laser beam intensity and/or power (affecting cutting temperature), cutting speed (also affecting cutting temperature), and suction pressure are recorded for later use. The parameters recorded at step 455 can represent one set of operational laser cutting parameters for the given thin pliable sheet material, sheet thickness, and cut pattern.

[00109] In other variations of method 400, not shown, steps 435, 440, 445, 450 can be completed before step 405, or after completing steps 405, 410 but before step 415.

[00110] Persons skilled in the art would understand from the foregoing disclosure that the laser cutting parameters can be inter-dependent. In particular, cutting temperature and cutting speed can be interdependent. The implementation of method 400 shown in Figure 4 starts by adjusting the temperature, and then adjusts the cutting speed based on the cutting temperature. In other implementations, not shown, the cutting speed can be adjusted first, and the cutting temperature adjusted based on the cutting speed.

[00111] Persons skilled in the art would also understand that the methods described above, particularly in relation to cutting temperature and/or laser power, speed, and cut pattern, can apply also to non- pliable and/or rigid thin sheets.

[00112] Fig. 5 shows a schematic drawing of laser cutting machine head where the laser beam is focused onto a thin pliable sheet of rubber using a focus lens, a.k.a. a focal lens. Fig. 6 shows a schematic drawing of the tip of a laser cutting nozzle in relation to a thin pliable sheet of rubber material. In this implementation, the focal point 615 of the laser beam is at first surface 605 of the thin pliable sheet. To achieve this positioning of the focal point 615 in relation to first surface 605, the tip of the cutting nozzle is adjusted to be 50 mm from second surface 610 of the thin pliable sheet. In other implementations, the focal point of the laser beam and the thickness of the thin pliable sheet can be different, which could require the distance between the tip of the nozzle and second surface 610 to be different than 50 mm. A direction of machining, i.e. laser cutting, is also shown.

[00113] Figs. 7 and 8 show two portions of a material properties table, showing ranges of material properties for silicone rubber. It is also contemplated that other variations of silicone rubber can have properties outside of the ranges shown in Figs. 7 and 8.

[00114] In order to obtain silicone rubber in the form of thin pliable sheets, liquid precursors can be placed in a mold and then made into a thin pliable sheet by a process comprising steps including, but not limited to one or more of pressing, curing, polymerizing, drying, and heating. Fig. 9 shows results for extraction tests of such a silicone rubber sample prepared from liquid precursors. The test was performed according to FDA 21 C.F.R. 117.2600 regulations. The level of materials extracted into distilled water and n-hexane under the test conditions were found to be within the permissible limits, and the silicone rubber material passed the extraction test. Fig. 10 shows a photograph of the silicone rubber sample that was tested to obtain the results shown in Fig. 9. The thickness of the sample was 2 mm. [00115] In some implementations, a fragrance can be added to the liquid precursors of the silicone rubber to obtain a silicone rubber thin pliable sheet that has a human-detectable fragrance. The fragrance can be added to the liquid precursors prior to the precursors being molded, pressed and dried into sheet form.

[00116] In a first trial, 10 grams of M-A-C^liV1 fra grance Turquatic Eau De Parfum was added to 500 grams of silicone rubber precursors (i.e. a 50: 1 ratio), and the mixture was formed into a 90 cm x 90 cm x 2 mm sheet of silicone rubber. Turquatic Eau De Parfum comprises 10% by volume of perfume oil diluted in an alcohol medium. The alcohol largely evaporates during the formation of the silicon rubber sheet from the liquid precursors. The resulting silicone rubber was fragrance tested by Estee Lauder laboratories located in New York City. The rubber sample was human smell tested for true fragrance and was approved as acceptable for consumer trials. Moreover, after 3 months of typical use, the sample was retested in a similar manner, and was again approved as acceptable for consumer trials.

[00117] This trial demonstrated that a fragrance can be added to the silicone rubber sheet, with the fragrance remaining true to the original within the detection limits of the test, initially and even after three months of typical use. As such, it is possible for an item made from the fragrance-infused silicone rubber to have a fragrance that can be matched, within limits of human detection, to the original fragrance added to the liquid precursors of the silicone rubber.

[00118] In a second trial, the same sample preparation process as the first trial was followed, with the difference being that the ratio of rubber precursors to fragrance was 100: 1. This sample was not tested by Estee Lauder laboratories because upon initial examination no fragrance was detectable in the silicone rubber sheets.

