Datasets:

WitchesSocialStream

/

HowItsMade

like 0

Follow

Witches Social Stream 4

{ "things": [ "Office Chairs", "Vinobrew", "Reconditioned Sander Drums", "Lithographs" ] }

[ "thomas jefferson, one of america's founding fathers, came up with the first swiveling mechanism for office chairs.", "Decades later, charles darwin added small wheels, called casters, to his chair to roll it around the study as he worked on the theory of evolution.", "Today, office chairs still swivel and roll.", "The office chair has become a status symbol.", "Executive versions have kingly dimensions.", "They're extremely plush and have serious lumbar support.", "Using a hydraulically powered machine, a worker bends 14-gauge steel tubing to form the bottom cushion frame.", "He joins the ends and welds steel bars to the middle.", "The bars will support the mechanism for adjusting the position of the seat.", "He hooks s-shaped steel springs from the front to the back of the seat frame.", "These sinuous springs will eventually provide a flexible web of suspension in the seat.", "He positions the rods laterally and clips them to the springs for additional stability and support.", "The office chair seat frame is now complete.", "Next, a worker builds the chair's back frame.", "The frame includes a spine lumbar support, armrest attachments, and other parts.", "He grinds burrs and other rough spots from the steel.", "In the upholstery department, another worker smoothes a leather hide so that it sits evenly on the cutting table.", "He cuts out the patterns following cardboard templates.", "As he cuts, he works around the natural flaws in the hide, making calculated decisions to minimize waste.", "By cutting carefully, he'll be able to get all the leather he needs for one chair from this large hide.", "That's important because color and grain can vary from hide to hide.", "Using pieces from the same one will give the chair a consistent look and texture.", "Once all the leather pattern pieces have been accumulated, another worker cuts foam cushioning for backing.", "The density of the foam in the chair varies.", "He uses more rigid foam for the chair's contoured cushioning so it will hold its shape.", "Another worker selects softer foam for the part of the chair that the occupant's back will rest against.", "He cuts slits into this softer back padding.", "This creates channels that will ultimately become a design feature.", "Using chalk, he draws lines onto the corresponding leather that match up with the slits in the foam.", "A worker aligns the chalk lines in the leather with the slits and puckers the leather as he sews the backing to it.", "This forms a ribbed pattern in the upper half of the chair upholstery.", "He stitches the padding flat to many of the other pattern pieces.", "This particular part is a side panel for the back of the chair.", "Returning to the upholstery with the ribbing now, he sews contoured casings to each side.", "To complete the back of the chair, workers add a chipboard panel and encase the structure with foam, then cover it with the leather upholstery.", "Once the chair seat has been upholstered, an employee installs a plastic cover to enclose the back.", "He screws a sliding plate to the base.", "This mechanism will work in conjunction with the plate to slide the seat forward and backward, depending on legroom needs.", "It also has features for adjusting the tilt and height of the seat.", "The hydraulic cylinder for adjusting the seat height is next.", "The cylinder also doubles as the chair's stem, and it swivels to allow the seat to rotate 360 degrees.", "He attaches the aluminum base to the cylinder.", "He snaps the casters into slots in the aluminum base.", "He equips the back of the office chair with an automobile-style headrest.", "The prongs fit into the brackets in the chair frame.", "Finally, he locks the armrests into the frame.", "This office chair is now ready to make someone's desk job a lot more comfortable.", "Vinobrew is just what the name implies-- vino, meaning wine, and brew, referring to beer.", "This hybrid beverage is part of a fledgling trend by some adventurous breweries and wineries to merge their two otherwise separate worlds of alcohol and create a unique drink.", "This vinobrew is made from port-style sweet wine, dark strong beer known as stout, and another ingredient that's brewed-- coffee.", "This concoction is the collaborative creation of a winery, microbrewery, and coffee producer.", "The microbrewery grows some 20 different varieties of hop plants whose flowers contain the resins and essential oils that give beer its bitter and aromatic characteristics.", "To begin the beer-making process, the brewmaster fills a tank, called a mash tun, with water, then ignites a burner.", "When the water heats to around 150 degrees fahrenheit, he pours in a blend of different types of malts.", "Malts are cereal grains such as barley or corn which have been soaked to kick-start germination, then, once sprouted, dried with hot air to halt germination.", "Stirring the malt into the hot water activates enzymes that convert the starches in the grain into fermentable sugars.", "After an hour or so, he transfers just the liquid, called wort, to the boil kettle and gradually adds different varieties of hops.", "He brings the wort to a boil to kill off bacteria and sterilize it.", "Next, he cools the wort and transfers it to the fermentation tank.", "Then he adds yeast.", "Over the next 10 to 14 days, the yeast consumes the fermentable sugars in the wort, converting them into alcohol and producing carbon dioxide gas, which creates bubbles.", "This process transforms the wort into beer.", "At the coffee company, the hot coffee beans must be cooled quickly after coming out of the roaster so that they don't overcook.", "This perforated cooling pan stirs the beans to help dissipate the heat, then a commercial coffee grinder grinds the beans into coarse-ground coffee.", "To prepare coffee for the vinobrew, a worker puts grounds into a filter bag, saturates the bag with cold water, then submerges the bag in water, letting the grounds soak for about 16 hours.", "Then he pours the coffee into a large jar.", "At the winery, winemakers harvest and press the grapes, add yeast and ferment them, then age the port wine for at least 2 years in oak barrels.", "To prepare to make vinobrew, the winemakers test samples from different barrels for acidity and sweetness to help decide which wines to potentially use.", "The winemaker and the coffeemaker then experiment with amounts of those wines and different cold-brew coffees made from various types of beans.", "The brewmaster also joins in, measuring out beer.", "This process is as much art as science.", "For each batch of vinobrew, the respective makers play with a selection of ingredients and with the proportions, tasting and smelling the samples to evaluate aroma, sweetness, bitterness, and acidity.", "What they try to create is a harmonious blend of the three elements, a new flavor without the taste of any one element dominating the others.", "Once they pin down the winning formula, they replicate it on a large scale for production.", "The winery pumps the selected wine from storage tanks into barrels for transport to the brewery.", "At the brewery, the brewmaster pumps the required amount of wine from those barrels into a blending tank.", "He pours the required amount of cold-brewed coffee into the blending tank.", "Then he pumps the required volume of beer into the tank.", "Beer makes up the largest proportion of the recipe, followed by wine, then coffee.", "After blending the ingredients in the tank, the brewmaster pumps the vinobrew into a beer keg.", "Then he injects carbon dioxide gas to add more carbonation.", "When you pour a glass of vinobrew, the bubbles rise to the top, producing foam known as beer head.", "But while this might look and feel like regular beer, one sip tells you that vinobrew is uniquely different.", "To refinish a hardwood floor, one has to sand it with a floor-sanding machine.", "After a few thousand hours of operation, the machine's drum, which drives the sandpaper, wears out.", "The contractor can either replace it with a new one or send the worn one out to be reconditioned.", "This company specializes in reconditioning worn sander drums, that means restoring them to like-new condition.", "A drum can be reconditioned as many as eight times before it has to be replaced.", "The first step is to grind off what's left of the aluminum drum's worn rubber surface.", "It gets worn down due to the drum rotation speed of up to 2,600 revolutions per minute and often gets damaged by running over protruding nails or carpet tacks.", "A worn drum doesn't hold the belt of sandpaper taut, which causes the machine to slip to the left and right, rather than sand smoothly in a straight line.", "A worker places the drum on a press to detach the arbor shaft, which attaches the drum to the sanding machine.", "When the drum was new, its aluminum sides were freshly painted.", "That paint is now mostly worn away.", "Sawdust and rubber residue fill the drum's nooks and crannies, so a worker places the drum inside a sandblast cabinet and puts his hands through gloves that reach inside.", "He holds the drum in one hand, a sandblasting nozzle in the other, and in a few minutes, the drum is pristine.", "But it still has an ever-so-thin layer of rubber remaining, so another worker mounts the drum on a lathe and shears off the rubber with a knife.", "Then he passes the knife again, removing a mere tenth of a millimeter of aluminum.", "This exposes a new smooth aluminum surface.", "Then a worker cuts a sheet of brand-new rubber to the exact length needed to cover the circumference of the drum.", "The rubber is nearly two-thirds of an inch think, roughly twice the thickness of the worn layer they grinded off.", "After clamping it down flat, the worker applies an adhesive designed for rubber.", "Then he sprays an accelerant onto the drum's primed surface to strengthen its bond with the rubber.", "He lets the accelerant dry for 6 hours, then spreads a second coat of adhesive on the rubber and wraps it around the drum.", "Twenty-four hours later, with the adhesive cured, another worker mounts the drum on a lathe and trims off the excess rubber from both sides.", "He then sands the trimmed edges to make them perfectly flush with the sides of the drum.", "The drum goes back on the grinder now to finalize the overall diameter of the drum.", "Using a ruler, a worker adjusts a measuring instrument, called a caliper, to the diameter measurement.", "He then grinds down the rubber a bit at a time, spot-checking with the caliper regularly.", "The worker stops grinding once the caliper check tells them the drum diameter is correct.", "If a sanding drum isn't perfectly balanced, it vibrates and disfigures the floor, so a worker mounts the drum on a balancing machine.", "He applies a band of masking tape and draws a black line on the tape to give the machine a reference point from which to start measuring.", "As the machine rotates the drum, a sensor measures velocity on both sides simultaneously.", "If the velocity is inconsistent on either side, he balances the drum by adding or reducing weight on the problem side.", "To reduce weight, a worker drills a hole to remove aluminum.", "To add weight, he fills the drilled hole with tin, a metal that's far heavier than the aluminum he removed.", "The final step is to repaint the sides.", "A worker masks the rubber with a template then sprays the aluminum with rust-inhibiting metal paint.", "Now this main component of a floor sander is as good as new, ready to bring a worn wood floor back to life.", "Lithography was discovered when german playwright alois senefelder had no paper handy for writing a laundry list.", "So he wrote it down on a stone using a grease pencil and stumbled onto a new method of printing, one that relies on the chemical aversion of grease and water.", "Lithographs can rival paintings for detail and mood.", "They have a unique visual quality, and that's why making them hasn't become a lost art.", "A lithograph starts with a flat limestone slab.", "The artist confirms the same thickness all the way around the slab.", "She now resurfaces the stone using a grinding tool called a levigator.", "She wets down the surface of the stone and the levigator to allow the levigator to move freely across the stone during grinding.", "The artist sprinkles silicon carbide grit on the stone.", "She spins the levigator across the stone and, together with the grit, it grinds off the top layer.", "This process removes the previous drawing and preps the stone for the next one.", "She finishes the grinding with a finer abrasive to give the limestone a smooth finish.", "Once the residue has been rinsed off, the stone is ready for a fresh image.", "She brushes a natural gum, called gum arabic, around the edges, creating a border that will be receptive to water but not the printing ink.", "This process makes a non-image area.", "The artist marks up a piece of paper with a crayon made of wax, charcoal, and clay.", "She places the paper on the stone, crayon-side down, and sets a drawing upside down on top.", "She tapes the drawing to the stone.", "She now follows the lines of the figure on the paper with a pencil, pressing firmly.", "This transfers the drawing to the stone and creates a reversed image on it.", "The artist simulates specks of snow, with a technique called stippling, with gum arabic and a brush.", "She fills in the drawing using a greasy crayon.", "The stone picks up and holds the greasy substance.", "These crayons come in varying degrees of hardness.", "Once the artwork is complete, she dusts the image with rosin which is a tree sap powder, followed by a talc powder.", "This will ultimately protect the image during etching.", "The artist then brushes gum arabic onto the art to protect the stone from the corrosive nature of the etching material, a mix of nitric acid and gum arabic.", "This mixture alters the surface of the stone so that the image areas will attract ink, and the non-image areas will repel it.", "She places a sheet of paper on the print stone and applies lubricant to the bottom of the scraper bar on the press.", "She spreads more lubricant onto a tympan, a thin sheet of durable plastic, that she's placed on the paper-covered print stone.", "This allows the stone to slide under the pressure of the press.", "The artist moves the sliding press bed forward so that the lithography stone sits directly under the scraper bar.", "She turns the mechanism to tighten the bar to the stone.", "She moves the press bed forward to test the pressure of the scraper bar.", "She confirms that the pressure is sufficient for printing but not too tight.", "Satisfied, she removes the tympan.", "She washes the crayon from the stone using highly refined mineral spirits.", "What remains is a ghost of the image.", "The artist then rubs a petroleum-based substance onto the stone that will serve as a base for the ink.", "The substance attaches to the image on the stone.", "Using a big leather roller, she picks up oil-based ink.", "An assistant dampens the stone with a wet sponge.", "The artist transfers the ink to the damp stone.", "The greasy parts of the stone pick up the ink while the wet parts don't.", "The assistant moistens the stone again.", "The artist places a sheet of print paper cut to size over the image.", "She covers the stone with clear plastic tympan.", "The press bed rolls forward until the stone sits directly under the scraper bar.", "The preset bar applies the exact pressure needed to print the image onto the paper.", "The artist carefully lifts the paper, revealing a perfect mirror image of the art.", "Using the same stone, she can make hundreds more, each one a work of art." ]

{ "things": [ "Giant Valves", "Sardines", "Barographs", "Disposable Diapers" ] }

[ "Valves control the flow of liquids and gases through pipes and tubes.", "They're so much part of our lives, we hardly think twice about them.", "But a faulty valve in an airplane or chemical plant could be catastrophic.", "Valves must be precision-made and trouble-free, whether it's small enough to fit inside the human body or as big as a car.", "Many gate valves use handwheels to control the flow.", "Turning this wheel opens or closes a gate or wedge inside the valve body.", "This giant 11-ton gate valve works the same way.", "It will receive an internal gate or wedge that starts and stops the flow of liquids or gases.", "First, an automated horizontal boring mill prepares the valve body for assembly and for a controlling mechanism.", "It takes a controlling mechanism or motor, not a handwheel, to open and close a wedge that weighs about 3,300 pounds.", "An automated drill pilot drills the flange of the valve body.", "This centers the holes used for the bolts that will connect the valve cover.", "A technician double-checks to make sure the holes are in the right place.", "Then an automated spade drill starts penetrating the flange.", "Coolant prevents the steel from heating up and removes steel chips from inside the perfectly centered holes.", "Meanwhile, the wedge is ready.", "A propane torch preheats the wedge for the plasma-arc welding machine.", "This machine hard-faces the sealing surface of the wedge, a process that ensures minimal wear.", "Hard-facing creates three rows of weld beads, which will be machined smooth.", "Before installing the wedge, a technician inserts a seat ring into the valve body.", "A seat ring helps ensure precision fit with the wedge.", "The ring fits into the grooved body cavity.", "Then the technician sets another seat ring into place.", "Before the wedge goes in, a semiautomatic welding machine welds the two seat rings into place using a rotating positioner.", "Then a lapping machine inserted into the valve body polishes each seat ring to guarantee their finish is flat and smooth.", "Next, a crane lowers the machined wedge into the body cavity.", "Using a gauge, a technician verifies the gap.", "He repeatedly checks to see what adjustments the wedge may need to ensure a tight shutoff.", "Another technician installs a sealer gasket to prepare the valve body for the cover or bonnet.", "Now he begins final assembly.", "A fully adjusted wedge with the stem attached fits perfectly in between the two seat rings.", "This stem will connect to the controlling mechanism that opens and closes the valve.", "A crane lowers the bonnet with attached yoke assembly onto the body.", "Its studs fit exactly into the holes that were drilled into the valve's flange at the start.", "A technician readies all the bolts for machine tightening.", "Then he greases the top part of the stem.", "He lowers the controlling mechanism onto the stem, and he screws it into place until it's flush with the yoke, the top part of the bonnet.", "A technician then bolts the controlling mechanism onto the yoke.", "Finally, another technician spray-paints the fully assembled gate valve with a protective coat of corrosion-resistant paint.", "Precision-made gate valves are expertly crafted.", "They come in all shapes and sizes and are equipped with controlling mechanisms or handwheels.", "From refineries and nuclear power plants to submarines and aircraft carriers, gate valves are helping our world run safely.", "The health benefits of eating fish are always under study.", "Today, it's said that most fish, like sardines, are a good source of vitamins, minerals, and omega-3 fatty acids.", "If you want to make healthy eating choices, you need to stay informed, so seeing how these little guys end up on your kitchen table is a good way to start.", "Sardines from the pacific coastal waters off of costa rica are freshly packaged in a variety of tasty flavors.", "It starts when sardines are put into a vat of icy water to keep them fresh.", "The temperature of the fish must be kept below 41 degrees fahrenheit to avoid spoiling.", "The fresh sardines then go through a machine that deposits the fish onto sorting lanes.", "Each lane allows a certain sized fish to fall through the gap onto a chute below.", "Sorted as small, medium, or large, the fish drop into the proper container.", "Then workers load a specific size of sardine into a machine that removes the scales.", "Removing the scales takes 3 to 11 minutes, depending on the size of the fish.", "Once done, there is no mistaking a sardine with or without scales.", "Workers then place descaled sardines onto trays that take them into a cutting machine.", "They arrange the sardines on the trays in such a way that blades inside the machine will cut off the heads and tails.", "A look inside the cutting machine shows how it removes the heads and tails and sends them on their separate ways.", "It also cuts open and cleans out the bodies of the sardines and readies them for packaging.", "The packing cans travel by conveyor to a work station, with their bottom side up and open.", "They fill the cans manually to decrease the possibility of introducing foreign matter into them.", "The worker draws on his experience to estimate the required weight, then stuffs and trims the fish to fill the cans one by one.", "To be sure each can is exactly the right weight, he weighs and adjusts the amount in each tin.", "In only a matter of minutes, he completes a set of cans.", "Then another worker turns the set over and sends the open-bottom cans into an oven that cooks the sardines at about 212 degrees fahrenheit.", "After cooking for about 25 minutes, a worker turns the set of cans over again and transfers them onto a conveyor system.", "All the cooked sardines gradually funnel into a single file, and depending on the product, a filling machine treats them to oil or a specific flavor of tomato sauce.", "The filling machine overfills the cans with sauce, but a flute hidden inside the machine removes just enough sauce to put the lids on properly.", "The machine pressure-seals the lids onto the cans so that when they exit the machine, they're airtight.", "The traveling cans then enter a machine that washes them in about 194-degree water and makes them spotless.", "Pallets of cans then go into a chamber that sterilizes the product to keep it fresh.", "Then the cans go into a labeling machine that applies a thin coating of glue and precut paper labels onto each one.", "The finished product comes out of the machine with an attractive full-color label, ready to ship to the customer.", "Sardines come in a variety of flavors with easy-to-open packages that maintain the freshness of the fish.", "Ancient civilizations tried to forecast the weather by observing cloud patterns or even using astrology.", "Today, we rely on instruments like the barometer or the barograph, which automatically records on paper the variations in atmospheric pressure.", "High pressure indicates good weather.", "Low pressure means bad weather is likely.", "This barograph has three main parts-- the recording arm, the cells that react to atmospheric pressure, and a rotating drum.", "To make the drum's lid, a die-press operator stamps out a 3½-inch disk from a long strip of brass.", "He cleans off the grease from the die press and places the disk on another press to form an edge.", "To make the drum, he cuts a 4-inch-long cylinder from a brass tube.", "Next, he places the drum on an arm that rotates at high speed.", "He etches fine lines into the brass using steel wool.", "Thanks to a handy rotating device, all the drums get an even coating of protective lacquer so the brass doesn't corrode.", "The barograph's mechanism rests on a solid brass plate that's 8½ inches long by 5 inches wide.", "A worker greases each one and then places them on a press that punches out the holes for the fastening screws.", "Next, he places the plate in a metal holder and buffs it with a rotating polishing brush.", "He applies wax to the brush to help achieve a perfect mirror finish.", "Now workers use a fine grade of sandpaper to polish the solid brass arms that will hold the working parts in place.", "Then they line them up on a board and buff them with a polishing brush.", "How do they get those parts so shiny?", "By washing off any machine grease before polishing them.", "Putting the barograph together is precision work.", "Laid out before the assembler are all the working parts she will need.", "She begins with an arm, inserts a brass screw, then sets in a second arm and attaches them to the baseplate.", "These hollow metal cells are the key to the mechanism.", "Air pressure makes them expand and contract.", "The barograph records this movement to measure high and low pressure systems.", "The cell stack is put in place on the baseplate.", "Then they add the lever system that connects the recording arm to the paper.", "This lever system connects to the arm, raising and lowering it so the felt pen at the tip can record changing air-pressure levels on the drum's rotating chart.", "The assembler inserts tiny pins to hold it together.", "Inside the drum's base is a battery-driven quartz clock, which maintains a steady rate of rotation.", "Now she wraps the chart around the drum and attaches a brass clip to hold it in place.", "The drum rotates once over a seven-day period, so slowly that the movement is invisible to the naked eye.", "There's a gear system inside the drum, which rotates it once it's set on the axle.", "A brass screw holds it in place.", "Now the worker puts the mechanism on a mahogany base.", "She screws it into place, then covers it with a glass and mahogany housing.", "Brass hinges and a closing mechanism hold the housing firmly in place and provides easy access.", "A quality controller places the barograph into a pressure-sealed chamber to check its accuracy.", "He compares the barograph's recordings to gauges outside the chamber that measure the changes in air pressure that he applies inside the chamber.", "This weekly chart shows hour-by-hour recordings of air-pressure variations measured in hectopascals, a unit of atmospheric pressure.", "Barographs are available in a variety of designs, from modern to traditional brass and mahogany models that any sailor would be proud to own.", "Parenthood has many joys, but a dirty diaper isn't one of them.", "And that's why we have disposable diapers.", "They were first introduced in the 1940s for travel use.", "It took several years for the idea to catch on.", "But when it did, diaper duty was never the same.", "Many would say disposable diapers represent a change for the better, helping parents make the best of a messy business.", "They start with superabsorbent polymer particles, which drop into a forming chamber.", "Pulp unwinds into the same chamber.", "A spray of water helps suppress any static electricity that could interfere with processing.", "Inside, the pulp mixes with the polymer particles.", "The result is this fluffy absorbent material that will be the diaper core.", "This rotating drum has a vacuum that shapes the fluffy material into padding.", "Another vacuum drum then merges the padding to a moving web of fabric.", "Guides fold the fabric around the padding, and a hot adhesive seals it.", "At this debulking station, rollers compress the padding, making the diaper core slim enough to comfortably fit a baby.", "A cylindrical cutter slices the diaper core to size.", "At another station, plastic film winds around guides and merges with another stream of fabric.", "Machinery glues the layers together to form the diaper's back side.", "Next, equipment pulls elastic bands into other layers of fabric to make leg cuffs and outer gathers on the top portion of the diaper.", "The elastic will ensure the diaper fits snuggly, preventing leaks.", "Each diaper will be equipped with a set of these front tabs punched out by this rotating die.", "This cylinder applies stretch side panels to the top part of the diaper, which has the leg cuffs and gathers.", "The absorbent core now meets up with the back side of the diaper.", "And then the other layers come together and adhere.", "A computerized system monitors the assembly.", "Incredibly, it takes less than a quarter of a second for all the layers of the disposable diaper to be assembled.", "The diapers now travel past guides that fold down the tabs and side panels.", "The diapers are then cut into individual units.", "Again, belted rollers compress the completed diapers.", "Paddles then fold them in half.", "Conveyor belts relay the folded diapers to a carousel.", "Finger paddles separate them and position them for packaging.", "Sensors count the diapers as they move toward compression arms that squeeze the required number together.", "A pusher swoops in to slide the diapers into a bag.", "Vacuum arms open the bags right on cue.", "Hot bars seal the package full of diapers.", "It then moves down the line to be packed into boxes for shipping.", "Each disposable diaper has a phenomenal capacity to absorb liquid, and the key is those polymer particles.", "They act as tiny gel sponges, expanding to hold many times their weight in fluid.", "Cut open a wet diaper, and you'll discover the liquid has turned the solid particles into gel.", "The proof is in the weighing.", "For example, this dry diaper comes in at about an ounce and a half.", "When wet, it weighs over 18 ounces.", "And that's the bottom line." ]

