Take whatever shape you want (shown is Thee Template) and lay out a polygonal mesh, using triangles, diamonds or hexagons as you prefer. Add
darts in your layout, one dart per hexagon for instance. Then cut and draw the darts closed or lap them. It would produce an approximately compound curve with minimal seamage.
An interesting means of joining the clear material might be
https://books.google.com/books?id=pg...=PA63&lpg=PA63 Radfast memory plastic.