[00119] If a more concentrated fragrance is used, i.e. more concentrated that 10% of fragrance oils diluted in alcohol, it may be possible to produce a silicone rubber sample with acceptable levels and longevity of the fragrance using a ratio of silicone rubber precursors to fragrance that is larger than 50: 1. For example, a more concentrated fragrance can have a concentration of 80%-85% by volume of alcohol and 15-20% by volume of perfume oil. In addition, by adjusting the concentration of fragrance that is added to the silicone rubber precursors, the intensity and the radius of human-detectability of the fragrance can be adjusted. Radius of detectability is also known as olfactory proximity. A higher concentration of fragrance can produce a fragrant silicone rubber sheet whose fragrance has a larger radius of detectability. For example, the radius of detectability can be adjusted to be 0 feet (i.e. no detectable fragrance), 1 foot, 3 feet, or 6 feet.

[00120] In addition, when apparel or other fragrant items made of fragrance-infused silicone rubber are used, they can be stored in a fragrance barrier bag when entering a fragrance free area such as a doctor's office. The fragrance barrier bag can comprise a resealable bag made of a material that is impermeable to the fragrance molecules. The resealable fragrance barrier bag can also be used to store the apparel and/or items when not in use.

[00121] In some implementations, the fragrance can be added by boiling the silicone rubber thin pliable sheet in a solution of the fragrance in a suitable solvent.

[00122] In some implementations, a human- visible dye can be added to the liquid precursors of the silicone rubber to produce thin pliable sheets of silicone rubber that are colored. As the silicone precursors themselves do not have a prominent color, the color of a dyed silicone rubber sheet can be reasonably closely matched, within the limits of human visual detection, to the color of the dye added to the liquid silicone rubber precursors.

[00123] The materials and methods described above can be used to make a fabric comprising a thin pliable sheet comprising silicone rubber, the silicone rubber comprising one of food grade silicone rubber and medical grade silicone rubber. The thin pliable sheet can have a thickness of less than or equal to about 5 mm, and the thin pliable sheet can be laser cut according to the methods described above to comprise a minimum feature size of less than or equal to about 2 mm.

[00124] In some implementations, the fabric comprises a thin pliable sheet of silicone rubber having a thickness of less than or equal to about 2 mm. In addition, in some implementations, the fabric can be laser cut to have a minimum feature size of less than or equal to about 1.75 mm. This fabric can be hypoallergenic, can move and flex with the body of a wearer, can be water-, lotion-, sunscreen-, and sweat-proof, can be breathable due to the features/opening cut into the fabric, and can be color and fragrance matched to a reference fragrance and/or dye/color.

[00125] In addition, this fabric can be attached to other materials in order to be incorporated into apparel, fashion items, and accessories. Table 1 below summarizes a selection of methods for attaching the fabric to other fabrics.

Table 1 : Methods for attaching the silicone rubber fabric to other fabrics and materials

Needle size: - Denim trim it down once it is Figs. 13a

110/18 or 80/12 - Silk sewn. and 13b.

Thread: polyester - Cotton

or nylon - Wool Fabric &

- Stretch fabric Rubber:

- Leather Figs. 14a

and 14b.

Hand Needle and thread Any material that can Fabric can have pre- Fabric &

Sewing can be based on be hand sewn. cut holes to sew cotton- the other material through. Holes can be polyester being sewn. circles that are about 1 blend:

mm wide, with about Figs. 15a

2 mm distance of and 15b.

fabric between each

hole.

[00126] Table 1 describes securing the fabric to another thin pliable sheet of rubber using Sil-Poxy Silicone Adhesive. Table 1 also describes using shoe glue to secure the fabric to another fabric comprising one or more of silk, cotton, wool, denim, and a stretch fabric. Figs. 11a and 1 lb show respectively top plan and side view photographs of an example of the fabric (shown in light color) glued to a wool fabric (shown in dark color).

[00127] Table 1 also describes securing the fabric to another fabric using both shoe glue and sewing. The sewing can be performed using a Singer stitch machine operating a 110/18 or 80/12 needle and using a polyester or nylon thread. The other fabric can comprise one or more of silk, cotton, wool, denim, and a stretch fabric. Figs. 12a and 12b show respectively top plan and side view photographs of an example of the fabric (shown in light color) glued and sewn to a stretch fabric (shown in dark color).

[00128] Moreover, Table 1 describes securing the fabric to rubber or another fabric using sewing only. The sewing can be performed using a Singer stitch machine operating a 110/18 or 80/12 needle and using a polyester or nylon thread. The other fabric can comprise one or more of leather, silk, cotton, wool, denim, and a stretch fabric. Figs. 13a and 13b show photographs of an example of the fabric 1305 (shown in light color) sewn to a denim fabric 1310 (shown in dark color). Figs. 14a and 14b show photographs of the fabric sewn to a thin pliable rubber sheet.

[00129] Table 1 also describes securing the fabric to another fabric by hand sewing. Referring to Figs. 15a and 15b, the hand sewing can comprise laser cutting a plurality of stitch holes 1505 in the thin pliable sheet, each stitch hole 1505 having a diameter of about 1 mm. Moreover, each stitch hole 1505 can be spaced at least about 2 mm from its nearest neighboring stitch holes 1505. The hand sewing can further comprise passing a thread through the other fabric and through two or more of the stitch holes 1505, as shown in Fig. 15b, to secure the fabric to the other fabric. The other fabric can comprise cotton and polyester blend, or any other suitable fabric or material.