{ "things": [ "Sawhorses & Toolboxes", "Sorbet Pops", "School Buses" ] }

[ "When it comes to construction, renovation, or simply repairs, whether you're a seasoned pro or a do-it-yourselfer, having the right tools makes the job easier.", "Sawhorses support the piece of wood you're cutting, and a toolbox keeps your implements organized and portable.", "Sawhorses are always sold in pairs because you need two under a piece of wood to stabilize it for cutting.", "By pulling the hinged tray upward, the sawhorse collapses flat for transport and storage.", "This model is made from pellets of an exceptionally strong type of polypropylene plastic.", "A vacuum system draws the pellets into an injection-molding machine.", "The machine melts them then shoots the liquid into a mold.", "It takes about a minute for the liquid to solidify, at which point the mold automatically opens, and an articulated robotic arm removes the parts-- for each sawhorse, two halves, the legs, and two panels which form the collapsible hinged tray that holds those legs open.", "The robot drops those parts at the first assembly station, where a worker joins each panel to a sawhorse half and applies non-slip footpads.", "These pads help keep the sawhorse stable and protect the floor from scratches.", "The worker lays out the parts for both sides of the sawhorse in a positioning fixture then activates the press a couple of times to snap the parts together.", "At the next station, a worker inserts ribbed rubber pads into molded holes on top of each sawhorse half.", "These anti-slip pads help hold large pieces of wood steady on the sawhorse.", "Next, he lays both sawhorse halves on the work table and with a tool called a stamping arm, snaps the two panels together.", "This forms a strong hinge, which opens and collapses the tray.", "The sawhorse is now finished and heads to the packaging station.", "There, a worker stacks two sawhorses, then, with a foot pedal, activates a machine which binds them with a plastic strap.", "Then she tapes on a wrap-around label.", "Have tools, will travel.", "This two-piece toolbox consists of a large storage tub on the bottom and a spacious toolbox on top.", "Like a rolling suitcase, it has two large polypropylene wheels with molded-on rubber treads and a collapsible pull handle.", "A toolbox doesn't have to withstand pressure bearing down on it, so it's made of standard, rather than high-strength, polypropylene.", "The injection-molding process is the same.", "The storage tub, the toolbox bottom, and the toolbox lid are each molded separately.", "In the assembly area, workers apply an adhesive label on the front of the toolbox then install the latches for locking the lid.", "The latches slide into molded slots.", "After inserting a removable tray, workers install the lid with a few strikes of a non-marring urethane hammer.", "Both lid and latches snap in easily because the polypropylene is still hot and flexible.", "Once it cools and becomes rigid, the lid and latches can't dislodge.", "To assemble each wheel, workers position a star nut and steel axle into the wheel, then, with an assembly ram, press the axle into the star nut to lock the parts together.", "They snap a wheel onto each side of the tub portion of the toolbox, then, with a press, force the wheels into their final locked position.", "Once the toolbox and tub portions are each separately assembled, workers hang a parts tray on the rim of the tub then sit the toolbox on the tray and lock it in place with two large side hinges.", "And that completes construction of this workshop on wheels.", "Traditionally, sorbets have been dished up between courses to refresh the palate, but served in a squeezed-up pop, a sorbet becomes a snack you can grab anytime-- no need for scoops, spoons, or dishes.", "Just squeeze the sorbet out of the paper sleeve.", "Now that's refreshing.", "A long favorite of foodies, fruit sorbet has gone mainstream with these squeeze-up pops.", "More fun than a few scoops in a dish, sorbet pops are also lower in calories than a lot of other snacks.", "They start with freeze-dried rice syrup.", "They pour it into a mixing vat that's a mega version of a home blender.", "They add strawberry puree.", "This is the main ingredient of the sorbet pops.", "The berries were pulped within 12 hours of harvest.", "The next ingredient is cane sugar.", "It's followed by strawberry essence-- compounds extracted from the berries for more intense flavor.", "They turn on the tap for the final ingredient-- water.", "It's time to close the lid and power up this industrial blender.", "The mixer has four blades that turn at a high velocity.", "They whip up the sorbet ingredients to the consistency of a fruit smoothie.", "The sorbet mixture then flows into refrigerated pipes that chill the mixture to 40 degrees fahrenheit.", "The pipes wind around the factory and finally deliver it to holding tanks.", "Inside, an agitator swirls the chilled mixture to maintain the smoothie-like consistency.", "Once a tank is full, a technician tests the acidity and the level of suspended sugars in the mixture.", "If the levels are right, they transfer the mixture into a continuous freezer.", "It pumps air into the sorbet mix, and it churns and scraps it against the freezing-cold walls of the machine.", "Cool water runs through the motor to keep it from overheating as it freezes the sorbet.", "This is only a partial freezing to keep the sorbet soft enough to be pumped into the paper squeeze tubes.", "A device with little robotic fingers pries the papers tubes from a stack and deposits them in slots in a moving tray.", "The tubes are in position to receive the partially frozen sorbet, and because the sorbet is only partially frozen, it is able to now flow through conduits.", "Frozen solid, it couldn't make the journey to the squeeze tubes.", "As the sorbet is pumped into the paper sleeves, its temperature is critical.", "It is precisely 37.8 degrees fahrenheit.", "One degree cooler and it would be too thick to pump.", "A degree warmer, and ice crystals would form during the final freezing.", "The next machine collects foil lids from a pack, using rubber heads with tiny magnets in the center.", "It deposits the lids onto the sorbet-filled tubes.", "The foil lids stick to the glue-coated rims.", "This line fills 280 paper sleeves with fruit sorbet per minute.", "That's just under 17,000 per hour.", "An iron applies heat to the lids to further melt the glue and provide a water-tight seal.", "It happens fast so the sorbet doesn't have time to start melting.", "Sealed and partially frozen, the sorbet pops cascade into crates.", "Each one holds about 100 pops, so they don't need to keep count.", "And then it's into the blast freezer, also know as the shock freezer.", "Fans circulate the cold air to rapidly lower the temperature of the sorbet pops, bringing it down to -24 degrees fahrenheit.", "This fast freezing prevents the formation of large ice crystals that would damage the consistency and flavor of the sorbet pops.", "Out of the freezer, a mechanized arm grabs and opens cardboard boxes.", "A pusher shoves the sorbet pops into the boxes.", "And they're ready to grab and squeeze.", "The big yellow school bus puts millions of children on the road to an education.", "It all started in the 19th century with horse-drawn trucks known as kid hacks.", "The word \"hack\" was short for hackney carriage.", "In the 20th century, they were motorized and became known as school buses.", "Every school day, children across north america wait for the school bus.", "Appearance-wise, it's hard to miss.", "Big and yellow, it is deliberately conspicuous, designed to stand out in traffic so other drivers slow down and take notice.", "Manufacturing starts with a support structure-- the steel underframe.", "They arrange several short rails down the top of two long frame rails.", "These cross rails will link the long rails and provide strategic support.", "Using the lift, they raise the long rails, and the cross rails slide into position just under the rims of the long ones.", "Now, in a fixture that pins the rails together, workers bolt them together.", "With the school-bus underframe assembled, they roll in two enormous wheel axles complete with brakes.", "Overhead cables lift the bus frame and workers guide it into place on the axles.", "They attach the axles to the frame with metal brackets, shackles, and spacers where needed.", "The chassis is ready for the engine.", "They lower it onto the front of the frame and secure it with bolts.", "The school-bus engine packs a lot of power.", "It's diesel-fueled with six cylinders.", "Next up is the front cal assembly, which includes the instrument panel and steering column.", "A workers wires the steering wheel to the controls in the column and slides it into place.", "They mount the tires and rims-- four on the back axle to handle the heavier passenger load and two on the front.", "Using a multi-pronged tool, the worker tightens numerous nuts to fasten the wheels to the axles.", "They now encase the engine with a fiberglass hood.", "The hood has been pre-painted and equipped with cross-view mirrors and headlights.", "They bolt it to the vehicle frame, and after adding antifreeze and coolant, the bus is technically drivable.", "They roll it over to a test station to check the brakes.", "The wheels turn on rollers so the bus runs in one spot.", "A computer monitors the performance of both the front and back brakes as a driver applies them.", "They now move on to build the school-bus body.", "The body starts with the floor.", "They unwind double-sided galvanized steel into a machine that slices it into panels.", "It also cuts holes to be used for assembly.", "A forming machine folds the sides to create support beams.", "Two more steel beams will really stiffen the floor panel.", "A worker positions those beams on the panel, and an automated machine welds them to it.", "It feeds the floor panel to the welder incrementally so it can spot weld down the length of the beams.", "It takes dozens of welds to solidly secure the steel supports.", "And with those reinforcements, the floor panel is complete.", "It's ready for assembly.", "Workers arrange several panels upside down in a precise configuration.", "Then it's into a second automated welder that joins them to make one school-bus floor.", "After manually welding pockets for wheels, a machine called the floor flip picks up the bus floor and turns it rightside up.", "They're now ready to build the passenger compartment, so stay tuned.", "A school bus transports precious cargo-- children.", "To hold the average bus together, they use an incredible 6,100 rivets, bolts, and screws and make a total of 840 welds.", "For the maker of school buses, there's strength in those numbers.", "To build the frame for the school-bus walls and ceiling, they bend steel beams into bow shapes.", "A hydraulic machine with pushers does the job in seconds, achieving an exact radius.", "The bows will serve as ribs for the school-bus body.", "They make several bows for each bus.", "The precise number depends on the bus size and capacity.", "Workers plug the ends of the bows into holes in steel rails and secure them with bolts.", "They weld lateral supports higher up, and the cage-like skeleton of the school bus takes shape.", "They're now ready to build on this framework.", "They attach the metal windshield surround.", "The team then moves the steel side sheets and skirting into place.", "They secure these panels with super-strong adhesive and numerous rivets.", "Using cables and nylon straps, they pull steel sheets to the roof structure to make them conform to the contours.", "The steel is 20-gage-- a grade that's flexible enough to be easily bent.", "The cables hold the steel panels tightly to the roof structure while the workers rivet them to it.", "The number of rivets and the strength of the joints are among many government safety standards the school bus must meet.", "Working from the inside, they glue fiberglass insulation into the pockets of the cage to keep the bus warm in winter and cool in summer.", "The insulation will also muffle road noise and absorb some of the student chatter for a quieter ride.", "The team installs steel panels on the ceiling.", "These panels have tiny perforations to allow sound to escape into the insulation.", "They tape up the windows and doors and sand some areas as they now prepare to paint the exterior of the bus.", "The paint, national bus yellow, takes the metal from dull to bold.", "This shade was developed specifically for school buses and can be noticed even with peripheral vision.", "With the paint now dry, they open the doors and lay a plywood subfloor inside.", "It too will absorb noise.", "An employee drives the chassis over to the school-bus-body production line, and parks it.", "Using cables, they lift the bus body over to the chassis.", "At over three and a half tons, it's hefty.", "They gently lower it onto the frame rails and mate the front to the hood.", "They tie the body to the frame with heavy-duty clips.", "They arrange the seating to surround the passengers with cushioning.", "This creates compartments around the occupants to protect them in a collision.", "Outside, a worker applies school-bus lettering.", "Another worker presses an adhesive-backed manufacturer's emblem to the hood.", "They equip the bus with the flashing lights and stop signs to get the attention of other drivers when children are loading and unloading.", "They also install a crossing gate to keep children within the bus driver's sight line.", "They test all of the warning lights and safety devices.", "And satisfied that everything is operational, the bus rolls off the production line.", "It's taken a day and a half to build it, and when it comes to an education, it's ready to deliver." ]

{ "things": [ "Compact Discs", "Mozzarella Cheese", "Pantyhose", "Fluorescent Tubes" ] }

[ "Today on \"how it's made\"...", "Compact discs...", "Mozzarella cheese...", "Pantyhose...", "And fluorescent tubes.", "Today there's virtually no limit to the information we can store on compact discs.", "Millions of bits of data representing words, numbers, music, graphics, or even video can be stored on the discs.", "Let's take a \"spin\" through a cd factory.", "Compact discs are copies made from an original glass master disc.", "A thin plate of glass is first placed in this unit, which brushes the surface clean.", "Cleaning is done with de-ionized water and a small goat-hair brush.", "The excess water is eliminated by the rapid rotation of the disc.", "The disc then goes into this surface analyzer, where a laser beam inspects the cleanliness of the surface.", "At this stage, two chemicals are applied-- a primer and a photoresistant coating.", "This operation is done at a temperature of 70 degrees fahrenheit and lasts three minutes.", "The disc is carefully retrieved from the apparatus.", "Then the photoresistant coating dries in an oven for 30 minutes.", "This developer has two spouts.", "One applies a de-ionized water, and the other sprays a solution to develop the data etched on the glass.", "The information is now engraved on the disc.", "Then the disc is placed in this metal-coating equipment.", "The next step consists of applying a thin coating of nickel and vanadium.", "This electroforming process results in the master from which discs will be made.", "The etched glass is immersed in a chemical solution for 70 minutes.", "Then the plated piece is removed, thus obtaining a die.", "The die is sent off for finishing.", "It is stamped out into the desired shape.", "The excess material is recycled.", "Next, the compact discs will be fabricated from this master unit.", "Here we clearly see the stamping-out technique.", "The master is taken out.", "A technician peels off the film which protected the data etched onto the die.", "After a visual inspection, the die is sent to the pressing department.", "The die is delicately installed in the mold, which will form compact discs.", "Discs are made from a very special plastic called \"polycarbonate\".", "The mold is closed, and liquid polycarbonate is injected into the die.", "It comes out as a small, hard, translucent disc.", "It is now ready to be metal-coated so it can be read by a compact-disc reader.", "A robotic arm lifts the disc from the mold and places it on these supports.", "This metallizing process is extremely short and very simple, taking but a second.", "It consists of covering the plastic disc with a very thin coating of aluminum.", "Here we see the inside of the mold, where the aluminum coating is applied.", "In this facility, almost everything is automated, helping them produce over 100,000 compact discs per day.", "Protecting the surface of the disc is essential, so a coat of varnish is applied.", "This also helps silk screening stick to the surface.", "Ultraviolet lamps quickly dry the varnish.", "And here in the pressing room, they apply the label.", "This step is also very fast since the machine prints 70 discs in 60 seconds.", "Once the silk-screening is completed, the finished discs leave for packaging.", "In a sandwich, as a topping, or all by itself, cheese has always been a popular food.", "This dairy product goes back thousands of years, and it's always started with three basic ingredients-- milk, curds, and whey.", "Just ask little miss muffet.", "Like all cheeses, mozzarella starts from milk.", "To assure good milk quality, the interior and exterior of milk-transport trucks must be washed after being emptied.", "A tank such as this one can carry an average of 8,000 gallons of raw milk at temperatures between 37 and 39 degrees fahrenheit.", "Raw milk destined for cheesemaking contains 3.8% fats and 3.3% proteins.", "They store the milk and whey, a milk by-product, in these immense silos, each with a capacity of 59,000 gallons.", "This milk separator extracts surplus cream to adjust the percentage of fat according to the type of cheese to be made.", "Fabrication begins with this tank, which feeds the pasteurizer.", "Pasteurization sterilizes beverages which can easily ferment.", "Milk samples are drawn off to accurately determine their milk-fat and protein content.", "Tests are carried out in this laboratory, where they impose controls.", "These test tubes contain milk samples which will undergo microbiological analysis.", "Milk quality must be impeccable.", "This is a curdler with a capacity of 6,600 gallons.", "Here milk and other essential ingredients are introduced, such as the enzyme, rennet, that curdles the milk.", "This mix must be well-stirred and cooked.", "The agitators are used to cut the whey into little lumps.", "This step takes about 30 minutes.", "The temperature of the tanks depends on the type of cheese they're making.", "Agitators continue stirring the milk.", "Once cooking is done, the whey is pumped onto tables to be drained.", "It stays there for about 25 minutes.", "The solid and the liquid are now well-separated.", "The liquid we see draining is called the \"lactoserum\".", "The lactoserum will be concentrated and transformed into milk by-products.", "The water has been almost entirely extracted, and the cheese particles are now sufficiently dry.", "This large automated blade then moves cheese particles towards the next step-- the molder.", "In the molder, the cheese is cut up before being carried to the cooker-- the final processing step.", "It appears that this mozzarella has just the right texture.", "The cheese finally arrives at the molder, which will give it the proper shape.", "Each mold has a 5 1/2-pound capacity and is rectangular.", "Brine, a salt solution, cools and salts the cheese blocks.", "The blocks are unmolded and fall into a brine tank.", "The cheese blocks will remain in another brine solution for a while.", "Then they're carried by a conveyor towards another tank, where they will be immersed for 4 to 10 hours at a temperature of 36 degrees fahrenheit.", "Sprays of brine remove the foam which forms at the surface of the tank.", "The 8,000 gallons of milk we saw coming in by truck at the beginning have enabled the factory to produce 1,400 blocks of cheese in 8 to 12 hours.", "Finally, the cheese blocks are vacuum-packed and ready for shipment.", "There was a time when women wore silk stockings.", "Then came the invention of pantyhose, a cheaper, more convenient alternative.", "Pantyhose are knitted from strands of raw nylon.", "It's no \"stretch\" of the imagination to say that when they go on sale, there's usually a \"run\" on them.", "Making a nylon stocking takes only a few minutes.", "However, it's a complex operation that involves the knitting of five to eight threads as fine as a hair.", "The threads, usually nylon and spandex, are used along with elastic.", "Sometimes polyester or cotton are added.", "The knitting machine goes into action.", "This one fashions a tube for sheer stockings in 90 seconds.", "In three minutes, it makes a tube for tights.", "Its speed is adjusted according to the product being made, varying between 750 and 1,200 revolutions per minute.", "Once the tube is knitted, it is sucked up and lands in a bag, where it will be inspected.", "More than 500 machines share the work, each making a specific model.", "The two ends must now be joined.", "This automated machine assembles the two tubes together to form the pantyhose.", "Then scissors cut the pantyhose, a necessary step in production of a pair.", "This opening is enlarged to allow for sewing, which will join the two tubes at the top of the leg.", "The label with the size or brand name is sewn in place in 10 seconds by this robotic machine.", "At this pace, it sews on 4,800 labels in 8 hours.", "Installing a gusset requires some preparation.", "Scissors makes a hole at the joining point.", "Then the stocking is turned inside out by suction so certain stitching can be done on the inside.", "Thus, these stitches will be less visible.", "Now the foot must be sewn.", "This robotic machine places the foot in position.", "Then a sewing machine makes stitches at the same time it cuts away excess material.", "This step takes only 10 seconds.", "Then the pantyhose is turned right side out, again using suction.", "Everything is ready for installation of the gusset.", "The pantyhose is placed in a tub and taken to this department.", "The stocking is again suctioned and placed on a gusset machine by the operator.", "This method assures that the gusset will be well-centered without a pleat.", "Putting in the gusset is the final operation in the process.", "A precut piece of cotton is slid into the space reserved for the gusset and automatically sewn in.", "Only aesthetic touches remain, such as adding a little color to the pantyhose.", "They're placed in this machine, which has a large drum with four compartments and a 99-pound capacity.", "The pantyhose are washed in soapy water, then immersed in dye.", "Temperature climbs gradually to 200 degrees fahrenheit.", "After a 5-minute rinsing cycle, a softener is added.", "This process takes 2 1/2 hours.", "Once dried, they proceed to inspection.", "The pantyhose is placed onto a form which stretches it to allow inspection for any imperfections.", "If all is well, the pantyhose is transferred onto another metal form, where it will be pressed.", "The pantyhose's position is guided by a magic eye.", "The pantyhose is then carried toward a steam room, where it will stay for 2 1/2 seconds before being dried in 7 1/2 seconds at 280 degrees.", "They fold and pack 420 pantyhose per hour and make 180,000 pairs per day.", "Throughout the ages, artificial light has let people extend the convenience of daylight long after the sun goes down.", "Fluorescent tubes are more energy-efficient than light bulbs.", "That's probably why they've become a \"fixture,\" so to speak, in stores, factories, and offices.", "Once, the only source of light was the flame of fire in the forms of torch, candle, and oil lamps.", "It remained so right up until the 19th century, when gaslight made its first appearance around 1840.", "Almost 40 years later, thomas edison invented his famous incandescent light bulb.", "In 1909, the frenchman georges claude developed the fluorescent tube, a light that remains unaltered to this very day.", "Did you know that mercury allows us to see in the dark?", "The production of fluorescent lamps is highly complex.", "The fabrication process starts with glass tubes that have been meticulously cleaned with warm water to remove dirt and impurities.", "Then the tubes have to be specifically shaped with a folder-shaper.", "They're heated for 30 seconds, then quickly curved using a template.", "This automated machine can bend 14 tubes a minute.", "The bent tubes go into the coating chamber, where a thin coat of phosphorus is applied to their inner surfaces.", "Phosphorus produces light by transforming ultraviolet photons generated by the ionization of mercury.", "The surplus phosphorus is removed from the ends of the tube to facilitate sealing.", "They now move to the electrical components.", "The cathode mount is made in this auto mount.", "Here, they make the wire that will carry the current from the mount.", "The wire carrying the current is shaped.", "And here, the wire is heated.", "This prepares it for the next step.", "It's essential to prevent the cathode coating from spreading to the prongs.", "The filaments are inserted into their mounts.", "The emissive substance plays a crucial role.", "When heated, it emits electrons, which participate in producing light.", "The emissive substance is actually this liquid.", "The wiring mount is transferred from the auto mount to the sealing machine.", "At this stage, the wiring mount and the glass tube are joined.", "Sealing is done at a very high temperature.", "One important step remains.", "This is where the glass tube is emptied of air and filled with gas.", "This machine also decarbonizes the tube and introduces the drop of mercury essential for producing light.", "Once the very tiny drop of mercury is injected into the tube, the fluorescent lamp is almost completed.", "But one step remains.", "This threader positions the wires for insertion of the tube cap, which establishes electrical contact.", "The tube cap is placed into position in preparation for sealing.", "The cap must be securely attached and installed in a watertight manner to eliminate any risk of leaking.", "The capper permanently seals the cap onto the tube, and it's all finished.", "Each lamp is tested on a large testing wheel to verify its quality and performance.", "Once the meticulous inspection is over, the fluorescent lamps are carried to the packaging department.", "A robotic machine handles the lamps and places them into the packages.", "The glass tubes have now become fluorescent lamps." ]

