Peartree,
If you are doing a conical nose cone then it is a Gaussian shape and can be flattened w/o any distortions. To flatten the sphere I just started with what I thought I needed and calculated a bunch of equations for a 1/2 sphere and then calculated the error on that. It took 3 times to come up with the correct way to divide a sphere to get the most spherical shape. It also helps that this semester I'm taking a math course and my professor is a great applied and numerical mathematician. He's helped lead me in the right direction.
As for what is on a baseball, I looked at those. It turns out that the leather is smaller and they count in it stretching to shape to form around it. They bend and stretch the cover with the seams. That is great for that purpose, but it doesn't translate well to a parachute where the fabric doesn't stretch.
As for the ranges I was going to fly a couple of them this weekend to get my descent values - but the one you see is rated for 6 pounds at 10ft/s at 8800' MSL, where I fly.
Edward