[00130] It is contemplated that other suitable adhesives and/or sewing parameters known to the skilled person can also be used to secure the fabric to another fabric or material. For example, other suitable sewing machines configured for sewing heavy fabrics can be used.

[00131] These attaching and/or securing methods can allow for the fabric to be incorporated into apparel, fashion items, and accessories. Fig. 16 shows the fabric 1605 incorporated into a leather shoe as the tongue and instep of the shoe. The fabric 1605 can be glued using shoe glue to the leather portions of the shoe. Once the glue dries, fabric 1605 can be sewn to the leather portions of the shoe using a Singer stitch machine operating a 110/18 needle. The glue can be used to hold fabric 1605 and the leather shoe parts together and to prevent fabric 1605 from stretching during the sewing.

[00132] Fig. 17 shows the pattern for fabric 1605 (shown in Fig. 16). As fabric 1605 forms the tongue of the shoe, and shoe tongues can be subject to pulling and stretching, the pattern was chosen to include a sufficient ratio of solid, contiguous portions to be able to withstand the pulling forces. In some implementations, the tongue portion of fabric 1605 was augmented by attaching a 1 cm wide border of another fabric to the outer perimeter of the tongue portion of fabric 1605. In other implementations, the tongue portion of fabric 1605 can comprise a 1 cm wide strip of uncut rubber adjacent and inside the outer perimeter of the tongue portion of fabric 1605. This uncut portion can further strengthen the tongue portion against pulling forces. Generally, when the fabric is used in shoe components, rivets, eyelets, and/or snaps can also be incorporated in the fabric.

[00133] Fig. 18 shows fabric 1805 used to form a front pocket of a hoodie. Fabric 1805 can be sewn to the material of the hoodie.

[00134] Fig. 19 shows fabric 1905 used to form the full back panel of a dress. Fabric 1905 cam have the body and the lightness to integrate into the delicate material of the dress. In addition, the detailed features and patterns of fabric 1905 can maintain their integrity, move well with the wearer, and show well while worn. Worn close to the skin, fabric 1905 can be comfortable and have a pleasant feel, which can make fabric 1905 suitable for semi-see through effects and for potentially replacing existing panels or patches in garments.

[00135] Fig. 20 shows fabric 2005 incorporated as an insert into a denim jacket using heavy denim stitching. Fabric 2005 can have a thickness that either matches the companion material (e.g. the denim jacket) and/or to have a different thickness to ensure sufficient strength and physical integrity of fabric 2005.

[00136] Fig. 21 shows fabric 2105 incorporated as a trim into a bikini top. Fabric 2105 can comprise sufficient flexibility to be used in active wear. In other implementations, fabric 2015 can be used as components of straps or trim on the top or bottom of intimate apparel, swim wear, crop tops, and the like. Fabric 2105 can be machine washable and water-proof, and its laser cut features can make it breathable and comfortable.

[00137] Fig. 22 shows fabric 2205 incorporated into the ankle strap of a high-heel sandal. Fabric 2205 can replace existing shoe embellishments, and can represent a fanciful ankle cuff, which can also be changeable to suit a wearer's tastes and outfits. Fabric 2205 can have enough body to keep its form and be supple enough to be comfortable. Fabric 2205 can be stitched and/or glued, and can have other fasteners incorporated in it, such as Velcro™. Fig. 22 also shows fabric 2210 incorporated into the hem of a skirt, and can have some or all of the features and qualities of fabric 2205. [00138] Persons skilled in the art will appreciate that there are yet more alternative implementations and modifications possible, and that the above examples are only illustrations of one or more implementations. The scope, therefore, is only to be limited by the claims appended hereto.

Claims

What is claimed is:

1. A method of laser cutting a thin pliable sheet, the method comprising: securing the thin pliable sheet to a cutting bed by creating an air pressure differential between a first surface of the thin pliable sheet facing the cutting bed and a second surface of the thin pliable sheet opposite the first surface, the second surface facing away from the cutting bed; adjusting a power of a laser to a cutting range of about 45 W to about 80 W, the laser generating a laser beam; directing the laser beam onto the second surface of the thin pliable sheet; adjusting a position of the cutting bed to maintain the first surface at a focal point of the laser beam, the first surface maintained at the focal point to within a predetermined tolerance; and moving the laser beam relative to the thin pliable sheet along a predetermined cut pattern at a cutting speed in a speed range of about 5 mm/s to about 20 mm/s.