{ "things": [ "Air Boats", "Onions", "3D Metal Printing", "Curved Cabinet Doors" ] }

[ "An airboat is a flat-bottomed vessel with a huge propeller at the back.", "All of the boat's mechanics are above the water line, and just a bit of the hull rests below.", "This makes the airboat the preferred mode of transport through shallow water, particularly marshes and swamps.", "to steer an airboat, large vertical rudders direct the propellers' airflow.", "At full speed, an airboat can hit 62 miles per hour.", "The boat's hull is made of aluminum that's about 2/10 of an inch thick.", "Workers stiffen the hull's bottom plate with aluminum \"t\" bars positioned 7 inches apart.", "After they clamp the \"t\" bars, a jig descends to hold everything steady as workers weld on the strips.", "Next, they weld on aluminum sheets to form the sides of the hull.", "At the front, they push the bottom up for welding, giving the boat a curved bow.", "They complete the hull by welding on a sheet across the back to form the transom.", "To that, they weld a splash plate that prevents water from coming over the edge into the back of the boat.", "Next, they weld various parts to the front of the boat to reinforce it structurally and to create a covered storage area.", "Once that's done, they screw a thick sheet of high-resistance polymer to the bottom of the hull.", "Should the boat scrape against a rock, this layer will shield the hull from damage.", "Once that's secured, they paint the inside of the boat with a blend of epoxy and paint.", "This forms a layer of what they call \"webbing\".", "On the outside of the boat, they apply a coat of primer followed by two coats of durable marine paint.", "Meanwhile, others have constructed and painted the boat's above-water structure out of steel or aluminum tubes.", "The rigging, as the structure's called, supports the mechanics, two fiberglass seats, and the instrument panel.", "They mount a belt-driven reduction unit to the boat's gasoline engine.", "This unit reduces the propeller speed in conjunction with a preassembled set of gears.", "Without it, the propeller would turn at the same rate as the engine.", "This would exceed the propeller's operating limits and destroy it.", "The engine is now ready to take its place at the rear of the rigging.", "Heavy-duty bolts secure it.", "Under the engine goes a 50-gallon fuel tank-- at the very back, an aluminum radiator.", "Then they bolt the rigging to the hull's \"t\" bars.", "Next comes a floor panel and a 3-passenger bench seat with a storage compartment underneath.", "The boat's exhaust system consists of stainless-steel pipe, which attaches with band clamps to a header coming off the engine.", "The other end leads to a stainless-steel muffler.", "From that, an exhaust pipe runs out the rear of the boat.", "Next, they mount the propeller guard, a stainless-steel safety cage that surrounds the engine and propeller.", "The three propeller blades are made of carbon fiber.", "Aluminum rudders steer the boat by directing the propellers' airflow.", "Cables or rods connect the rudders to a control stick.", "Smaller airboats, like this one, are ideal for hunting and fishing.", "There are also much larger pleasure models that can carry 18 or more passengers on excursions.", "Historians believe consumption of this common vegetable dates back to prehistoric times, when it grew in the wild.", "Man eventually learned to cultivate onions, and this strong-tasting plant bulb became a food staple of many ancient civilizations throughout the world.", "In ancient egypt, the onion was an object of worship, the inner structure of concentric rings symbolizing the eternal circle of life.", "Today mechanical harvesters pull the bulbs out of the ground and lay them out in rows.", "After drying for a day or two, a tractor collects them into large baskets for storage.", "To prevent spoilage, the onions are stored at between 34 and 36 degrees fahrenheit.", "When they arrive from the field, their first stop is a cooling tunnel from which powerful fans remove the heat.", "The vegetables take about five hours to cool down to the storage temperature.", "The grower separates the onions according to variety and size, then either bags them for sale whole or sells them to a processing plant.", "At the processing plant, workers load the onions on a conveyer that leads to the peeling and cutting stations.", "A cutter chops off each bulb's top and tail simultaneously.", "It also scores the skin to prep it for peeling.", "The onions then move into a custom-designed peeling machine.", "It uses a combination of air and water pressure to blow off the skin.", "The onions then roll off the peeler and pass before quality-control workers who swiftly cut away bruises and any other imperfections as well as anything the cutter and peeler might have missed.", "The next machine rinses the onions with cold, ozonated water that kills bacteria.", "Then the onions pass through a metal detector, just as a precautionary measure.", "At this point, there's a fork in the processing road.", "One direction leads to slicing, the other to dicing.", "On the slicing line, workers load the onions into tubes that feed slicing blades.", "These blades are adjustable to output slices anywhere from 1 1/2 to 25 millimeters thick.", "Workers gather up the complete slices and fill 5-pound plastic trays.", "A conveyer moves the trays through a machine that seals them with plastic film.", "The film has microperforations designed to allow in just the right amount of oxygen to keep the onions fresh.", "On the dicing line, meanwhile, the onions collide head-on with a rotary blade that chops them to bits ranging from 3 to 25 millimeters in diameter.", "The diced onions then go for a bath in cold water.", "Chopping an onion releases juice from its tissue, paving the way for bacteria to grow.", "This cold-water treatment reverses the damage, restoring shelf life.", "Next, an escalator transports them from a spin dryer to the packaging department.", "There an automatic scale portions out the specific weight they're packaging in this production run.", "When the target weight is reached, a trapdoor swings open, dropping the portion into the waiting package.", "Restaurants buy their diced onions in jumbo-sized bags.", "The filling machine automatically forms plastic into a bag, adds a zipper closure, then seals the bag.", "For grocery stores, the factory packages smaller quantities of both diced and sliced onions in plastic containers.", "Kept in the fridge, they remain fresh for at least a couple of weeks.", "For busy cooks, it's a convenient, no-tears time-saver.", "Building complex shapes out of metal typically requires weeks of manufacturing, using tailor-made casts or precise machining techniques.", "But 3-d metal printers are faster and cheaper.", "They build objects from successive layers of metal powder, which are then fused together at high temperatures.", "3-d metal printing makes it easy to manufacture complex metal shapes using a fully automated process.", "Every item starts with a computer model of the object.", "This is the build box in which the object will be created.", "A technician plugs in electric heaters and pours superfine stainless-steel powder into the box.", "The heat will keep the metal powder from clumping.", "He pushes the box into the machine, then fills the feed box with more stainless-steel powder, which will be needed later in the process.", "The machine spreads the first layer of stainless-steel powder in the build box.", "Tubes carry a binding substance to the machine's printhead.", "This binder acts like a weak glue and is injected in very narrow jets by the printhead.", "As the printhead moves back and forth over the stainless-steel powder bed, it deposits binder at the exact locations specified by the computer.", "As soon as the printhead has finished printing a full slice of the object, powerful overhead heaters ensure the layer is completely dry.", "A roller applies a new layer of powder a fraction of a millimeter thick.", "Then the printhead adds a new layer of binder.", "This builds the object from the bottom up.", "The printing process takes several hours.", "Once the layering is done, they put the build box in a curing oven heated to 350 degrees fahrenheit for 24 hours.", "This will evaporate all the moisture and harden the binder.", "They vacuum out the loose powder, and the piece emerges, its stainless-steel particles lightly held together by the binder.", "They gently blow air to dislodge any excess powder.", "At this point, the object is very porous and contains about 40% air.", "It is so fragile that it can easily be crushed with bare hands.", "Using more stainless-steel powder, they prepare another box in which the piece will be infused with bronze.", "They're making a support structure on which to rest the pieces during the next phase of the process.", "They carefully fill the box with alumina oxide grit, which will support the pieces during the infusion process.", "This dam prevents the grit from leaking out.", "Now they pour in bronze powder.", "The piece is then heated in a furnace at more than 2,000 degrees fahrenheit for 24 hours.", "This melts the bronze, which then gets sucked up into the piece like water by a sponge.", "Infused with bronze, the piece is now solid metal.", "They knock off the base with a hammer.", "It's taken just a few days to build this intricately designed piece of hardware.", "It can now be polished, gold-plated, or painted to match any decor.", "Whether they build sophisticated door handles or fancy sculptures, 3-d metal printers work faster than conventional methods at just a fraction of the cost.", "To create classic, elegant style in a kitchen or bathroom, decorators typically use traditional materials such as wood and marble.", "Curved cabinets can heighten that effect.", "But their unique style comes at a higher price because, for the most part, these elegant doors must be custom-ordered and handmade.", "Most cabinet doors produced by this factory are custom-made.", "They typically start out as a sketch, which the factory transforms into a technical drawing.", "They then use that drawing to program the automated woodworking machines.", "After cutting all the pieces of wood they'll need, they run each one through a planer.", "It simultaneously smoothes both the top and bottom surfaces.", "A cabinet door consists of a center panel surrounded by a frame.", "This machine, called a molder, carves the frame's two vertical pieces and cuts a groove on one edge into which the center panel will fit.", "To construct that center panel, a worker feeds planks through a wood shaper that bevels their edges.", "The angle of the bevel is such that when the pieces line up side by side, they'll form a curve.", "After trimming the pieces to the length of the center panel, another worker runs them through a glue applicator, which coats the beveled edges in adhesive.", "Then she lines up the pieces in an assembly fixture that's been adjusted to the center panel's width and radius.", "Once everything's positioned, she applies clamps which force the pieces tightly together.", "The glue sets in 20 minutes.", "Once the glue cures to full strength, the piece goes onto a computer-guided router.", "It rounds both sides of the panel for a smooth, seamless look.", "This particular door has a concave curve.", "Others can have a convex curve or a crossbow curve, which is \"s\"-shaped.", "The same router now automatically switches to a different type of tool and profiles the panel's edges.", "It also carves a tongue that fits into the groove in the frame pieces.", "The same machine can then load another tool to engrave a custom motif or monogram if the customer desires.", "Next, a computer-guided sander smoothes out the panel, preparing the wood for stain or paint later on.", "Making the frame's horizontal pieces is more complex than making the vertical ones because the top and bottom have to curve just like the center panel.", "Workers coat thin slices of wood with heat-activated glue, then stack them over a curved form in a press.", "The press squeezes the slices tightly together.", "Then a high-frequency electrical current generates intense heat, triggering the adhesive.", "The bonded slices exit the press looking like a solid, curved piece of wood.", "Once the glue has set, a computer-guided router carves it to the same decorative style as the vertical pieces.", "It also miters the corners so the horizontal and vertical frame pieces will fit together seamlessly.", "All that's left to do is glue the frame to the panel.", "The tongue running along the panel's perimeter fits neatly into the groove of each frame piece.", "Workers now clamp everything together and let the glue set for a half-hour.", "Then the cabinet door goes off for painting or staining.", "This factory produces curved cabinets in 10 different types of wood and dozens of colors and finishes, opening the door to endless design possibilities." ]

{ "things": [ "Plastic Cups and Cutlery", "Special Effects Makeup", "Gold", "Harps" ] }

