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@MrE
@moocher @hugo7 I'll just throw this in as an idea: mostly laser cut stuff is a taken from a layer of material, but there's nothing to stop a 2D shape being 3D printed. Also I haven't had access to a laser since retiring...
A corner reinforcement could be printed as a 3D object, but will be relatively weak across the layers, so avoid possible delamination by printing the whole thing as a flat piece in a flexible material such as TPU.
Pictures are probably more informative than words - V shaped channels define the folds - I'm fairly sure a bone folder won't work on polymers! The slot is offset slightly and sized to accommodate the thickness, but the centre hole is a bit too large.
Possibly heating the folds after shaping will relieve stress - I'm thinking boiling water might be sufficient.
Similarly a stitching groove might be a good idea when I get round to version 1.2 - having the thread below the wear surface can only improve things.
I've only got black TPU which doesn't photograph well, so 1st pic is a screenshot of the 'design', second shows how CNC holes guide the stitching. I think the rivet will be needed as TPU probably won't work well with adhesives. Will post more photos when I find time to give V1.2 a go.
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