2. The method of claim 1, further comprising: reducing the cutting speed in zones near portions of the predetermined cut pattern that specify a corner that is about 90° or sharper; and when the cutting speed is reduced, reducing the power of the laser to a reduced cutting range of about 40% to about 60% of the cutting range.

3. The method of any one of claims 1 to 2, wherein the air pressure differential falls in a range of about 28 KPa to about 90 KPa.

4. The method of any one of claims 1 to 3, wherein during the moving the air pressure differential creates air flow past the thin pliable sheet.

5. The method of any one of claims 2 to 4, wherein the zones comprise a length along the predetermine cut pattern spanning 1 cm before and 1 cm after an apex of the corner.

6. The method of any one of claims 1 to 5, wherein the predetermined tolerance comprises about half a thickness of the thin pliable sheet.

7. The method of any one of claims 1 to 6, further comprising: preparing the thin pliable sheet for cutting by covering with masking tape at least a portion of the second surface.

8. The method of any one of claims 1 to 7, wherein a diameter of the laser beam at the focal point is less than or equal to about 1.5 mm.

9. The method of any one of claims 1 to 8, wherein the thin pliable sheet has a thickness equal to or less than about 5 mm.

10. The method of any one of claims 1 to 9, wherein the thin pliable sheet has a thickness equal to or less than about 2 mm.

11. The method of any one of claims 1 to 10, wherein the laser beam has a cutting kerf of less than or equal to about 2 mm.

12. The method of any one of claims 1 to 11, wherein the laser beam is configured to cut the thin pliable sheet at a minimum feature size of less than or equal to about 1.75 mm.

13. The method of any one of claims 1 to 12, further comprising: cutting a shape out of the thin pliable sheet by moving the laser beam along internal portions of the predetermined cut pattern inside of the shape before the laser beam moves along a peripheral portion of the predetermined cut pattern, the peripheral portion tracing a perimeter of the shape.

14. The method of any one of claims 1 to 13, wherein the thin pliable sheet comprises a silicone rubber comprising one of food grade silicone rubber and medical grade silicone rubber.

15. The method of claim 14, wherein the thin pliable sheet further comprises one or more of a human- detectable fragrance and a human-visible dye, added to the silicone rubber.

16. The method of any one of claims 1 to 15, wherein the laser is configured to pulse.

17. The method of claim 16, wherein the laser is configured to pulse in a frequency range of about 70 pulses per inch of cutting to about 110 pulses per inch of cutting.

18. The method of any one of claims 16 to 17, wherein the laser has an average output power of about 65 W.

19. The method of any one of claims 1 to 18, wherein the speed is in a range of about 6 mm/s to about 10 mm/s.

20. A fabric comprising: a thin pliable sheet comprising a silicone rubber, the silicone rubber comprising one of food grade silicone rubber and medical grade silicone rubber, the thin pliable sheet having a thickness of less than or equal to about 5 mm, the thin pliable sheet laser cut according to the method of claim 1 to comprise a minimum feature size of less than or equal to about 2 mm.

21. The fabric of claim 20, further comprising a human-detectable fragrance added to the silicone rubber before the laser cutting.

22. The fabric of claim 21, wherein the human-detectable fragrance is added to a liquid precursor of the thin pliable sheet, the human-detectable fragrance added at a concentration of about 10 grams of human-detectable fragrance per about 500 grams of the silicone rubber.

23. The fabric of any one of claims 20 to 22, further comprising a human-visible dye added to the silicone rubber before the laser cutting, the human- visible dye added to a liquid precursor of the thin pliable sheet.

24. The fabric of any one of claims 20 to 23, further comprising another thin pliable sheet secured to the thin pliable sheet using Sil-Poxy Silicone Adhesive, the other thin pliable sheet comprising rubber.

25. The fabric of any one of claims 20 to 23, further comprising another fabric secured to the thin pliable sheet using a shoe glue, the other fabric comprising one or more of silk, cotton, wool, denim, and a stretch fabric.

26. The fabric of any one of claims 20 to 23, further comprising another fabric secured to the thin pliable sheet using a shoe glue and by sewing, the other fabric comprising one or more of silk, cotton, wool, denim, and a stretch fabric.

27. The fabric of any one of claims 20 to 23, further comprising another fabric secured to the thin pliable sheet by sewing performed by a Singer Stitch machine operating one of a 110/18 needle and a 80/12 needle and using one of a polyester thread and a nylon thread, the other fabric comprising one or more of silk, cotton, wool, denim, and a stretch fabric.

28. The fabric of any one of claims 20 to 23, further comprising another fabric secured to the thin pliable sheet by hand sewing, the hand sewing comprising: laser cutting a plurality of stitch holes in the thin pliable sheet, each stitch hole having a diameter of about 1 mm, each stitch hole spaced at least about 2 mm from its nearest neighboring stitch holes; and passing a thread through the other fabric and through two or more of the stitch holes.