[ "Today on \"how it's made\"...", "Plastic cups and cutlery...", "Special-effects makeup...", "Gold...", "And harps.", "The industry calls it single-usage plasticware, but that's just a fancy way to say throwaway plastic dishes.", "Plastic plates, bowls, drinkware, and cutlery come in many styles and colors.", "So for your next party, you can go disposable for everything from champagne flutes to parfait glasses.", "Factories make cutlery by injecting plastic into molds.", "They make cups, plates, and bowls using a different process called thermoforming.", "Before the forming phase can begin, an automated system loads polystyrene pellets into a machine called an extruder, adding pigments for colored plastic.", "The extruder heats the pellets until they melt.", "Then it forces the molten plastic through a die to shape a hard-plastic sheet about 8/100ths of an inch thick.", "They use molds to form this continuous sheet into plastic cups.", "First, the sheet passes through an oven that's 10 feet long.", "It heats the hard plastic until it becomes malleable.", "Then it enters the thermoforming machine, which simultaneously pushes and vacuums the sheets into the mold cavities...", "Forming row after row of cups.", "The entire process takes just three seconds.", "The cups then travel to the trimmer, which uses a die to cut them off the sheet.", "The machine grinds up the leftover plastic and remelts it into new sheets, so there's no loss of material whatsoever.", "The trimmer feeds the cups directly to a machine that stacks them...", "Then feeds them to a conveyor belt in one long line.", "The conveyor transports them to a machine called the lip roller.", "It reheats the cups just enough to make the plastic flexible.", "Then, as we see here in slow-motion, it folds the rim over, forming a rounded lip.", "They also make cutlery from melted polystyrene pellets, as well as from polypropylene-- a lighter, more flexible, and less expensive type of plastic.", "The cutlery molds consist of two halves.", "You can see the difference in this fork mold.", "In one half, the utensil cavities are right-side up-- the fork prongs indented.", "In the other half, the cavities are upside down-- the fork prongs raised.", "A plastic-injection machine melts the pellets and injects the molten plastic into the mold.", "A built-in cooling system solidifies the form in about 10 seconds.", "The extracted cutlery drops to a conveyor belt that leads directly to the automated-packaging equipment.", "For certain customers such as fast-food restaurants, the factory packages utensils individually.", "The automated wrapping machine cuts polyethylene film to size, heat-sealing the ends.", "This factory also uses polypropylene pellets to make straws.", "The black beads are pigments to color the plastic.", "An extruder-- a different one this time-- melts the pellets, then forces the molten plastic through a circle-shaped die.", "As the long, continuous straw exits the extruder, it cools and hardens in a tank of chilled water.", "As it leaves the tank, a knife chops it into individual straws.", "They fall onto a conveyor belt which transports them to the packaging line.", "Just like the forks, these straws will also be individually wrapped-- but in paper, not plastic film.", "The wrapper machine feeds them one-by-one into a paper sleeve.", "Gears mesh the edges together, creating a crimped seal.", "The dies on this machine turn ordinary straws into flexible ones by forming a corrugated section that lets you bend the top of the straw toward your mouth.", "The machine compresses the corrugation to preserve the shape.", "Back to the plastic cups now.", "This factory can print customized designs in up to six colors applied simultaneously.", "Ultraviolet lamps built right into the printing press dry the ink instantly.", "Polystyrene is naturally transparent.", "Combining two grades of polystyrene creates plasticware that's semiopaque and also highly flexible.", "On \"how it's made,\" we usually stick to the show's title and show you how products are manufactured.", "But this next segment is about special-effects makeup-- the kind that makeup artists use on theater and movie actors.", "So in this case, we'll show you how it's made, but we'll also show you how it's applied.", "Watch as this special-effects-makeup artist works his magic to transform this 28-year-old woman into a senior citizen.", "After gelling her hair flat, he glued on a bald cap using a theatrical adhesive called spirit gum.", "He protects her eyebrows and eyelashes with petroleum jelly, then covers her face in alginate, a material generally used to take dental impressions.", "Then he applies wet plaster bandages.", "After 25 minutes, the materials harden into a mask.", "Now he lines it with plaster.", "In a half-hour, the plaster hardens into a perfect replica of the woman's face.", "Like putting non-stick spray on a baking pan, he coats the model in a release agent.", "Then, using professional-grade plasticine, he begins to sculpt an elderly face.", "He smoothes out the wrinkles with strong rubbing alcohol so they'll look realistic.", "He uses a bumpy rubber pad to give the skin an aged orange-peel texture.", "The finished sculpture sits in water for 2 to 3 hours.", "This activates the release agent, detaching the plasticine from the plaster underneath.", "The artist carefully cuts the sculpture into sections.", "The number of pieces varies with the size and complexity of the mask.", "Now he can start producing the mold he'll use to cast the elderly woman's face mask.", "First, he takes a thin plaster impression of each piece.", "Then he coats the impression in plaster to make the positive half of the mold.", "Once it hardens, he applies the plasticine piece to space the depth of the mold cavity.", "Then he coats that in plaster to create the negative half of the mold.", "When it hardens, he applies release agent to both mold cavities, pours in hot gelatin, then closes the mold.", "In a half-hour, the gelatin hardens into a flexible replica of that particular piece of the plasticine sculpture.", "He implants synthetic hairs to create eyebrows.", "Now, using surgical glue, he begins to apply the pieces, called prosthetics.", "He starts with the largest facepiece first.", "It includes the nose, cheeks, neck, and upper lip.", "He cuts a hole in the chin area so that he can apply the chinpiece.", "Now the lower lip.", "He cuts off the excess, then glues the edges of the chinpiece to the large facepiece.", "Now for the forehead-- again, he applies glue along the edges to connect it to the rest.", "To age the eyes, he uses contact lenses.", "They create a ring around the iris-- a typical feature of elderly eyes.", "Using tweezers, he applies eye bags, again gluing the edges to the rest of the mask.", "And finally, some wrinkly eyelids.", "With the mask fully assembled, it's makeup time.", "Using a toothbrush, the artist sprays it unevenly over the mask, then smudges it with his fingers.", "This technique creates a realistic look because the human face-- aged skin especially-- has color variations.", "Using a very thin brush, he accentuates some wrinkles by creating depth with a darker color.", "Now some freckles and age spots...", "And a gray wig.", "And finally, just a bit of lip color because lips dull with age.", "All this takes an experienced makeup artist about a month of work.", "And such expertise doesn't come cheap.", "A major transformation like this for stage or screen can cost up to $10,000.", "Gold is the softest and most malleable metal.", "It can be pressed extremely thin, crafted into various shapes, even drawn out to form a fine wire, and all without breaking.", "Gold isn't affected by water or oxygen, as many metals are, so it doesn't rust or tarnish.", "Most gold comes from lode deposits, also called vein deposits-- concentrations of gold and other metals in the cracks of rocks.", "Lode deposits require hard-rock mining, using drilling and blasting to remove gold-bearing rock called ore.", "Miners descend more than 1,600 feet underground.", "There they drill holes for explosives using what's called a long hole air drill.", "They drill in a specific pattern set out in a plan prepared by the mine's engineers.", "The engineers know exactly where those veins of gold are thanks to the mining company's geologists, who've studied ore samples.", "The company collects these samples by drilling deep into the rock at 50-foot intervals.", "These diamond-drill cores, as they're called, are up to 330 feet long and measure 1.5 inches in diameter.", "Gold in its natural state isn't pure.", "It's usually intertwined with silver or other metals.", "So the mined ore has to be processed afterward to isolate and extract the gold.", "A ton of ore yields only about 2/10ths of an ounce of gold.", "After blasting the rock apart with explosives, miners use what's called a muck machine to transfer the ore to cars headed to the main shaft and then aboveground to the mill.", "There, a crusher reduces the large chunks into smaller rocks about the size of road gravel.", "A mill then pulverizes them to the texture of beach sand.", "The factory adds a water and cyanide solution, then another mill grinds it further into a mud-like pulp.", "The pulp flows into large settling tanks.", "The wet solids are heavier and sink to the bottom.", "The water at the top drains to another area.", "They transfer the wet solids to an agitation tank and blow in air.", "The oxygen sets off a chemical reaction between the cyanide and the gold trapped in the ore, triggering the gold to dissolve and leach into the surrounding water.", "Drum filters then separate the water from the solids.", "This water now joins the water that was separated earlier.", "They pour in zinc powder to solidify the dissolved gold and form pieces containing both zinc and gold.", "To smelt it into bars, they first have to mix several chemicals-- manganese dioxide...", "Fluoride...", "Silica flour...", "Borax...", "And sodium nitrate.", "This chemical mix, called flux, will separate the gold from the impurities.", "They pour it into the smelter, whose temperature is a fiery 2,910 degrees fahrenheit.", "They rotate the smelter so that the contents heat evenly over 2 1/2 hours.", "The heavier gold eventually sinks to the bottom, while the impurities, called slag, float to the surface.", "They pour out the slag, taking a sample to make sure it contains no gold.", "If it does, it goes back in until it's gold-free.", "By now, the gold has cooled slightly, so they reheat it to 2,910 degrees fahrenheit, then cast it into bar-shaped molds.", "The gold takes about four minutes to solidify.", "It's put in a basin of cold water, where it will cool completely after an hour.", "They extract the gold bars from the molds and clean off any slag residue.", "Gold bars are also called ingots.", "At this stage, the gold is 80% pure.", "The united states mint will refine it to 99.9%-- the international gold standard.", "Harps come in many sizes.", "The type that classical musicians play is known as the orchestral, or concert, harp.", "It produces more tones than any other stringed instrument.", "The player plucks the harp with the thumb and first three fingers of each hand, while at the same time operating foot pedals.", "The harp is one of the oldest string instruments, originating in the middle east as early as 3000 b.c. harps begin appearing in europe in the 700s.", "They initially had a curved pillar.", "By about 1500, this evolved into a sturdier straight pillar that could support more tension.", "As music became more sophisticated, they added a second row of strings as well as pitch-raising mechanisms, enabling the orchestral harp to produce more notes.", "This harp is a cross between a classical harp and a celtic harp.", "There's the pillar in the front, the sound box in the back, and the neck running across the top.", "The sides of the sound box are called the ribs.", "They're made from pieces of solid poplar, 3/10ths of an inch thick.", "The instrument maker traces a rib-shaped template on the wood and then cuts out the shape using a band saw.", "He clamps them onto his worktable and, with a plane, makes them symmetrical.", "Now he draws three lines across each rib to mark where he'll cut slots.", "You'll see what those slots are for later on.", "Next he glues on a notched strip of wood called a lining to the curved side of the rib.", "The lining enlarges the glueable surface, making it easier to assemble the side to the back of the sound box.", "The notches enable the lining to bend to the curved shape.", "Now he glues on the lining that will connect the straight side of the rib to the front of the sound box.", "He shaves off some wood with a small plane, then rounds off a corner.", "He planes the back lining as well, removing a corner to flatten it.", "Trimming the linings reduces the final weight of the instrument.", "Now he cuts off the ends of the linings on both sides to be able to slide into place the adjoining parts, the bottom plate, and the top plate.", "They're made of russian plywood, which is a piece of plywood sandwiched between sheets of birchwood 1/10th of an inch thick.", "He glues the top plate into place, then clamps it.", "He does the same with the bottom plate.", "He closes the back of the sound box with what's called the back plate.", "It's also cut from russian plywood.", "He glues it onto the lining, applying pressure with tight rubber strapping.", "When the glue dries after about an hour and the strapping comes off, he marks the location of the sound holes, the holes from which sound exits the instrument.", "He constructs the top plate on the front of the sound box from solid spruce.", "He lays the pieces down from widest to narrowest, then glues on a reinforcement strip made of solid maple.", "The strings pass through the strip and another on the inside.", "They prevent the tension from rupturing the top plate.", "He attaches a solid poplar frame to strengthen where the top plate and the ribs join.", "After sanding with fine sandpaper, he coats the sound box in varnish.", "Remember those slots in the ribs?", "They now hold bracings to prevent the ribs from bowing under the tension of the strings.", "Using a band saw, the instrument maker cuts the neck from a board of russian plywood about an inch thick.", "He makes a slot for gluing the pillar, also made of russian plywood.", "Once the varnish on the neck and pillar are dry, he hammers in pins for the strings.", "This type of harp has 34 strings.", "Brass bridge pins space them evenly apart.", "Steel zither pins adjust the tension for tuning.", "He uses a wooden guide to hammer the pins to a uniform depth.", "The three finished pieces fit together with dowels and slots.", "He secures the joints with glue and a long screw through the pillar.", "Strength is critical.", "This harp has to withstand 790 pounds of string tension.", "Reaching through the sound holes, he threads the strings through the reinforcement strips to the pins outside.", "These are nylon strings.", "Harps can also have steel strings.", "He winds them around the zither pins with a special key.", "The last step is to tune the harp with the help of an electronic tuner." ]

{ "things": [ "Horse" ] }

[ "Today on \"how it's made\"...", "Horse-drawn carriages...", "Artificial eyes...", "Dog and cat food...", "And mirrors.", "Nothing takes you back to the past quite like a ride in a horse-drawn carriage, a timeless vehicle in both appearance and construction.", "Building one today still requires the expertise of several traditional craftspeople, from ironworkers to wheelwrights.", "The carriage's turning mechanism is a fifth wheel that is positioned horizontally above the two front wheels.", "Workers weld the fifth wheel to the carriage's steel frame then weld the boarding steps to the frame.", "Until now the frame has been positioned upside down.", "Now they turn it right side up to install the driver's seat.", "First they measure carefully to ensure it's perfectly centered.", "Then they weld it in place.", "Once the frame is complete, it goes through an acid wash to remove any residue.", "Then they buff the welded joints to smooth out their surface.", "The carriage has drum brakes.", "Workers install them onto the axle then assemble the steel springs that make up the suspension and bolt them onto the axle as well.", "Next, they connect the brake line.", "Then they install the whole assembly under the carriage's frame.", "Like in the olden days, they make the wheels out of wood.", "Metal isn't flexible enough to withstand bumps in the road.", "They use ash because it's a very hard wood that doesn't rot easily.", "Workers position 16 spokes around a steel hub.", "They clamp the spokes in place, compressing them against the hub.", "Then they secure them with nuts and bolts.", "Next, they mark the spokes in two places.", "The first line shows how long to cut each spoke, the second line how far to dowel the end.", "To form the dowel, they first shape the end into a cone.", "Then the cone into a dowel.", "Those doweled spokes will fit into corresponding holes they now drill into two semicircular strips of wood.", "The strips form what's called the fellow, the round part of the wheel.", "Workers tighten the hub then press a steel band called a channel against the fellow.", "They cut the channel to size.", "Then weld the ends together.", "Finally, they buff the joint smooth.", "Next, they drill eight holes through the channel then, using a tapering tool, thread the holes to fit the bolts that bind the channel to the fellow.", "Finally, they tighten the bolts with a special gun.", "The tires are made of rubber.", "They contain two steel wires to hold them in place over the wheel.", "Workers grease the channel of the now-painted wheel so that the tire will slip on easily.", "Then they mount the wheel on the automated tire-installation machine, which pulls on the wires, installing the tire tightly over the wheel.", "They solder the wire ends together using bronze solder for a stronger joint.", "Then-- here comes the high-tech part-- they bang the wheel on the ground four or five times until the distance between the tire ends closes, covering the soldered wires inside.", "A tap of the hammer followed by a final bang ensures the tire joint is secure.", "Now they can mount the wheels onto the axles and install the axles under the body of the carriage.", "After testing the fifth wheel and the brakes...", "It's time to apply the finishing artistic touches.", "All they need now is a little horsepower.", "The ancient romans and egyptians fashioned artificial eyes out of painted clay.", "By the 1500s, europeans started making them out of enameled gold and soon out of glass, which remained the norm for hundreds of years.", "Today most artificial eyes are made of acrylic.", "If you've lost an eye in an accident or to a disease, a specialist known as an ocularist can fit you with an artificial eye.", "You can get a ready-made model or a custom-made prosthesis, like the one for which this patient is being fitted.", "No two people's eye sockets are the same, so the first step is to take an impression.", "After inserting an impression tray, they inject a material called alginate, filling the entire socket cavity.", "After 90 seconds, the alginate sets, and they can remove the hardened impression.", "They place the impression in a mold.", "And pour in a type of plaster.", "When the plaster has hardened, they remove the impression tray and then the impression itself.", "What's left in the mold is a plaster replica of the socket.", "Now they put a wad of acrylic plastic dough into the mold...", "Lock the mold into a press, and submerge it in a high-pressure curing unit for 25 minutes.", "Then they cool the mold in cold water.", "Here's the original impression compared to the acrylic model they've just cast.", "This model is called the fitting shape because they use it to fit and mark the positioning of the fake iris.", "They accentuate the markings, then attach a peg with a drop of wax.", "The peg indicates the natural angle of the iris when the patient is looking forward.", "Next, they add wax around the perimeter to enlarge the fitting shape.", "This excess will give the ocularist some room to work with for the final sizing.", "Now they take this marked and enlarged fitting shape and make a plaster mold.", "They will later use that mold to cast the actual artificial eye.", "But first they have to make the iris.", "They take a curved, black acrylic disc and paint it as realistically as possible with high-quality artist oils.", "The patient has to be present so they can match the real eye.", "Next, they glue an acrylic cornea with an appropriate-sized pupil onto the painted iris.", "At this point, the artificial iris is half an inch in diameter.", "If the patient's real iris is smaller, they trim down the replica to match.", "The iris then goes into the plaster mold covered with white acrylic dough.", "After the same high-pressure curing process as before, out comes the artificial eye covered with excess white acrylic.", "They trim off that excess and the peg using a grinding tool and a cutter.", "This refines the shape and exposes the iris buried underneath.", "They smooth the surface against a grinding stone and verify the measurements.", "Then, using hard coloring pencils, they add finishing touches to the iris and draw blood vessels.", "They label the eye with the patient's initials and then apply an acrylic coating to seal the pencil marks.", "To create veins with some dimension, they use the same acrylic coating to stick on some delicate silk threads.", "Once they're satisfied the artificial eye is a perfect match, they seal the artwork with another acrylic coating.", "Once that cures, they polish the eye to a shine with a cotton wheel.", "The shapes and colors of artificial eyes are endless because patients' eye sockets and irises vary greatly, as do their scleras, the white of the eye.", "This artificial eye, or ocular prosthesis, is ready.", "The final step is to ensure that the fit is perfect.", "The patient's ocular muscles attach to the implant, enabling his artificial eye to move in unison with his real eye.", "So much for feeding fido scraps from the table.", "Today's pet food is the stuff of sophisticated nutritional science.", "It's about protein, carbohydrates, vitamins, minerals-- a well-balanced diet.", "Want to bet some dogs and cats eat healthier than their owners?", "The formulas for dog and cat food differ because dogs and cats have different nutritional requirements.", "Cats, for instance, need more fat and protein in their diet than dogs do.", "But the basic ingredients that factories grind up to make dog and cat food are similar.", "First, corn kernels.", "Then cereals, such as barley...", "Wheat...", "And rice.", "Workers weigh the ingredients, grind them in a mill, then combine everything in a mixer until they have an even and well-blended powder.", "A machine called the extruder transforms that powder into bite-sized pieces of pet food.", "It steam-coats the mixture, then forces it through dies at high pressure.", "The dies shape it, the way the tip of a pastry bag shapes icing into swirls or roses.", "Check out this dog-bone die.", "As the continuous stream of shaped mixture exits the die, a spinning knife cuts it into pieces.", "The company has different dies to produce different shapes.", "This is a batch of round pieces.", "Next stop, a hot-air dryer for 25 minutes.", "It heats the pieces to 300 degrees fahrenheit to draw out the moisture, then cools them at room temperature.", "Once the pieces exit the dryer, they enter a revolving drum, where they're sprayed with fat and flavoring.", "The fat is designed to add food energy while the flavoring gives the bland pieces an appetizing odor and taste-- appetizing for pets, that is.", "The rotation ensures the pieces get coated evenly.", "From here, the pieces go into storage silos.", "When they leave the silos for bagging, the machinery screens out any crumbs.", "The pet-food industry has made some interesting observations about the likes and dislikes of its four-legged clientele.", "Apparently, cats and dogs aren't crazy about food that's too dry, too hard to chew, or too mushy.", "If the pieces are too small, they'll swallow them whole without chewing and not digest them properly.", "But if the pieces are too big, they'll gag and get turned off to the food altogether.", "In the packaging department, automated scales weigh the exact quantity per package.", "This batch is destined for bags weighing about 6 1/2 pounds.", "The package sizes range from just under one pound all the way up to 44 pounds.", "Shelf life is from 12 to 16 months, depending on the formula.", "Pet-food experts say dogs and cats prefer food with a fattier content and a combined meat-and-cereal formula over just cereal alone, but too much meat flavoring can turn them off.", "Cats, as a rule, are more particular.", "They favor more acidic food, while dogs tend to have a sweeter tooth.", "And you thought kids were fussy eaters.", "No bathroom is complete without one.", "And any parent will tell you that no teenager can survive without one.", "Mirror, mirror on the wall, how do they make you, after all?", "Well, \"how it's made\" is about to show you.", "But first, let's reflect on the history of mirrors.", "The earliest mirrors were curved pieces of highly polished metal, such as brass or bronze.", "They're even mentioned in the bible.", "Then, in the 14th century, the venetians invented very crude glass mirrors that reflected off a metallic backing.", "They later perfected this technique using an amalgam of tin and mercury.", "Eventually, the secret of mirror-making spread to other cities.", "By 1835, a german chemist developed the silver-backed mirror that we know today.", "A mirror starts out as clear glass.", "A robot lays each panel horizontally on a conveyor belt, which transports it to the washing station.", "There, sprayers blast the glass with water and cerium oxide, a powder derived from a type of soil.", "Rotating brushes scrub and polish both the top and bottom surfaces, removing oils and other contaminants.", "This washing process takes about a minute per panel.", "Next, sprayers rinse the glass with piping-hot demineralized water, demineralized because the minerals in plain tap water would damage the metals they apply next.", "The first metal is liquefied tin, which goes on what will be the back of the mirror.", "It allows the second metal, silver, to adhere because silver won't stick directly to glass.", "The silver is also in liquid form mixed with a chemical activator.", "Within seconds of interacting with the tin, it hardens.", "And as it does, you begin to see a reflection.", "It's this silver backing that transforms clear glass into a mirror.", "Sprayers rinse off the excess silver, which gets recycled back into the system.", "The factory will seal the silver backing with two coats of paint.", "Paint by itself, however, isn't enough to protect the silver in the long term.", "So they first spray on a layer of copper.", "Sprayers rinse off the excess copper.", "Then the panel passes through a dryer at almost 160 degrees fahrenheit.", "This evaporates the moisture on the surface in just 75 seconds.", "Now the panel passes, copper side up, through what is called the curtain coater, a machine that runs a continuous curtain of paint across the conveyor belt.", "With its fresh coat of paint, the mirror then passes through an oven heated to 210 degrees fahrenheit.", "After a minute and 45 seconds, the paint is cured.", "Now the second coat of paint.", "There's no reason for the different color other than to differentiate the coats.", "This time, the curing period is twice as long and at a higher temperature, close to 245 degrees fahrenheit.", "After an acid wash to remove any metal residues, they stand the panel upright to inspect it.", "If they find a fault, such as a bubble in the glass, they cut that portion out.", "The factory now cuts these large panels into whatever size and shape the customer has ordered using a special mirror-cutting machine that's precision-guided by computer software.", "It scores the mirror using a carbide wheel.", "Carbide is a strong metal.", "To make round mirrors, the machine first scores the panel into squares.", "Then, in each square, it scores a circle.", "Using special tools, workers separate the squares, then the circles.", "To make beveled mirrors, they use what's called the shape-bevel machine.", "First, it carves out the edge.", "Then polishes it to a shine using concentrated cerium oxide, a stronger version of what they used earlier to clean the glass surface before plating it with metals.", "Mirror factories also ship whole panels to shops that do the cutting themselves, a fragile feat that's certainly not for the superstitious." ]

{ "things": [ "Induction Cooktops", "Truck Scales", "Tetra Pak Containers", "Harmonicas" ] }

