Re: How are beach volleyballs made?

Most inflated sports balls are designed with an outer skin of leather, plastic, or rubber and an inner bladder that is made of rubber. The inner bladder has a small column that leads out to the opening where air is pumped into the ball. This is the same way tires work -- an outer layer of rubber for protection and strength and an inner-tube. For a ball, the inside air pressure and a wee bit of spit/moisture provides the seal that keeps the ball inflated for long periods of time.

Therefore for a volleyball, basketball, or a football the sewing does not need to be air tight. This makes sewing the ball together a little easier.

I spoke to a couple people that are much more experienced at sewing than I am to get their ideas on t his.

Basically the pattern is laid out inside out and the parts are put together with the tabs for stitchi ng on the inside. A seem with the threads will be seen from the proper side. The pattern is put together except for on e part so that it may be flipped inside-out with inner bladder being enveloped as it flipped. And since it started out inside-out, it is now the way you want it -- outside-out or rightside-out de pending on your term for it being the way you want it.

Then the final piece(s) are sewn into place very carefully through the hole that will serve as the en try point for the inflation needle into the inner bladder. Actually, this is a full automated proces s nowadays. Remember the ball is still mushy and somewhat flexible, so the sewing may not be very di fficult for someone who knows what they are doing.

Finally the bladder opening is pulled into place and the ball is finished. Usually some sort of lip on the bladder valve stem prevents it from slipping back inside once it is pulled out and there is so me air inside.

Here is an example you can perform at home to help you understand the process. Try making a pillow case. Start by getting the two pieces of the pillow case and lay them side by si de inside-up. You could paper and tape for this if you don't want to sew, or just take a pillowcase and turn it inside-out just look at it. Sew three edges together so that you form a pocket. Turn the pillow case inside-out so that the outside is on the outside. Then put the pillow inside it -- and presto. Pillow inside pillow case with the sewing edges inside.

Sincerely,

Tom "Friend of Betsy Ross" Cull