Son #1 took three years (maybe a little less even) to finish his PhD thesis. Six years later I've finished the proof-of-concept notebook for the binding.
The ideas we came up with for the cover was an order of magnitude harder than any I'd done so far. Without a laser cutter it would have been well beyond me (I can cut accurately but not that accurately).
This notebook is half the size that the finished thesis will be and has a quarter of the design. I went through many iterations of maquettes until I got a technique I was happy with.
The bookcloth mosaic is cut with a slight positive ease and then laminated on Japanese lens paper. The coverboard is debossed by laminating a thin card with the cut-out design onto a thicker board. The made cloth is then pasted to the board and smoothed into the recess. Finally the paper inserts are pasted in place.
On to bind the thesis!