[ "Mankind has always cooked food, using everything from campfires and barbecues to gas and electric stove tops.", "Now he can use an induction cooktop.", "It doesn't need a fire, a flame, or a red-hot burner.", "It uses innovative cooking technology our ancestors never dreamt possible and would swear was pure magic.", "An induction cooktop doesn't use traditional cooking elements above or below the cooking surface.", "It uses copper induction coils that generate high-frequency electromagnetic fields.", "These fields excite the molecules in the pan, creating heat only in the cookware itself.", "That's why the yolk remains cold and only what touches the pan cooks.", "The magic starts with a punching press that stamps computer-generated shapes into sheets of cold-rolled steel.", "These cutouts fix the position of the induction coils that sit under the glass surface.", "A press break bends the four sides of the steel so it will hold a glass-ceramic top in place.", "In the meantime, a machine spray-paints the burner box, the visible part of the cooktop.", "A technician affixes the labels and the power cord onto a housing box that will conceal the induction electronics and coils.", "She secures the power cord for strain relief.", "She then attaches the power-cord ground and a system ground wire to the housing box.", "She places a cover on the box and screws it into place.", "Another technician puts together the induction electronics.", "These assemblies of circuit boards, cooling fans, and semiconductors drive the cooktop.", "She covers the electronics with insulation and a metal carrier plate that will support the induction coils.", "Then she feeds the user-interface wires through the top of the coil-carrier plate.", "The technician screws the carrier plate and the electronic assemblies together, then grounds the electronics.", "Protective tape around the openings will prevent the user-interface wires from rubbing against the coil-carrier plate.", "And some insulation will protect the electronic assemblies.", "She closes that side of the electronic housing box and attaches all the power cables.", "A sheet of insulation goes on the flip side of the box, where she mounts the electromagnetic-coil assemblies.", "The iron slugs on the back of each coil pod help distribute the electromagnetic energy to the cookware evenly.", "She connects the coil assembly to the system board.", "Then she places the remaining four coil assemblies onto the carrier plate and connects their leads to the system board.", "Meanwhile, another technician assembles the components of a glass touch-user-interface panel.", "She connects the interface to the steel holder that was bent into shape at the start and is now attached to the black burner box.", "She covers the cooking surface and control panel with an attractive stainless-steel frame, then connects the system board to the control panel.", "She closes up the other side of the burner box.", "Then she bolts everything down to complete the cooktop.", "A technician tests the unit.", "Using a metal object to activate the electromagnetic field, he verifies that the controls respond properly.", "He makes sure all five induction coils are working and the power output from each coil is correct.", "The control panel confirms it's a success.", "Clean, safe, and energy-efficient, induction cooktops make cooking food quick and easy.", "At a highway weigh station, inspectors weigh each transport truck on a road-level scale to calculate taxes on the goods it's hauling and to make sure the load doesn't exceed safety limits.", "You also find truck scales at grain silos, quarries, and other sites that move bulk products.", "The key to this enormous scale is the tiny component called a strain gauge, which sends signals to the scale's computer when compressed.", "They make the strain gauge from a laminate by bonding paper-thin sheets of nickel-iron foil, epoxy, and teflon in a press.", "Then they coat the laminate in a light-sensitive chemical and apply a plastic film with an image of strain gauges in negative format.", "Then they expose the setup to ultraviolet light.", "The light-sensitive chemical reacts, imprinting the images into the laminate's metal surface.", "Now they have rows of strain gauges.", "An inspector examines every gauge and marks any flaws to be discarded.", "Now a technician measures how much voltage flows through each gauge.", "If it's too low, she raises it by rubbing off a microscopic amount of surface metal.", "When the strain gauges are finished, they cut them apart and send them to the load cell department.", "There, workers delicately tape four strain gauges into each stainless-steel load cell.", "Then they solder electrical wiring to each one.", "The wires all run to a circuit board at one end of the load cell.", "And from the load cell, wiring runs to the scale's computer readout.", "The smallest amount of moisture or dirt would cause a strain gauge to malfunction, so they weld a cup over each one to hermetically seal it within the load cell.", "Every finished load cell undergoes a quality-control check to verify that it works properly.", "The testing machine applies weight in increments until it hits the maximum weight the cell can bear-- 34,000 kilograms, or 75,000 pounds.", "The truck-scale structure in which they'll install the load cells is called the weighbridge.", "They begin assembling it upside down, with a surface made of steel plates.", "To build the base of the weighbridge, they lay out a grid of thick steel tubes and crossbeams.", "Workers lower a guide to help them align the parts perfectly.", "Beneath each load cell is a pin.", "In order to weigh accurately, a load cell has to be level, so it's critical to make sure this pin is level before welding on the bulkhead that holds it.", "Once fully welded, the weighbridge is assembled and ready for painting.", "The paint equipment laces the powdered paint with a positive electrical charge and the weighbridge with a negative one.", "This evenly draws the paint particles onto the steel like a magnet.", "In another department, they assemble the steel stand on which the load cell will sit.", "A welder tacks the pieces together, then a robot does the full welding.", "Now that all parts are ready, final assembly of the truck scale can begin.", "The weighbridge, right-side up now, contains eight load cells at different locations.", "The first step is to install each load-cell stand into its respective position.", "They insert a link on each side of the stand.", "They position the load cell at the top of the links...", "And the bulkhead pin at the bottom.", "Then they close up the location with an access plate.", "The last step is to calibrate the scale.", "They lay a 10,000-pound weight on different parts of the scale to check if the digital readout is accurate.", "It takes a lot of time to get a truck scale just right, but it's definitely worth the \"wait\".", "[weight] tetra pak containers keep drinks and food products safe to consume for up to a year without refrigeration or the use of additional preservatives.", "Made mostly from paper, they're recyclable into things like egg cartons, paper towels, and toilet paper.", "A tetra pak container is packaging built with nature and freshness in mind.", "Tetra pak containers hold all sorts of food products, from smoothies to fine wines.", "The package gives products a long shelf life because of its special layers-- the plastic layer, the paperboard, and the foil.", "A plastic coating makes the package leakproof.", "Tetra pak containers are made entirely from recyclable materials.", "The first step to making them is printing.", "A worker selects the appropriate printing plates for a given customer and applies them to the cylinder of the printing press.", "The press transfers one color at a time to the paperboard layer using solvent-free ink.", "A tetra pak container can have up to six colors.", "At full speed, it takes only minutes to print.", "A strobe light visually stops the motion, helping the pressman check the quality of the printing.", "A worker feeds the printed paperboard into a lamination machine that will join it with the plastic and foil layers.", "At the same time, a worker loads a roll of micro-thin aluminum foil into the laminator.", "A gas flame heat-treats the paperboard to ensure adhesion to the plastic layer.", "The laminator extrudes liquefied plastic between the roll of aluminum and the heated paperboard.", "Rollers squeeze all the layers together.", "The printed paperboard, with all its protective layers applied, then comes off the back end of the laminator in a large master roll.", "The operator threads it into a cutting machine called a slitter.", "It cuts and winds the printed material onto individual rolls.", "The slitter's knives cut the material into four lanes, each of which becomes a smaller roll.", "The operator trims the excess material from each roll.", "Then a conveyor system sends the rolls for shipping to a packer to be filled with their product.", "At the packer's plant, an operator loads the roll of flat packages into a filling machine built and installed by tetra pak.", "Tension rollers guide the material into the filling machine where it is sterilized.", "The machine then forms and seals the material into one continuous tube.", "And a little further down, the machine fills the tube with product.", "It then cuts the tube into individually sealed packages...", "And drops them into a chute for folding.", "It ejects the finished packages onto a conveyor belt.", "Finally, it sends the packages on their way to the customer.", "Lightweight, compact, and recyclable, tetra pak containers are eco-friendly, and that's certainly something to celebrate over a glass of fine wine.", "There are two main types of harmonicas.", "A diatonic harmonica has 10 mouth holes.", "It plays a 7-note major scale in a single key of music.", "A chromatic harmonica has up to 16 holes, plus a special slide mechanism to produce extra notes so it can play in any key.", "as air goes through a harmonica, so does saliva, which is why they make the inner structure from a type of wood that doesn't expand or smell with repeated exposure to moisture.", "Making a standard chromatic harmonica begins with a block of pearwood measuring about 5 1/2 by 1 1/4 inches.", "They run it against a cutter that carves a row of air chambers front and back.", "This produces the component known as the comb.", "A press stamps slots in a millimeter-thick brass plate that will hold the reeds.", "The plate will eventually go on top of the comb, its slots aligning with the comb's air chambers.", "Another machine cuts reeds from brass-based metal specially formulated by this company to produce quality sound and be corrosion-resistant.", "Working one size at a time, they cut a batch of a few hundred reeds.", "They test a reed from each batch with a tuning machine, plucking it to see if it produces the correct pitch.", "The size and profile of a reed determines the note it produces.", "The longer it is, the lower the note, and vice versa.", "Now they rivet the reeds to the reed plate-- one reed for each note.", "Consecutive reeds go on opposite sides of the plate.", "With this configuration, blowing into the harmonica vibrates one reed, while drawing air out vibrates the other.", "They flatten each rivet on one side of the plate.", "This fastens the reed securely at the bottom, leaving the rest free to vibrate.", "If necessary, they file the reed down so the slot doesn't obstruct its movement.", "now a tuning specialist gets to work.", "She plays each reed on the plate and compares the tone to a perfectly tuned set of reeds for reference.", "If the pitch is off, she adjusts it with a bit of filing.", "once the reed plate is in tune, it goes on top of the comb, the reeds and slots aligning with the comb's air chambers.", "Workers attach the parts with steel nails that have a brass plating to prevent corrosion.", "Now for the two-piece cover that encloses these internal components.", "For standard models, the factory uses stainless steel, starting with a sheet that's less than a half a millimeter thick.", "Fancier harmonicas have silver- or gold-plated covers.", "The sheet goes through a press that has a series of dies.", "They progressively stamp out the cover pieces, first embossing the artwork, then cutting the size, then forming the shape.", "Workers sandwich the comb between the two cover pieces, then attach everything with either brass-plated nails or brass- or nickel-plated screws.", "Chromatic harmonicas have a mouthpiece over the blowholes.", "It's usually made of chrome-plated brass that they curve slightly in a press.", "The mouthpiece shields the lips from a slide mechanism inside.", "That mechanism has three parts-- a slide with a button positioned in between two plates.", "They screw the mouthpiece onto the front of the harmonica.", "When you press the mouthpiece button, it redirects the air, raising the notes half a tone.", "No harmonica leaves the factory without a sound test.", "Rather than blow into every instrument, the testing department uses a machine that blows air in and out.", "last stop is the cleaning department.", "There, workers inspect for scratches, then polish and package so that each and every harmonica will look as good as it sounds." ]

{ "things": [ "Bronze Bells", "Wooden Airplane Propellers", "Charcoal Briquettes", "Gas Log Fireplaces" ] }

[ "Today on \"how it's made\"...", "Bronze bells...", "Wooden airplane propellers...", "Charcoal briquettes...", "And gas-log fireplaces.", "Throughout history, bells have played both practical and ceremonial roles.", "Village bells would ring to mark time and to warn of danger.", "Church bells would toll to summon worshipers.", "Bells are traditionally cast of bronze, a metal that's as durable as it is melodic.", "when it comes to bell making, there'd be neither swing nor ring without a mold.", "And only a quality mold makes a quality bell.", "The mold is made using a pattern.", "This particular bell will have decorative lines on the surface, which will require a separate mold made from this five-piece pattern.", "After greasing the pattern's surface with a release agent, workers lower a wooden casing around it.", "This casing will hold the mixture of fine silica sand and epoxy they'll use to make the mold.", "Workers pack the material tightly between the pattern and casing.", "The epoxy sets in 10 minutes, and now they have a sand mold in which to cast the bell's decorations.", "They still need a mold to cast the bell itself.", "They make it with this aluminum pattern.", "After spraying it inside and out with a release agent, they lower the decoration mold they just made right over it...", "Then on top of that, a steel casing to contain the sand mix.", "Workers pack the sand mix and wait for it to set.", "Then they flip the casing and add another section to hold even more sand mix.", "But before the next load of sand, they insert what's called the gate.", "This aluminum rod shapes the channel through which they'll pour the molten bronze into the mold cavity.", "They fill up the mold with more sand.", "Then they form a funnel around the central channel because it's virtually impossible to pour molten bronze directly into such a small hole.", "They poke the sand mix to make sure it's set, then pull out the gate.", "They separate the two casings, each of which contains a section of the mold.", "Then the patterns come out, leaving behind the mold cavity.", "Workers tidy up the mold walls and paint on a powdered graphite solution which will act as a barrier, preventing the hot metal from eroding the epoxy that holds the sand mold together.", "Next, they spray on a second coat of wash.", "The sand is so fine that without this step, the mold would reproduce the brush strokes onto the cast bell.", "Now they measure the size of the pour hole and custom-make a ceramic filter to glue inside.", "This filter will screen out the slag, oxidized particles that form when molten metal meets air.", "Workers stack the two mold sections back together and clamp them tightly so that the bronze won't leak out during casting.", "Melting enough bronze ingots for an average-size bell takes about two hours.", "To get a smooth enough consistency, the furnace has to heat the metal to about 2,100 degrees.", "For a quality casting, they must pour the bronze in one continuous flow-- no stops and starts.", "The funneling basin they made in the sand prevents overflowing.", "The bronze takes about a half-hour to solidify and up to 24 hours to cool.", "Workers remove the sand mold with a jackhammer, being very careful not to hit the bell inside.", "The extracted bell is covered in a residue of burnt epoxy, which they remove with a wire brush.", "Then, with one well-aimed strike of a sledgehammer, they disengage the gate.", "Now they mark the exact center point of the bell.", "That's where they'll install the hardware from which the bell will hang.", "They drill a small hole, then gradually drill it larger and larger.", "A big hole can't be bored in one shot because the friction-induced heat would crack the bell.", "Workers tip the bell on its side to hang the clapper-- the official name for the bronze hammer inside.", "Every bell this factory produces goes through six stages of polishing, starting with a coarse grinding belt and finishing with a fine-cloth buffing wheel.", "Two hours of polishing later, the bell looks as beautiful as it sounds.", "coming up...", "A new spin on a centuries-old invention-- the wooden propeller.", "The propeller dates back to 1493, when leonardo da vinci sketched out the concept for a helical screw that could propel a machine vertically into the sky.", "The propeller is still occasionally referred to as an airscrew-- a term that accurately reflects its basic design and function.", "The key to making one-- plenty of sanding.", "Wooden propellers start out as a laminated block of maple wood.", "Lamination is a process where several layers are glued together.", "The block has between 36 and 48 layers less than 1/16 of an inch thick.", "Depending on the model, workers select a master pattern that is between one and two yards long.", "They lay this pattern over the maple block and mark a one-inch center hole.", "They drill the hole...", "And lay in a centering pin to hold the pattern in place.", "A worker traces the pattern on the top of the block.", "He then cuts the outline with a band saw.", "This is the propeller's profile.", "Next, he traces a pattern on the side of the block.", "This is the propeller's pitch-- the amount of twist in the blades, which dictates the amount of propeller thrust.", "Using a pattern guide, he marks where the pitch blends into the center hub, then removes the bulk of the pitch with a band saw.", "Now he clamps the block onto a computer-guided milling machine that carves the pitch to very precise dimensions.", "The machine's carbide-tipped cutters shave infinitesimal amounts of wood with each pass.", "Precision milling just one end of the propeller can take up to 60 passes.", "Next, a worker shapes the airfoil with a band saw.", "The airfoil is the side of the propeller that is shaped like an airplane wing and produces forward thrust.", "The pitch side...", "And the airfoil side.", "Workers use a tool called a spokeshave to smooth the propeller even more.", "Then they verify the airfoil's thickness and curve with a hand gauge.", "A spray of dark paint helps them know where they've been as they begin smoothing the propeller's surface.", "They remove any remaining carving marks using a belt sander.", "Then they check the propeller for balance.", "Using a pneumatic sanding drum, they perform an overall sanding and punch in propeller specifications-- diameter, pitch, flight direction symbols, and manufacturer i.d. workers hand-inspect the propeller, then perform a final sanding and balance.", "A coat of clear enamel seals the wood.", "And a safety color sprayed on the tips makes the propeller visible while it's spinning.", "Two final protective coats of clear enamel, 24 hours of drying time, and these propellers are ready for takeoff.", "When we return, fire up the grill.", "It's time to make some charcoal briquettes.", "The charcoal briquette was invented in 1897, but interest in it was slow-burning, so to speak, until the 1920s.", "That's when automaker henry ford decided to recycle wood scraps from car making into barbecue briquettes, and these little nuggets became a smoking sensation.", "Barbecuing with charcoal has become immensely popular since ford's time, and every year, several million tons of wood scraps are converted into high-quality charcoal briquettes.", "Today, briquette production starts with sawdust and wood chips from lumber mills.", "A truck unloads it all into a pit.", "Bulldozers blend the material called fuel to obtain a uniform end product.", "As the mix travels up a conveyer, an electromagnet removes any metal contaminates.", "The mix falls onto a vibratory screener, which sifts out the larger pieces of wood.", "At this point, the fuel is still very moist.", "To dry it, a worm screw draws the mix up into a long, rotating dryer.", "The dryer heats the wood mix to a searing 1,400 degrees.", "The dryer is sealed to prevent oxygen from leaking in.", "This allows the wood to dry without catching fire.", "After four minutes in the dryer, the moisture has been cooked out of the mix.", "Workers add anthracite coal to the hopper, and it mixes in with the fuel.", "Anthracite coal is known for burning at high temperature.", "Then they mix in lime.", "Lime makes the briquettes turn white after they're ignited-- a visual indication that the barbecue is ready to rock 'n' roll.", "The mix, now blackened, passes under a second electromagnet to remove any metal that could damage the equipment downstream.", "Finally, workers blend in cornstarch, which binds the ingredients together.", "A worm screw supplies the mixture to a press roll, where a constant spray of water keeps the mixture from sticking.", "The press rolls compact the mixture into briquettes.", "The process takes just a fraction of a second.", "At this point, the briquettes contain 35% moisture and are very soft.", "A screener shakes out fine material from the briquettes, which is recycled back into the process.", "A sweep belt transports and distributes the briquettes in a 250-foot drying tunnel.", "They are heated to 280 degrees for 2 1/2 hours.", "This will reduce their moisture level from 35% to just 5%.", "The lower the moisture level, the better it burns.", "A conveyer transports the briquettes to automated scales that weigh them for packaging.", "Every portion is the same, plus or minus one briquette.", "As the scales release the briquettes, robots below move bags into position to capture them.", "A sealing machine glue-seals the bags, then prints a production date and shipped code on each one.", "Open the bag, and a backyard barbecue is just one match stroke away.", "And who can resist the smokey flavor of charcoal-grilled food?", "When we return...", "Turning up a different kind of flame with gas-log fireplaces.", "Gas-log fireplaces are clean-burning, fully contained units that are growing in popularity.", "They provide instant warmth at the flick of a switch.", "And you'll never have to head out on a cold winter night to get more logs or clean up the ashes.", "To make a gas-log fireplace, workers first screw fittings to a gas-control valve.", "Then they attach the valve and gas pilot to the frame.", "The gas pilot is a small flame that burns continuously, enabling you to ignite the gas instantly.", "They cap the control valve with knob extensions that allow the user to control the flame's intensity from outside the fireplace.", "Next, they install burners and orifices.", "The orifice controls the gas flow in each of the burners.", "They attach an electrical connection from the gas pilot to the control valve...", "Adjust the length of the gas-pilot supply line...", "And screw the line to the control valve.", "Finally, the line is attached to the gas pilot.", "The fireplace's ignition system is now complete.", "Next, workers attach a safety device called a thermocouple to the control valve.", "If the flame ever goes out, the thermocouple cuts the gas supply.", "The unit now undergoes testing to ensure that there are no leaks.", "What's a fireplace without logs, even if they're replicas of the real thing?", "This factory makes artificial logs from a mixture of fire-resistant ceramic fibers and a liquid resin that binds the fibers together.", "Workers attach a log-forming mold to a pumping arm...", "Then immerse the arm in the mixture.", "The mixture fills the mold cavity.", "The mixture is soft when it comes out of the mold and is held together by the dense, interwoven layers of fibers.", "The excess fiber is trimmed off, and the log is placed on a baking rack.", "Then it's into an oven at 450 degrees for 5 hours.", "When it comes out, it's as hard as a log.", "Workers remove the sharp edges with a rasp, then dip the log in a mixture of binder and heat-resistant paint.", "Over that, they hand-paint details replicating the look of charred wood.", "The paint is baked on, making this decoration permanent.", "And it'll have no problem taking the heat.", "The paint can withstand temperatures up to 2,300 degrees.", "Back in the testing department, workers calibrate the mechanism that adjusts the fireplace flame.", "They use a flowmeter to verify the rate at which the gas flows.", "The back burner produces a yellow flame, while the front burner gives off a reddish glow.", "Combined, they look more realistic.", "Workers package the individual components and include some lava rock to simulate a bed of ashes underneath the logs.", "It all adds up to a beautiful, cozy fire...", "At the flick of a switch." ]

