;)
This kit was designed entirely with CAD software. Nothing fancy just take measurements and make curves. Basic pattern making skill here (need to work on that).
Free tools for this would be inkscape and open office spread sheet.
Process behind this is:
Make some sketch; in my case doodle a plan on some random scrap of paper
Take measurments
Use spread sheet to devide according to planned design
Draw it up in CAD
Export to laser and cut
Paper parts were made first to test scale and fit (as well as one can test with paper)
Edits made; cut latex.
Hours of gluing and random profanity to assemble everything neatly
Optional things to do:
Lose sleep
Rush like hell
Meet deadline by a hair.
Hexagon pattern is a laser cut appliqué.
Cut using the Site3 Laser (site3.ca)
Another photo on my deviantart page here http://dainsane1.deviantart.com/art/Hexagon-Latex-220374483
Model credits: Fenix Targaryen
Photographer & Make-up Artist credits: Jonah Fheonix
Latex sheeting from sheetlatex.com