{ "things": [ "1000th Item" ] }

[ "Cycling shoes have cleats for bolting the foot to the pedal.", "The cyclist is connected to the bicycle, body and soul.", "Bike shoes with clip-in cleats are a fairly recent innovation.", "The first versions appeared in france in the 1980s and were modeled after alpine ski bindings.", "Avid cyclists are very attached to their bicycles through special shoes that clip to the pedals.", "Cycling shoes transfer power from the foot to the pedal more efficiently than ordinary shoes.", "To start, an overhead press drives cookie-cutter shapes called dyes through layers of fabric to punch out shoe parts.", "They use breathable nylon mesh for these upper pieces and synthetic leather for parts like the shoe toe box.", "Synthetic leather is rigid, waterproof, and lightweight.", "It takes 18 pieces of fabric to make one cycling shoe.", "This assembler pieces together the upper mesh parts and stitches on synthetic leather trim.", "She adds a synthetic leather side with vent holes.", "It gives the cycling shoe structure.", "With one half of the cycling shoe now complete, it's ready for the other half.", "She joins it to the other half at the toe end using high-density nylon thread.", "The next part is the heel cup.", "It's a piece of molded polyurethane that adds strength and form to the back of the cycling shoe.", "She stitches on trim and joins the heel cup to the rest of the cycling shoe.", "Next, using superstrong kevlar thread, she sews the toe box and tongue to the cycling-shoe assembly.", "The configuration leaves open areas for mesh vents at the front of the shoe.", "The shoe upper is now complete and ready for the inner sole.", "It's made of high-density plastic.", "The employee tacks it to a foot mold using small nails.", "He sets it aside and places a pair of shoe uppers in hot and rounded clamps to warm them to a pliable state.", "He stretches each upper around a foot mold with a tacked inner sole.", "Then it's over to a machine that oozes epoxy-- a high-strength glue that is impervious to weather extremes.", "The machine grips and folds the cycling-shoe upper to the sole as it applies epoxy to seal them together.", "The epoxy hardens quickly, and a computer-controlled grinder gets rid of the excess.", "Now a spinning brush applies a different epoxy that will need heat to activate it.", "At the next station, a worker applies a release agent to a mold.", "He inserts a piece of carbon fiber-- a high-tech composite material.", "He adds nylon for texture.", "He flips the upper part of the mold, and the two parts come together like a waffle iron.", "Inside, the layers melt into one and then cool, creating a tough and lightweight outer sole.", "They punch out vent holes and trim the edges of the sole.", "They paint designs on to it and add a nonslip clear coat.", "He glues tough nylon mesh over the vent holes to keep the dirt out.", "He tapes the cleat mount onto it.", "It will be more securely installed for the individual cyclist at the bike shop.", "And after an application of epoxy, it's into the oven.", "At the same time, he heats the glue-covered outer sole in another oven.", "The heat activates the epoxy.", "It's time to join the outer sole and the shoe upper.", "He carefully aligns them and presses them together.", "He then sets the shoe on a cradle, and hydraulic pushers apply pressure as the glue sets.", "He presses the foot form that's still inside the shoe onto a sharp post, stabilizing it to pull the shoe off.", "The next employee installs a cable-closure device that acts like a shoelace but doesn't become tangled.", "She adds a ratchet-style plastic buckle.", "Crafted by hand using high-tech materials, it's taken about an hour to make these cycling shoes.", "And now they're ready for a spin.", "For centuries, yurts have been home to herders on the asian plateau.", "They continue now for practicality and portability.", "Today yurts used as second homes or studio spaces offer durability, comfort, and a barely detectable footprint.", "This is the engineered, modern version of the ancient nomadic structure.", "Compression and tension together form freestanding yurts that today feature all the modern conveniences, including kitchens, dining areas, and lofts.", "The vinyl polymer roof is gradually shaped into a cone.", "A worker folds the polymer, laying two edges beside each other on top of a formica board.", "Using a hot-air welder, he melts the two edges together.", "A vinyl laminate valance is heat-welded to the bottom perimeter of the roof, creating a watertight connection.", "Together, the workers pull the entire bottom perimeter of the roof through the heat welder.", "In the woodworking area, a worker drills a hole in a roof rafter.", "With a router, he cuts a notch that will eventually fit over a support cable.", "Workers spray an oil finish onto the tooled rafters for aesthetics and added weatherproofing.", "To keep the rafter from slipping off its cable, a worker screws a keeper bolt into a brass thread in the hole.", "He assembles the compression ring, which sits at the top of the yurt.", "He screws in rafter brackets made of galvanized steel.", "A worker uses silicone glue to attach a rubber gasket to the bottom edge of the roof's acrylic dome.", "The workers rest it on the compression ring, where it'll be held in place by cables and stainless-steel springs.", "They begin preparing the yurt's lattice wall.", "The vertical-grain pieces of douglas fir are dipped in water-based nontoxic penetrating oil.", "The pieces for the lattice wall are placed in a multiple-head boring machine.", "In one shot, it precision drills 200 identical holes through several pieces of wood.", "A worker begins assembling the lattice wall.", "As he lines up the pieces of wood, he flexes them to test their strength.", "The alloy rivets he places in the holes will act as hinges.", "He uses a pneumatic riveting machine to assemble the wall.", "Its load-bearing capability, once fully assembled, is extremely high.", "Larger yurts will have walls with as many as 200 pieces, while smaller yurts will have closer to 100.", "Once riveting is complete, the worker makes sure the wall spreads properly.", "On-site, workers spread the lattice wall.", "They bolt both ends of the lattice to the doorjambs.", "A worker places the galvanized aircraft cable in the upper notch of the lattice wall.", "Workers attach roof rafters to the compression ring.", "The ring end of the rafter is attached to the brackets with a through bolt, while the wall end of the rafter attaches to the cable.", "The rafters are made of machined stress-rated wood, which can withstand the weight of snow.", "They level the compression ring.", "They drape a polyester insulation lining over the rafters and fasten it securely in place.", "They cover the insulation lining with a highly-efficient reflective insulation.", "Using fiberglass-reinforced aluminum tape, they seal the seam.", "The foil insulation rests between the lining underneath and the exterior roof.", "The workers now roll the vinyl laminate exterior wall around the sides of the yurt.", "The exterior wall is securely laced into grommets along the bottom edge of the roof valance.", "A worker standing in the compression ring hoists the acrylic dome up to the top of the roof and positions it on the compression-ring frame.", "Yurt windows are sewn in with mosquito netting and have a clear vinyl covering.", "All in all, yurt living means never pulling up stakes.", "Marine plywood is used in the construction of docks and boats.", "You can't use standard plywood in such wet environments.", "Marine plywood isn't affected by moisture because it's made from sheets of a tropical hardwood that's naturally water-resistant and bonded with water-resistant glue.", "Marine plywood is typically used in boats for flooring, bulkheads, and furniture.", "The surface is typically a decorative type of wood veneer, such as oak, maple, teak, or mahogany.", "The core, however, is made of bonded layers of okoume, a water-resistant species that grows in the hot and humid equatorial forest of gabon in africa.", "When the okoume logs arrive at the factory, an automated chainsaw cuts half the shipment into pieces, measuring the length of a finished panel of plywood, and the other half into pieces measuring the width of a finished panel.", "This produces logs with the grain running in one direction, as well as logs with the grain running in the opposite direction.", "This is critical because when they construct the plywood, they'll crisscross grain directions to add strength.", "Next the logs go through a series of rotary blades that progressively shave off the bark.", "The now-barkless logs enter the rotary peeling machine.", "It works like a giant pencil sharpener, shaving off a continuous thin sheet called a ply, hence the term plywood.", "The ply is between 1/100 and 1/10 of an inch thick, depending on its position in the finished panel.", "Blades on both sides trim the ply, producing neat, straight edges.", "Then the machine rolls up the ply.", "The next machine unwinds the continuous ply and slices it into separate plies.", "If the log that produced this roll was one of those cut to the eight-foot length of a finished plywood panel, then this machine makes a cut every four feet-- the width of the finished panel...", "And vice-versa.", "This thickness of plywood has a five-ply core.", "Three of the plies remain dry, while two go through this machine, which rolls strong, water-resistant glue simultaneously on both sides.", "Now assembly begins.", "Alternating grain directions, the first ply is a dry one, the second a glued one.", "The bottom of it sticks to the ply underneath-- the top to the dry third ply that goes over it.", "The next ply-- the fourth-- is a glued one.", "The bottom sticks to the ply underneath, and the top to the fifth and final ply a dry one above.", "Workers use a powerful pneumatic staple gun to attach this assembled core along the front edge so that it doesn't come apart as it enters the press.", "The press holds 10 core assemblies at a time.", "The current thickness of a core is the sum of the piles plus glue.", "The press will reduce that by 10%.", "It applies about 170 pounds per square inch of pressure, while at the same time heating the core to 250 degrees fahrenheit to literally cook the adhesive.", "The core exits the press after seven minutes, the plies now perfectly flat and solidly bonded.", "The wood veneer for the core's decorative facing is very thin, barely more than 1/100 of an inch.", "To create a pattern resembling a hardwood floor, they join two strips at a time with a wavy thread of glue.", "Next they join the two mated strips to two others, and so on, until the assembled veneer are the length and width of the plywood core.", "The core, meanwhile, goes through the glue machine, which coats both top and bottom with adhesive.", "The veneer sheet is also glued, but on one side only.", "Workers lay the veneer glued-side up then carefully place the core onto it.", "A second veneer, glued-side down, goes on top.", "The okoume core is now sandwiched between two decorative wood veneers.", "The press applies the same heat and pressure as it did to the core assembly, but for just one minute.", "The result-- a finished sheet of, in this case, cherry veneered marine plywood.", "Marine plywood comes not just in a variety of veneer choices, but also in a range of thicknesses.", "Typically comprised of three to 13 plies-- always an odd number in order to have equal weight on either side of the central ply for balance.", "There are many types of paints at an artist's disposal, each producing a very different effect.", "Oil paint is opaque and rich.", "Encaustic paint, being wax-based, has a unique texture that the artist can shape, then reheat, and reshape in countless creative ways.", "Oil paint comes in liquid form and stick form.", "With either, the artist can combine it with other products to modify the consistency.", "Being oil-based, the paint takes a couple of days to dry, so there's lots of times to work with it.", "However, once the coat is dry, it can't be reworked.", "Encaustic paint, by contrast, is wax-based, so the artist must melt it while applying it.", "Because wax cools and hardens so quickly, encaustic paint has a short working time.", "However, the artist can reheat it and work it some more.", "The main ingredient in encaustic paint is white beeswax.", "To that, they add carnauba wax, which comes from the leaves of the carnauba palm tree.", "Carnauba wax is quite fragile, which is why they strengthen it with beeswax.", "They melt them in a microwave oven on convection mode.", "Next they add dammar resin, which comes from trees native to southeast asia.", "They grind the chunks of resin into of powder in a coffee grinder, then mix it into the molten waxes.", "The resin will act as a solidifying agent, as well as make the paint glossy.", "Once the ingredients are evenly blended, they pour the mix through cheesecloth to filter out minute plant particles, which the resin contained.", "They weigh out a quantity of synthetic pigment and add it to the wax-resin mixture.", "The ratio of pigment to mixture varies by color.", "Some have more wax and less pigment and others vice-versa.", "This manufacturer won't reveal any specifics about ingredient proportions.", "Its paint recipes are top-secret.", "After mixing for about 15 minutes, the paint is ready.", "They carefully pour it into a mold.", "This type of mold produces sticks.", "The paint hardens in just a few minutes.", "They scrape off the excess and melt it back to liquid to cast the next batch of sticks.", "Then they unscrew the mold and pry it apart.", "Once the mold is safely opened, they gently extract the finished encaustic sticks.", "They wear gloves because the sticks are still a bit hot and can stain their hands.", "For those same reasons, they wrap the sticks, once labeled, in plastic.", "This manufacturer also produces handmade encaustic paint in another format-- rectangular blocks.", "The process is identical.", "The mold is made of flexible rubber.", "The paint hardens sooner than in a metal mold because rubber dissipates heat far faster than metal does.", "Workers don't need to wear gloves when extracting the blocks because the paint is already cool and therefore won't stain their hands.", "To make oil-paint sticks, they first make a large batch of oil paint out of walnut oil, pigment, a drying agent, and a bit of wax.", "Then they weigh out a specific quantity and add more walnut oil.", "Next they add combined carnauba wax and beeswax, which are necessary to form the stick shape, however less wax than for encaustic sticks.", "They blend all these ingredients for about 15 minutes, then pour the paint into a metal mold to cast sticks.", "Every batch of oil sticks undergoes drying tests to ensure the paint dries within two days after being applied to paper.", "Encaustic is the more durable of these two types of paints because it contains a larger percentage of beeswax, which is resistant to moisture.", "And encaustic painting, therefore, doesn't have to be varnished or put behind glass." ]

{ "things": [ "Worcestershire Sauce", "Lawn Bowls", "Radio" ] }

[ "Its name can be a bit of a tongue-twister-- \"wuss-te-shire\" sauce, \"woos-ter-sheer\" sauce, \"wuss-te-sure\" sauce.", "All those pronunciations are acceptable, as are the endless ways to use this condiment, from flavoring beef recipes and salad dressings to joining tomato juice and vodka in a bloody mary.", "In the early 1800s, an english nobleman in the county of worcester hired two local chemists, john lea and william perrins, to duplicate a sauce he had tasted while traveling in india.", "The resulting concoction was unpalatable, so they relegated it to the cellar.", "Years later, they came across it during a cellar cleanup and gave it another taste.", "Lo and behold, the sauce had matured and was now delicious.", "They christened their creation \"worcestershire sauce\" and went into business.", "Today, more than 170 years later, that same company produces that very recipe, the specifics of which remain a closely-guarded secret.", "The process begins with onions and garlic pickled in malt vinegar for one to two years.", "Inside the pickling barrels, the bulbs slowly liquefy, their flavor infusing the liquid.", "Other barrels contain anchovies cured in salt for several months.", "Additional ingredients include salt, sugar, white vinegar...", "Malt vinegar...", "Tamarind concentrate...", "Molasses...", "And a top-secret blend of flavorings and spices.", "Starting with the two vinegars, workers pour the ingredients one at a time into gigantic blending tanks.", "There goes the tamarind concentrate.", "Now the anchovies.", "The ingredient proportions are top secret, as is the prescribed mixing time between ingredients.", "Now the pickled onions and garlic...", "Sugar and salt...", "And that secret blend of flavorings and spices.", "Next, they pump the mixture into maturation tanks.", "There, over the course of several months, the ingredients age and interact with each other, undergoing complex changes in their natural chemistry which produce the sauce's distinctive flavor.", "Agitators rotate intermittently to keep the ingredients well-blended.", "The sauce then goes through a sieve, then through a press, followed by another cycle of blending and straining.", "The sauce is a smooth liquid by the time it progresses to the next phase-- pasteurization.", "This process heats the sauce to kill off organisms, ensuring optimal flavor for at least 18 months.", "The sauce needs no artificial preservatives whatsoever because the vinegars it contains are natural antimicrobial agents.", "The bottling process is entirely automated.", "The factory produces different formats.", "This one is modeled after the original bottle from the 1830s.", "The machinery closes each bottle with a one-piece, plastic flip-top cap.", "Inside, there's a small hole to ensure the sauce dispenses at the right flow rate.", "This prevents accidentally pouring too much sauce.", "As each bottle enters the labeling machine, an arm descends onto the cap.", "The machine applies glue to a label, slaps it on the bottle, then the arm spins the bottle against brushes that push the edges of the label flat.", "Then, depending on the format they're packaging, the equipment groups 6 or 12 bottles together and, from underneath, folds a carton around them.", "Then it shrink-wraps the carton, which then joins others on a pallet.", "The production process and recipe have remained essentially the same since worcestershire sauce was first bottled in 1835.", "Lawn bowling is a quiet, civilized game, not something you'd expect to be outlawed.", "But in 16th-century england, henry viii banned lawn bowling among commoners because it was a distraction from work.", "It took a couple of centuries before his ban was lifted, and the game became completely legit.", "In lawn bowling, the path to victory is not straight.", "The bowl is designed to roll in a curve towards the object ball-- the smaller yellow one called the jack.", "For many years, lawn bowls were made of a tropical hardwood called lignum vitae, but as this wood has become increasingly rare, manufacturers have turned to melamine.", "And unlike wood, melamine doesn't change shape with temperature and humidity fluctuations.", "Production begins with melamine granules that have been pre-dyed in a variety of colors to appeal to individual preferences.", "An employee scoops the granules into a tub and weighs them.", "Lawn bowls come in a range of sizes to fit different hands, so the weight varies accordingly.", "He drapes a cloth over the melamine granules and holds it in place with pieces of wood.", "Then it's into a machine called a pre-heater.", "It uses high-frequency radio waves to melt the plastic into putty.", "The cloth absorbs moisture generated in the process.", "All those melamine bits have now merged into a malleable mass.", "He squeezes it to reshape it a bit so it can be inserted into a molding press.", "This 150-ton press forces the plastic dough into a hot mold to shape it into a lawn bowl.", "This lawn bowl may look round, but it's not a perfect sphere.", "This slightly irregular shape will cause it to roll into a curve.", "He marks the size and other information onto it, and then it's over to a computerized lathe.", "It spins the lawn bowl while the blade carves it to perfect that asymmetrical shape.", "Other tools then etch two rows of half-moons onto the surface.", "This engraved pattern makes the lawn bowl easier to grip.", "The next blade slices off the nubs used to spin the lawn bowl in the lathe.", "It also smoothes the surface until all evidence of the nubs disappears.", "This receptacle uses suction power to hold the lawn bowl steady while a carousel moves it forward to undergo a vigorous polishing.", "The polisher rubs paste onto the surface to buff the lawn bowl to an even sheen.", "A robot then turns the lawn bowl upside down to expose the unpolished side...", "Then puts it back in the receptacle so the polisher can buff this side of the lawn bowl.", "The entire lawn bowl now gleams, and an unpolished bowl next to it looks dull by comparison.", "But there's more polishing to come.", "The next machine spins the lawn bowl against another polisher.", "This one applies a finer-grade compound to it.", "Down the line, lasers move in unison to engrave the same emblem onto four bowls.", "It's a scottish thistle, one of over 4,000 team insignias available in this production facility.", "Each lawn bowl then goes for another spin, and an employee paints over all the detail work.", "He wipes the paint from the surface, but it remains in the engravings to accentuate them.", "Some lawn bowls get two-tone paint jobs.", "The worker brushes red paint into a hawk engraving, which provides a nice contrast to the yellow detail work.", "Then it's over to the testing department, where they roll each bowl down a chute and check its swerve.", "They also verify that each bowl lands in approximately the same spot as the master bowl, which means they're all equal and they conform to world standards.", "Including cooling time between processes, it takes about two days to make a lawn bowl.", "But once the work is done, it's all fun and games.", "Radio-controlled model jets first flew onto the radar in the 1970s and have since evolved into sophisticated flying machines.", "Many have turbine engines and use real jet fuel.", "They allow people who would otherwise never pilot a jet to experience the thrill of flight with both feet on the ground.", "Radio-controlled model jets can roll and dive like actual jets.", "And they can reach speeds of up to 280 miles an hour.", "Operating one isn't child's play.", "It takes practice and skill to pilot this kind of model aircraft.", "It also takes money because they cost up to $20,000.", "Making a model jet begins with the paint job.", "They airbrush designs directly into the molds that will be used to shape various parts.", "This particular mold will be used to make one half of a wing shell.", "When the paint dries, they roll epoxy resin into the mold...", "Then put down a layer of fiberglass.", "They reinforce the fiberglass with superstrong carbon fiber, then brush on more epoxy resin.", "The next layer is balsa, a lightweight wood from south america.", "They apply carbon fiber to sections of the wing where parts are to be attached.", "Another sheet of fiberglass, and epoxy is the final layer.", "Now they add a layer of absorbent material, then sandwich the mold in plastic film.", "They install a connector for a vacuum hose and hook it up.", "The vacuum pulls out the air, squeezing the layers together.", "Then they bake the unit, which activates the epoxy, fusing the materials together.", "Next, they assemble the wooden framework for the wings.", "They reinforce it with strips of carbon fiber and apply epoxy on the edges.", "The model makers carefully install the framework on the wing shell.", "They apply an extra rib along the wing tip...", "Slide aluminum cylinders into tubes in the framework, then bead more epoxy along the wing shell's perimeter.", "They use high-strength adhesive in strategic parts of the framework to attach the other half of the molded wing.", "They bolt the molds together and set the assembly aside to allow the epoxy to cure.", "After a few hours, they extract the wing, its artwork nicely transferred from the inside surface of the mold.", "Machinery then cuts holes in the wing for installing landing gear and motors called servos.", "This router is computer programmed to make perfect cuts without damaging the internal framework.", "This is critical because just a fraction of an inch off, and the router would destroy the carefully crafted wing.", "The modeler now perforates the fiberglass layer of the wing.", "He's creating a hinged section called an aileron.", "It's a control surface that will cause the plane to turn or roll.", "The ailerons and other control surfaces will be powered by servomotors.", "The front fuselage shell has been molded and is now ready to be revealed.", "Like the wings, the body of this model jet needs a supporting framework along with brackets for attachments.", "Another computerized router carves them out of multilayered carbon-fiber board.", "The modeler glues these parts inside the fuselage and the tail of the jet.", "Coming up next, this model jet gets its wings and prepares for takeoff.", "Controlling one of these jets is challenging and requires concentration.", "These are expensive toys, and the learning curve is steep.", "One bad landing, and this model jet could end up in a crumpled heap.", "It's why flyers hone their skills at airfields and test them in international competitions.", "Back at the factory, the molded pieces of this model jet are coming together.", "They attach the wings to the fuselage using the cylinders installed earlier.", "Then the modeler moves to the aircraft's tail and attaches the stabilizers...", "The rudder...", "And the vertical fin.", "Super-strength glue cements the assembly.", "Next, they build the motor.", "This one is a ducted-fan electric system, a type used in smaller jets.", "The modeler first assembles the casing that will hold the fan and its motor.", "He slides airfoils into the casing to create four ducts, which will properly channel the flow of air.", "He slides the electric motor into the aluminum hub...", "Then anchors the assembly with a screw from the other side.", "The next part is a speed-control mechanism.", "He solders its wires to those protruding from the motor.", "He encloses the mechanism in a vented tube, then sets the assembly aside temporarily.", "Now focus turns to the fan, which he hooks up to a testing device.", "As the fan spins, the machine analyzes it for vibrations that would indicate the blades are out of balance.", "The gauge shows it's vibrating slightly, so he makes adjustments, and then it's ready to install.", "He attaches the fan to the motor shaft and secures it with a bolt in the center.", "It's now time to power up this motor at a test station.", "he brings it up to full throttle and measures the thrust it generates.", "It passes the test, so he installs it in the model jet's fuselage.", "Later, this ducted fan motor will be connected to a battery pack.", "Now he moves on to the landing gear and attaches air cylinders to the front and rear wheels.", "Pumping air into these cylinders will cause the wheels to retract after takeoff.", "This system will also cause the wheels to engage for landing.", "Next, a sheet of clear thermoplastic is transformed into cockpit-canopy parts.", "A machine heats the plastic, then vacuum-shrinks it to two molds.", "The plastic hardens in seconds to create two clear plastic bubbles for the jet canopy.", "They mold the cockpit shell in two sections using the same technique.", "With the cockpit now installed and a doll for a pilot, this '50s-era korean war jet replica is in fighting form.", "All that's left is to install the radio-control system, which will be done by the operator after purchase.", "From nose to tail, the attention to detail isimpressive.", "Some of these model jets even have gas-turbine engines for added authenticity.", "With radio controls installed, this turbine model jet is ready to taxi down the runway.", "The operator does one last check of the control surfaces, then it's time for takeoff.", "Miniature turbine engines sound and work like those of a big jet.", "These jets rumble and soar and can be made to perform many aerobatic stunts.", "Of course, it all hinges on both the skill of the operator and a job well done at the factory.", "But this looks like another successful landing." ]

{ "things": [ "Umbrellas", "Outboard Motors", "Silver Cutlery", "Tape Measures" ] }

[ "Today on \"how it's made\"...", "Umbrellas...", "Outboard motors...", "Silver cutlery...", "And tape measures.", "It provides shelter from the rain, protection from the sun, and it's a chic fashion accessory.", "The umbrella originated in ancient china some 1,700 years ago.", "Since then, it's evolved from the original parasol to the modern-day collapsible canopy.", "Unlike mass-produced models, this quality umbrella is meticulously crafted by hand.", "Production begins with a birchwood shaft, which an artisan stains to match the umbrella's handle.", "He narrows down the shaft so it will fit perfectly into the handle.", "After buffing the handle to a shine, he glues it onto the shaft.", "Next, the artisan forms two springs from wire made of nickel silver, a metal that can withstand extreme tension.", "He bends one end of the wire into a triangular shape...", "And hammers it flat to ensure a neat fit.", "He cuts two slots in the shaft, one at the top and one at the bottom.", "Then he pierces each slot, creating a hole for the spring to hook into.", "With a bit of stain, he hides the exposed wood.", "For the umbrella to open and close easily, the springs must fit snugly, so the end of the spring gets a right-angle bend.", "This shape sets the correct tension.", "With a tap of the hammer, the springs now rest firmly into the slot.", "After trimming the spring, the artisan forms it into the perfect shape by purposely overbending, then correcting the position.", "A small pin inside the shaft prevents the spring from opening fully.", "This brass runner is what you slide up the shaft to open the umbrella.", "A stop pin limits the runner's travel, preventing the canopy from blowing inside out.", "The artisan fits a length of tying wire around the slot in the runner, then threads the canopy's eight ribs onto it.", "The ribs are made of a type of steel that's strong, yet flexible, so they curve into a dome shape when the umbrella's open, then straighten out again when it's closed.", "The ribs' other ends are wired to what's called a notch.", "Once they're in place, they'll rest just below the handle line.", "At the spot where the notch will sit on the shaft, a hole is drilled.", "This will hold the pinning wire in place.", "Workers cut eight triangular-shaped panels called gores from durable nylon.", "They attach a label, then assemble the canopy by sewing all eight gores together.", "Next, eight metal tips are inserted into a machine that wraps them in fabric.", "Then they're stitched to eight locations inside the canopy.", "These smaller pieces of fabric, called prevents, stop the canopy from chaffing against the frame.", "This decorative rosette hides the point at which the runner and ribs meet.", "Next, the canopy is draped over the shaft and hand-sewn tightly over the notch.", "A tip is attached over the end of each rib.", "Then each rib is aligned with a canopy seam.", "After checking the fabric for imperfections, a worker secures the ribs in position by sewing them to their respective seams.", "They roll up the umbrella to check that the fastening button and band attached earlier are in the right place.", "A decorative ring goes over the notch.", "Then the top of the shaft is crowned with a ferrule-- a brass cap with a protective steel tip.", "This company embellishes its shaft with a steel-plated band, ideal for engraving the owner's initials.", "After a quick wash, the canopy is ironed for a neat, crisp finish.", "The final touch is a matching cover which you can slide off in an instant if you're caught in a sudden shower.", "When we return, an inside look at the outboard motor.", "Outboard marine motors come in a variety of sizes and horsepowers, ranging from single-cylinder models to powerful eight-cylinder configurations.", "They can run on gas, diesel, or electricity, and they can provide power for a quiet day of fishing or an exhilarating offshore drag race.", "Outboard motors have an engine on top and a gear case below.", "This aluminum engine block is the skeleton that houses the cylinders-- the heart of the engine's internal-combustion system.", "Under a stream of cutting fluid, machines hone the cylinders to precise dimensions.", "Miniscule x's are carved into the steel that lines the cylinder walls.", "Oil will settle into these x's, keeping the walls well-lubricated for the piston.", "Workers assemble each piston manually.", "First they build a ridged bearing and insert it into the loop at the end of a connecting rod.", "Then they fit the rod into a pistonhead, securing it with a pin.", "The pistons are placed in the cylinders.", "Then they lower the engine's crankshaft into place and attach it to the loops at the ends of the connecting rods.", "The crankshaft's bearings are lubricated and capped off.", "Then this part of the engine is sealed with an aluminum cover.", "To get the cover's positioning just right, the first bolt is driven into place manually.", "A precision torque wrench does the rest.", "Now the top is screwed on.", "A magneto system is mounted onto the crankshaft.", "As it spins, it generates electricity for the engine's electronics and pumps.", "Meanwhile, on another assembly line, the gear case takes shape.", "This machine locks the case's forward gear to a shaft that'll turn the motor's propeller.", "The propeller shaft connects the lower driveshaft.", "The factory buys these pieces readymade from a supplier but still has to refine the dimensions so that everything fits together perfectly.", "This machine analyzes the shaft.", "It concludes that this one needs to be a fraction of an inch longer, so workers add the required number of steel disks called shims.", "They insert this driveshaft into the gear case, then attach the propeller shaft with the forward gear.", "Now the gear case is linked to the driveshaft, which connects to the propeller shaft, which turns the propeller.", "The next piece to go into place is the middle section of the motor-- the part in between the engine and the gear case.", "First, workers attach the gear case-- now fitted with a shift rod for switching gears-- and an upper driveshaft which transfers power from the engine to the propeller.", "Next, the unit gets a coat of paint that's salt-water resistant.", "When the paint's dry, workers bolt the engine on top of the assembly.", "The engine is plugged into a master computer which automatically uploads an operating system onto the engine's internal computer.", "Then, using a scanner, they input information about each cylinder.", "The motor is now fully operational.", "Workers insert a propeller onto the propeller shaft, then lower the motor into a test tank.", "This factory tests every motor it produces.", "They run the engine for about 10 minutes while a computer analyzes the performance data.", "After drying the engine thoroughly, workers apply the finishing touches, starting with the two-part cover that encases the lower portion of the motor.", "Then they latch another cover over the engine...", "And stick on decals.", "Both covers are made of heavy-duty plastic coated in paint that won't fade, even after a lifetime of sun, wind, and water.", "Up next, turning out the silverware that turns an ordinary dinner into something special.", "Cutlery dates back to the stone age 300,000 years ago.", "Prehistoric people made the first cutlery from splinters of stone, shells, horn, and wood chips.", "During the bronze age, humans found a better material-- metal.", "Forks came along much later, originating in ancient greece.", "Whether cutlery is sterling silver, silver-plated, or stainless steel, the production process is the same.", "It all starts with thin sheets of metal.", "As workers manually feed the sheet through a press, a die inside punches out utensil shapes called blanks.", "Fork blanks go into a piercing tool which slices away three strips of metal.", "This creates four prongs with a support bar across the top-- for now.", "Meanwhile, spoon blanks go into a machine called the cross roller, which expands the spoon head sideways, thinning out the metal at the same time.", "Then it's into a clipping tool which trims the spoon head to precisely the right size and shape.", "Both spoon and fork blanks now go into a grinding machine that smoothes away rough edges by vibrating them against small plastic cones.", "Elsewhere in the factory, a specialized tradesman sculpts the steel die that will stamp the pattern on the cutlery handles.", "Working from a designer's illustration, he has to interpret the pattern in three dimensions.", "This requires tremendous skill because the depth of the design varies throughout the handle.", "He measures these minute variations with a tool called a micrometer.", "In the press, the die does three things-- emboss the pattern, gently bend the handle, and mark the back of the utensil with the manufacturer's name.", "Now back to the head of the utensils.", "The forks go into a press that bends the prongs to the right curve.", "Now that support bar can finally come off.", "Spoons, meanwhile, go into a press fitted with what's called a bowling die.", "It strikes the spoon's flat head into a bowl shape.", "Every time you strike metal, it hardens a bit.", "So repeatedly during the shaping process, workers have to heat the blanks to soften them again.", "Making knives is more complicated than making spoons and forks.", "Each knife handle is constructed from two halves.", "A press punches them out and stamps the pattern.", "Then a clipping machine removes excess metal around the perimeter.", "Now workers coat the edge with flux, a chemical cleanser.", "The surfaces have to be spotless to bond properly.", "The two halves are wrapped together with string.", "Then powdered metal is poured into the cavity.", "It immediately sticks to the flux on the edges.", "The excess is discarded.", "Then the handles are run through a mini furnace for 12 minutes.", "The 1,600-degree heat liquifies the metal powder, soldering the two halves together and burning off the string.", "After polishing, the solder line will be invisible.", "Workers pour cement into the center of a centrifuge machine and load the hollow handles all around.", "As the machine spins, it fills each handle with cement.", "Now each handle gets a stainless-steel blade.", "The blade's stem goes directly into the wet cement...", "And a clamp holds the parts together during the hardening process.", "A 12-minute bath in hot water cures the cement, making the handle/blade connection rock-solid and giving the handle weight.", "For worker safety, it's only now, near the end of production, that they sharpen the blades.", "A good polishing and this elegant silverware is ready for even the most sophisticated dinner party.", "Coming up, a factory that goes the whole nine yards.", "A popular tool in any utility closet, the spring-driven, retractable tape measure was invented in the middle of the 19th century.", "But it didn't really become popular until the 1940s.", "Today, any handyman without one just doesn't measure up.", "Measuring tapes take the guesswork out of any job, and if you don't use one, you'll soon see the error of your ways.", "Production begins with a three-dimensional computer design.", "To bring that vision to life, a machine first pulls hardened strips of steel-- five at a time-- across a network of rollers that coat them with primer.", "Then comes the paint.", "After the paint dries, the strips are rewound in preparation for printing.", "Printing cylinders roll the measurement markings onto the steel strips.", "They use black ink for millimeters and red for meters.", "Next, they heat the measuring tape.", "This ensures that the protective plastic film applied by this machine will stick well to the steel.", "Rollers then give the tape a concave contour so that it can be extended rigidly.", "Every few seconds, the presses grind to a halt and a blade cuts the tape to the correct length.", "At the same time, it punches a hole for the end hook, which is then riveted into place.", "Another machine rolls up steel to make springs.", "The spring enables the measuring tape to retract into the casing.", "The end of the spring is clipped to an automatic-winding machine.", "A worker places the lower half of the tape measure's casing into position.", "The machine then rewinds the steel spring and transfers it into the casing.", "The spring gets a little lubricating oil.", "Then workers install the control breaks, which can be used to lock and unroll tape in place.", "Assembling the rest of the casing is a snap.", "Everything is screwed together.", "The measuring tape is attached to the spring.", "And then it's time to test that spring action.", "This factory makes some longer measuring tapes from glass fibers, which are far lighter than steel.", "Multiple strands of glass are pulled through a tub of white liquid plastic so that they'll stick together.", "The fibers then enter a machine that coats them with more plastic melted down from hard pellets like these.", "This process transforms the glass fibers into a strong yet flexible tape, the type commonly used for surveyors' tape measures.", "A computerized printer transfers measurements to the tape a meter a second.", "Lights illuminate the tape so a camera can check for printing defects.", "An inspector double-checks the print job and also examines each tape for accuracy.", "Some tapes are more accurate than others because of varying standards in different industries and different countries.", "She grades each tape and marks it so that it can be tracked back to the operator.", "A laser then moves over the tapes to check the accuracy level again.", "If the reading is off by even a few thousandths of a millimeter, then the tape is rejected.", "Winding a surveyor's tape is a manual job.", "No spring system here, because that would make the tape measure too heavy and unwieldy.", "After winding, the tape is cut and the end hook is fastened into place.", "And finally, these measuring tapes are ready to roll." ]

{ "things": [ "Copper Pipe Fittings", "Cylinder Music Boxes", "Pepper Mills", "Hot Rod Steering Columns" ] }

[ "In the world of plumbing, it's all about connections.", "And we're talking about elbows, t's, and other fittings.", "Fittings hold everything together.", "They're also used to reroute pipes and control the flow of liquids.", "Without them, things just wouldn't flow as they should.", "With so many shapes and sizes to choose from, today's pipe fittings literally have all the angles covered.", "They start with sheets of copper.", "This copper has been refined until it's 99.99% pure.", "They load the sheets into a furnace that's fired at just over 1,800 degrees fahrenheit.", "The copper melts into a piping hot soup and then flows into a second furnace.", "This one has cylindrical molds which draw the liquid copper up and cool it as they shape it into solid copper rods.", "These rods are flexible enough to wind through rollers as they travel towards a big spindle.", "They spiral around the spindle, accumulating in big coils to await the next step.", "This device uncoils the copper and chops it into little pucks about the diameter of a quarter.", "Incredibly, each one of these pucks will be used to make a plumbing fitting.", "This tool pushes the copper puck into a cylindrical die to shape it into tubing.", "In this one swift action, a little copper puck is transformed into a much longer piece of pipe.", "This copper has been reshaped as easily as a piece of putty.", "One end is closed, but it's just temporary.", "At the next station, equipment bends the tubing around forms to give it an elbow shape.", "At the same time, a blade cuts the closed end to open it up.", "Next, these elbows will get some fine-tuning.", "A 2-part device comes together to steady them as tools stretch the internal diameter so the part will fit on other pipes.", "A spinning cutter then carves bevels onto the rims.", "This beveled edge will allow it to slide more easily onto other pipes during installation.", "Over at the next furnace, they're working on a larger-scale project.", "This molten copper will be used to make fittings for high-rises and other buildings with bigger plumbing systems.", "The copper flows into a casting furnace.", "It generates copper rods that are about the size of a telephone pole.", "Each one weighs about a ton, so it takes a crane to move it down the production line.", "A circular saw then carves them up, producing copper chunks that look a bit like firewood.", "They heat each chunk in a furnace to make it more pliable.", "Then it's into an extruder.", "It uses tons of hydraulic pressure to hollow out the copper log.", "At the same time, it forces the copper into a die that stretches it 12 times its original length and slims it down considerably.", "The lengthy tubing cools down in a milky bath.", "Then a crane moves it down the line to equipment that adjusts the diameter and chops it up.", "Water now flows into the shorter piece of pipe, which is encased in a mold.", "Tools push into the pipe, forcing the water in a vertical direction.", "Sheer water pressure reshapes the tubing into a \"t,\" while the mold establishes the contours.", "\"t\" fittings are used to combine or split the flow of fluid in a plumbing system, and the water forming press does a seamless job of making them.", "But there's still the matter of the closed end at the base of the \"t,\" so they chop that off.", "They machine all three openings, because when they connect it to other pipes, it has to fit-- to a \"t,\" of course.", "Now these fittings are ready to join other pipes and parts.", "And by doing so, they'll make our lives a whole lot more convenient.", "In victorian times, the cylinder music box could make or break a party in the parlor.", "Its rich, ringing tones filled the room, and the design was truly a mechanical marvel.", "Today that distinctive sound still resonates as companies make these instruments for a growing collectors' market.", "Open the box, and you'll discover the gift of music from another era.", "just wind up the mechanism inside for live music without any human performers.", "a cylinder revolves, and strategically arranged pins strum a comb to produce the notes.", "The ethereal sound is similar to that of a bell choir or a harp ensemble.", "It all starts with equipment that stamp and cut steel to produce a comb shape.", "A circular saw carves teeth in it, and this tool sharpens them.", "They bake the combs over flames and then plunge them into a cool oil to create a thermal shock that hardens the steel.", "With a flat tool, they direct melted lead into a mold positioned under the comb.", "The lead hardens into a weight that will help produce the low notes.", "A rotating tool cuts teeth into it.", "They now spread lead solder on the comb's edge and on a corresponding piece of lead.", "They file off excess lead and then tune the comb by first clipping the teeth...", "Then grinding them until the notes they produce are precisely pitched.", "This bit of fine-tuning is computer controlled.", "they dip synthetic feathers in glue and apply them to the bass notes to soften the vibrations.", "This completes the musical comb.", "They move on to the brass cylinders and drill holes in them to transfer the musical score.", "A computer controls this process, as well as the next one, which involves cutting steel wire and inserting it into each of the cylinder's holes.", "This is called pinning.", "And, of course, in the old days, it was all done manually and was far more time consuming.", "Next, they pump resin into the cylinder and it adheres to the wall, securing the pins from the inside.", "They spray compressed air to cool the cylinder as the resin cures.", "After an axle has been installed inside, they arrange the cylinder on a baseplate and install little racks for the axle to turn on.", "The cylinder speed will be regulated by the governor.", "Using a special tool, they wind a long spring into its housing near the governor.", "It's the release of this spring's pent-up energy that will cause the cylinder to rotate and strum the comb.", "Positioning the comb next to the cylinder takes a certain know-how.", "If it's even slightly out of place, there will be a lot of sour notes.", "Dust can also affect the music, so they make sure to get every speck.", "It's time to attach the lever that winds the music-box motor.", "This little spring completes the connection.", "They slide this mechanical musical instrument into its box, and it's showtime.", "The classic wooden cabinetry sets the stage for a musical act that has timeless appeal.", "there also are more contemporary-looking music boxes.", "this art-glass design showcases the centuries-old technology.", "And then there's a version that comes with all the bells and whistles.", "Here, the cylinder operates cams that hit bells while, at the same time, plucking the comb.", "It's a good example why the music box continues to be a tough act to follow.", "ever since the 14th century, people have been using pepper mills to kick up the flavor factor, so they definitely have a well-seasoned reputation.", "Today, pepper mills come with state-of-the-art grinding mechanisms and there are even electric models for a truly crushing experience.", "Freshly ground pepper has more spice than pre-ground pepper, which makes pepper mills a hot commodity.", "They make the grinding mechanism from tough, hardened steel.", "An automated chiseling tool carves teeth into the outer ring, making a row of larger ones to crack the peppercorns and a row of smaller ones for fine grinding.", "This smaller ring is to be the moving part of the grinding mechanism.", "After the stamp trademark information onto it, a tool etches teeth into it, as well.", "They're designed to grind freely against those in the outer ring without locking together.", "Thick steel wire now uncoils and travels between rollers for straightening.", "Then there's quick chopping action as a rotating cutter slices it into shorter pieces.", "Each one will become a drive shaft for a pepper mill.", "A tool slims and trims one end of the shaft so it will fit into the inner grinding part.", "Rolling cutters carve threads into the other end for attaching it to the adjuster knob of a manual mill.", "Robots install the inner grinding ring on the drive shaft.", "They randomly select parts for close-up scrutiny.", "A camera zooms in on the pepper mill's grinding teeth, and a computer analyzes their dimensions and general quality.", "Now it's time to assemble the grinder's outer ring, shaft, and inner grinding device, which they press-fit to the pepper mill body.", "They surround the grinder with a metal ring and brace it with a bracket.", "They insert a light bulb to illuminate your food so you don't add too much pepper.", "Then they attach a test motor, which turns the grinding mechanism and checks the bulb.", "A few units are selected to undergo a grueling test.", "They run them for hours at a time to confirm this production run can handle the daily grind.", "But a pepper mill just isn't complete without its partner, the salt mill.", "They use stainless steel to make its grinding device because it resists the corrosiveness of salt.", "Hydraulic machinery punches the metal into dies 10 times to shape the salt mill's outer grinding rings.", "Here you can see the various stages of the forming process.", "The final result is a part with three large, jagged teeth in the lower section.", "They're designed specifically to move salt crystals towards the inner grinding ring.", "After a computer check, this part is ready for assembly.", "They install it in the salt-mill housing and then insert the inner grinder and shaft.", "Once the electric motor is attached, this salt mill is done like dinner.", "For a traditional pepper mill, they sculpt wood into that classic shape recognized by pepper fans everywhere.", "They insert the same kind of grinding hardware that's used in the electric mills, but the shaft is longer because this manual mill will be quite a bit taller.", "Chefs often prefer a pepper mill with height because it's easier to use.", "Once assembled, the pepper mill gets a fill-up.", "Then they cap it and adjust the top knob to a medium grind.", "Of course, all mills can be adjusted for different-sized grinds.", "From fine to coarse, the choice is yours.", "It's really a matter of taste.", "The driving force behind a vehicle's direction is the steering column.", "It connects the steering wheel to the front wheels.", "But despite the name, steering isn't the steering column's only job.", "It also houses the turn-signal switch and a tilt mechanism to adjust the angle of the steering wheel.", "This company makes custom steering columns, the kind you order when building your own classic car or truck.", "For the main shaft of the column, an automated band saw slices steel tubing, two at a time, to a specific length.", "This belt sander smoothes out the rough edges.", "The next machine forms the shaft into a specific shape that'll engage and turn with the steering wheel.", "A computer-guided laser cutter makes the steel housing that'll cover the steering column's upper components.", "It cuts holes for the various control levers that'll connect to the steering column.", "The upper housing now goes onto a device that holds it steady while a belt grinder removes any surface imperfections.", "Meanwhile, workers weld together the two steel pieces that make up the steering column's lower housing.", "Then, to make the steering column look sleek, they attach a steel cone using a fine welding torch.", "With an abrasive belt, they polish the weld line until it's barely noticeable.", "Then they do an overall polishing to make the entire surface smooth and ready to paint.", "They've attached a component called the lower yoke shaft to the main shaft made earlier.", "After greasing it, they snap an upper yoke shaft into it.", "These enable the shaft to pivot when you tilt the steering column.", "Here, they install a component in the lower housing to which they'll later attach the tilting mechanism.", "Once that's in place, they install a pull wire to help pull through the electrical system later on.", "Finally, they slide the shaft through the housing.", "A computer-controlled milling machine shapes the tilting mechanism's aluminum body.", "The next machine installs position-locking fingers which allow the column to tilt when you pull the tilt lever then re-engage to lock in the selected position.", "This press installs bearings to make the turning process smooth.", "Now the upper section joins the lower section.", "They attach with two pins that allow the column to pivot.", "A thick steel spring supports the column so when the fingers disengage the column doesn't just drop into the driver's lap.", "Next, they install the column's upper housing.", "That's the part with the holes for the levers to control the tilt, the turn signals, and the emergency flashers.", "Remember that pull wire?", "They tape the signal switches and wiring to it then pull them through the column.", "They'll later cushion this exit hole with a rubber grommet to prevent any chafing.", "Next, they install the horn cam.", "It passes power from the horn to the steering wheel to enable honking.", "Using this tool, they lock in a retaining clip to hold everything together.", "All the wiring that passes through the steering column connects to a plug.", "You just insert it into the vehicle's electrical system.", "These steering columns come in a choice of finishes.", "You can also buy an unfinished column and paint it yourself.", "After installing the column, you just add a steering wheel then mount the levers and knobs included in the kit.", "Then, from that point on, you're in the driver's seat." ]

{ "things": [ "Race Car Oil Tanks", "Plaster Mouldings", "Lemongrass Oil", "Fly Tying Vises" ] }

[ "In racecar engines, excess lubricating oil is stored in tanks rather than oil pans.", "This prevents the oil from sloshing around during the race and causing drag on the crankshaft.", "With less drag, performance is increased.", "So these oil tanks are part of a winning strategy.", "Racecar oil tanks come in various shapes and sizes in order to fit into difference vehicles.", "But their purpose is the same-- to keep excess oil out of the engine to boost performance.", "Each tanks starts with a computer design.", "The engineer maps out the precise dimensions.", "They input the measurements into computerized machining systems.", "This first one cuts a long piece of aluminum into smaller pieces, creating blanks to make parts known as tank rings.", "A vertical milling tool sculpts a recess in the blank to seat an o-ring sealer.", "Then, switching bits, the machine contours the outside of the blank, taking it from rectangular to round.", "Other tools carve a large hole in the center and profile the inner diameter so that the part will mate to the tank.", "This ring is designed to be removable to access the tank for maintenance.", "Here's the blank before and after machining.", "Like powerful cookie cutters, computerized punches cut out numerous parts from an aluminum sheet.", "They include the oil tank body, the top, and other assembly pieces.", "To make the tank body cylindrical, a worker turns a crank to curl it around a roller.", "This tank body is called the wrapper.", "He drills a hole in the bottom cone.", "The hole is for the line that returns lubricating oil to the racecar engine.", "Using a thin band saw, he trims the cone to fit the tank ring.", "With a device known as a hydraulic tube bender, a worker shapes a piece of pipe to a precise radius.", "This pipe will be used to vent air into a chamber at the side of the oil tank.", "He trims the ends of the vent tube using a band saw.", "A worker welds the tank ring to the bottom cone, creating a thick seam all the way around.", "He then seals the seam of the cylindrical wrapper body and welds a top cap to a deaerating baffle.", "Air will rise through it and vent it into and out of a side chamber, leaving only oil in the tank.", "He slides the baffle into the wrapper body.", "He inserts the vent tube in a hole on the side of the tank.", "He fits an adapter ring to the upper lip of a tank and taps it down with a rubber mallet.", "He welds the baffle and filler neck to the tank body, and then assembles the air vent chamber to the side of the oil tank and welds it to it.", "Moving to another station, a worker now taps perforated plastic inserts into holes in the air vent chamber.", "These inserts will both vent and filter the air from the tank.", "He fits a rubber sealing ring around the fill neck and screws the cap on.", "He applies the adhesive-back decals to the tank for branding purposes.", "He caps the oil inlet tube to keep contaminants out during shipping.", "He turns the tank upside down and installs a valve on the bottom of the vent tank.", "He inserts a rubber o-ring into a groove on the base of the tank wall and tucks it into place all the way around.", "After equipping the fittings on the cone with caps for shipping, he installs the cone on the base of the tank and screws the ring tightly to it.", "Accessing the tank for maintenance reasons will mean unscrewing this part.", "That completes this racecar oil tank.", "Hooked up to a system of pumps, these tanks will receive and dispense oil sparingly to improve engine performance.", "They've been well-equipped for life in the fast lane.", "The ancient greeks first began beautifying interiors with ornate columns and moldings shaped from plaster.", "Decorative moldings were a popular design feature in much of europe from roughly the 17th century onward, with italian tradesmen becoming famous for their mastery at plasterwork.", "Specialists in traditional plasterwork are a rare breed these days.", "But that's who you need to hire to properly repair plaster moldings in a historic home or to craft plaster moldings from scratch.", "To repair this damaged ceiling medallion, the plasterman first saws and chisels off the problem portion, clearing a flat work surface.", "Then, he drives and screws part way to anchor the new portion of molding.", "The heavier the plaster molding, the more screws you need to hold the load.", "Another plasterman, meanwhile, prepares the plaster.", "The first ingredient is lime compound-- a simple mixture of lime, also known as calcium hydroxide, and water.", "He forms a well with his scraper...", "Then fills the well with a mixture of roughly three-quarters water to one-quarter construction-grade bonding glue.", "He adds just the right amount of plaster of paris, which is powdered gypsum, the same stuff they use to make casts for broken bones.", "He takes his trowel and thoroughly blends the lime compound, glue mixture and plaster of paris.", "When it has the consistency of pudding, the plaster is ready.", "The plasterman does this all by eye, without ever actually measuring a single ingredient.", "After applying bonding glue to the repair area, the other plasterman trowels on lots of plaster.", "Then, he takes what's called a circular running mold.", "Its profile is out of the existing molding.", "He runs it back and forth over the wet plaster, hence the term \"running mold\".", "Then, he carefully scrapes away the excess and runs a wet paintbrush over the new and old portions of the molding.", "This makes the transition between the two appear seamless and smoothes out any imperfections.", "To make the running molds, he cuts out a cross section of the existing molding and traces it to produce a sheet metal template with the same profile.", "Then with that, he cuts the shape in wood, producing what they call a stock.", "After sanding the stock smooth, he screws on the metal template.", "The wood backing prevents the metal from bending as he runs it over thick plaster.", "He screws more wood to the stock to form a handle.", "To make crown moldings, the plasterman mounts a track to guide his running mold.", "He checks for anchor screws obstructing the path.", "If he finds any, he drives them a bit further into the ceiling.", "He brushes on bonding glue and lets it sit for five minutes.", "Then, he begins applying the plaster in sizable globs.", "He passes the running mold over the plaster.", "He repeats several times with additional plaster, waiting 20 minutes or so between coats to let the plaster harden just enough to hold the shape.", "He applies the final coat by hand, filling in crevices and imperfections.", "Then, he passes the running mold one last time.", "The wet plaster molding takes anywhere from 48 to 72 hours to dry, depending on its size and on the humidity in the room.", "Only when the molding is completely dry can the plasterman begin the next step, crafting the corner pieces, called miters.", "Starting with larger knives and scrapers, he uses the edge of the adjacent moldings as a guide, adding some plaster, sculpting it, then removing the excess.", "He keeps repeating these steps until each side of the miter matches the molding it joins perfectly.", "It's a slow and meticulous process that takes patience and an expert eye.", "Once he has perfected the profile, he refines the edges with smaller knives and scrapers.", "Finally, he blends the surface with a wet brush, rendering the transition from miter to molding visually seamless.", "Brand-new yet distinctively old-world.", "Lemongrass isn't just a culinary herb.", "Oil distilled from the plant is a popular ingredient in soap and spa products.", "Used in aromatherapy for numerous therapeutic reasons with a fragrance that's citrusy yet sweet, lemongrass oil definitely passes the smell test.", "Follow the scent of lemongrass, and the trail leads to thailand.", "It's here that the plant is grown and processed into an essential oil.", "Lemongrass oil is the signature scent in this part of the world.", "After harvesting lemongrass, workers select the most fragrant specimens and dry them.", "They transfer these plants, stalk and all, to a distillation facility.", "The heady aroma of lemongrass will now be concentrated into a potent essential oil.", "Workers unlock the top of the still and pour in chlorine-free, deionized water.", "Once the still is one-quarter full, they add the lemongrass.", "They stack the bundles in a crisscross fashion, creating gaps for steam to pass through.", "They fill the still to the brim.", "It will take 66 pounds of lemongrass to make roughly 1 quart of highly-fragrant essential oil.", "They screw the lid tightly to prevent the loss of steam during distillation.", "They activate the still, and it heats the water to the boiling point.", "Steam rises through the plants and picks up the oils.", "It carries the oil vapor up through a pipe and into a condenser, where the vapors cool and return to a liquid form.", "The liquid oil and water drip out into a flask.", "Oil and water don't mix.", "So the oil floats to the top.", "And the water is drained off and recycled back into the distiller.", "The technician then collects the lemongrass oil in a bottle one drop at a time.", "The lemongrass oil undergoes a second distillation in a laboratory, using a more sensitive piece of equipment known as a rotary vacuum evaporator.", "The oil flows into a flask that's spinning in a hot bath of vegetable oil.", "The evaporator pumps out air and creates a vacuum in the flask, which lowers the boiling point.", "This prevents damage to the delicate molecules responsible for the lemongrass scent.", "The oil vapors rise to a condenser coil where they reliquefy, leaving any residual water and impurities behind.", "The pure lemongrass oil drips into a receiver flask.", "As distilled lemongrass oil is collected, more flows into the evaporator beaker for purification.", "The distilling process is continuous.", "The rotary vacuum evaporator processes roughly 2 to 3 quarts of fragrant oil per hour.", "They store the lemongrass oil in a cold room with other essential oils.", "Like fine wine, it must be kept cool, or it could spoil and ruin its bouquet.", "When it's time to formulate ingredients for a cream or lotion, a technician blends lemongrass oil with other essential oils.", "Just a few drops make a difference you can smell.", "They also use lemongrass oil to enhance the soothing qualities of bath crystals.", "The technician first sifts epsom salts and baking soda into a bowl.", "He adds measured amounts of the blend to sea salt crystals.", "He stirs the ingredients by hand to evenly distribute them in the mix.", "The bath salts are now ready for an infusion of the double-distilled lemongrass oil.", "He adds it to a submixture of other essential oils to create a blend with calming effect.", "He pours the essential oils onto the crystals.", "And they soak into the tiny spaces in the particles.", "They then add some more aromatic spice-- a freshly-ground blend of lemongrass, turmeric, and other ingredients.", "He sprinkles the herbs onto the crystals and folds them into the blend.", "The final effect will be skin-tingling and rejuvenating.", "Incorporated into many products, lemongrass oil will awaken the senses.", "Fly fishing uses artificial lures called flies rather than natural bait like worms.", "A fly is a hook that has materials like feathers tied to it with thread to trick the fish into thinking there's an insect floating on the water.", "To make your own flies, you use a fly tying vise.", "This fly tying vise has pockets at its base to hold your materials and sturdy steel jaws to grip the fishhook while you tie those materials onto it.", "This machine makes the sand molds for casting the metal pocket bases.", "It deposits moist sand into a flask to form one half of a mold, then rolls over the flask to a pattern on the other side.", "After spraying the pattern with a nonstick coating, a worker sifts sand onto it.", "Then the machine deposits sand on top to form the other half of the mold.", "It compresses the sand with roughly 4 1/2 tons of hydraulic pressure.", "The pattern sandwiched at the center forms the mold cavity.", "A machine separates the halves to remove the pattern, then puts them back together.", "In the casting area, workers heat pieces of bronze to approximately 1,922 degrees fahrenheit, melting them down.", "They remove the pot from the electric furnace and place it in a pouring shank.", "They pour the molten bronze down a channel leading to the mold cavity.", "After about a half hour, once the bronze has cooled and solidified, the flip the mold onto a vibrating grate.", "First the impact and then the shaking break the mold.", "The sand falls through the grate while four connected bronze pocket bases remain on top.", "Once they're cool enough to be handled, a worker saws them apart.", "The bases go into a rotating drum filled with tiny steel beads.", "As the drum spins, the centrifugal force throws the beads against the bases.", "This removes all remnants of sand and polishes the surface smooth.", "The bases go onto a computer-guided milling machine.", "It drills a hole to affix the mounting piece for the stem that holds the head of the vise.", "The mill also cuts a circular hole at the center of the base for a decorative coin bearing the manufacturer's logo.", "They finish the bases with a clear protective coat, a proprietary formula that prevents the bronze from oxidizing.", "The vise's other parts are machined out of metal bars.", "Here, a computer-guided lathe transforms two square steel bars into the vise's jaws.", "First, it cuts a small half circle on one piece for the cam that opens and closes the jaws.", "Then, it turns the ends to form a point.", "The entire transformation from bars to jaws takes about 90 seconds.", "They place the jaws, one at a time, into a press and make a slight bend to set the correct spring tension.", "They verify the depth of the bend with a specialized measuring tool, then send the jaws to an outside facility that applies a black protective finish.", "When the jaws come back, workers assemble them.", "First, they put the cam through the semicircular hole.", "Then, they compress the jaws in a vise and slide an aluminum head onto the back.", "When the jaws come out of the vise, they expand to their original position, retaining the head.", "Workers apply the manufacturer's sticker, then thread a brass thumbscrew that you turn to lock in the position of the head, which swivels left, right, or 360 degrees.", "They then bolt the handle into the cam.", "When you depress the handle, the cam opens, opening the jaws.", "On the reverse side of the jaws, they mount a clip for holding the feathers, yarn, or other materials you're using to tie your fly.", "Then, they glue the logo coin into the pocket base.", "They install the mounting piece for the stem, then the stem itself.", "A thumbscrew on the mount holds the stem in place.", "The head connects to a swivel at the top of the stem.", "The jaws securely hold the hook while you tie your fly using anything from feathers and fur to tinsel and beads, creating your imitation of an appetizing insect or tiny fish." ]

{ "things": [ "Personal Watercraft", "Wine", "Office Furniture", "Ice Skates" ] }

[ "Today on \"how it's made\"...", "Personal watercraft...", "Wine...", "Particleboard office furniture...", "And ice skates.", "They're to water what snowmobiles are to snow, what motorcycles are to road.", "The proper term for these adrenaline-pumping, wind-in-your-face vehicles is personal watercraft, but most people call them sea-doos.", "The fiberglass shell that's the body of the craft is molded at another factory.", "It arrives here ready-made.", "Workers use a template to position decorative decals on the upper shell, called the deck.", "Next, they install rubber footpads on the steps.", "A robot drills holes in the lower shell, called the hull, first for the drainage system...", "Then for the exhaust system.", "Next, workers install the straps that will hold the internal components in place.", "Then they install the rubber pad that goes under the motor.", "Next comes the motor mount to hold the motor in place.", "Finally, the motor itself.", "This 130-horsepower engine arrives at the factory fully assembled.", "It's a matter of putting it in place.", "Next, they install the jet pump-- that's what gives the watercraft its jet power-- then the battery, then the driveline-- that's what links the motor and the jet pump.", "The 14-gallon gas tank goes in next.", "They connect the driveline...", "Then install the jet housing.", "That's the protective casing around the jet pump.", "Meanwhile, a robot works on the deck.", "It applies globs of glue in key locations.", "Workers stick on various straps that will hold internal components in place.", "Then the robot glues the circumference of both the hull and deck.", "They heat the hull to activate the glue...", "Then clamp the deck to the hull.", "The glue takes about 15 minutes to dry.", "Using an ultrasound machine, they inspect the seal to make sure it's watertight.", "Next, they install the hood and the steering column.", "Now it's time to run an engine test.", "The last step is to install a plastic bumper.", "A roller presses it securely into place.", "Researchers invented a way to identify faraway objects, even in thick fog or complete darkness.", "They use a laser combined with military night vision technology to locate objects or people up to miles away.", "The system is so precise, it can read the name of a boat in the dead of night.", "The next time you enjoy a glass of wine, think about your place in history.", "Wine may date back to 6000 b.c. nowadays, wine comes in bottles, not animal skins, but the basic principles of winemaking remain the same.", "Wine grapes grow best in temperate climates.", "The riper the grapes, the sweeter the wine, so growers wait as long as possible before harvesting their crop.", "Pickers gather grapes by hand, cutting off the bunches with shears to avoid tearing the plant.", "For red wine, winemakers use the entire red grape-- juice, skin, pulp, and even seeds.", "For white wine, they use just the juice of white grapes.", "While the winemaking process itself is certainly a factor, the quality of the grapes is what ultimately determines the quality of the wine.", "Grapes are affected by weather, by soil conditions, and by how the vines are pruned during and between seasons.", "The grapes go into the crusher, then into the presser, which squeezes out the juice.", "Inside the winery, the result of all that crushing and pressing ends up in large stainless steel tanks.", "The winemaker adds yeast to convert the sugar in the grape juice to alcohol.", "That's called fermentation.", "Winemakers constantly experiment with fermentation to try to improve the quality of their wine.", "They take samples of grape juice and mix them with different types of yeast.", "Yeast is found throughout the environment, in wild berries, for instance.", "They hydrate the yeast with a bit of grape juice, then pour the mix into the grape juice sample, let it ferment, and then see how it turns out.", "The big fermentation tanks are refrigerated, and monitoring their temperature is critical.", "White wine must be fermented at around 63 degrees, red wine at 86 to 95 degrees.", "The fermentation period depends on the type of wine.", "White wine has to ferment for three weeks, red wine for just 10 days.", "Rosé wine is somewhat of a half-breed...", "Made with red grapes, but fermented slowly, like white wine.", "It comes out pink.", "There's an extra step in making red wine.", "During fermentation, they drain the tank to aerate the wine.", "The oxygen helps the yeast work faster over the short 10-day fermentation period.", "Then they pump the wine back in through the top of the tank to mix everything thoroughly.", "During fermentation, they not only monitor temperature, but also the sugar level.", "As the juice becomes wine, the sugar level drops, and the alcohol level increases.", "Except for very sweet wines, fermentation is finished when the sugar's gone and the alcohol content is 11% to 13% for red wine, or 11% to 11 1/2% for white and rosé.", "The wine is stored for a few months, then it's run through several pressure filters to remove any particles.", "Then it's time to bottle the wine.", "Large wineries have fully automated bottling plants.", "Smaller operations have semi-automated systems like this one.", "The key in bottling wine is to avoid getting air inside because oxygen turns wine sour.", "The colored wine bottles protect the wine from light, which can also affect the taste.", "People have used cork to plug wine bottles since ancient times because it creates a tight seal that keeps the air out.", "Cork, incidentally, is a type of tree bark.", "Inside the bottle, the wine continues to undergo subtle organic changes as it ages.", "Nowadays, you have to be pretty high up in a company to have a solid wood desk.", "Your desk is more likely made of pressed wood-- an inexpensive alternative made from lumber by-products.", "Particleboard is a common type of pressed wood.", "Lumber mill leftovers provide the raw materials for particleboard.", "The process starts with truckloads of sawdust.", "The next ingredients are wood shavings and wood chips from all types of lumber.", "They feed those chips and shavings into a large mill that works like a giant food processor, chopping them up into little bits.", "When the milling's done, the particles are between .", "008 and .", "5 inches in size and less than .", "03 inches thick.", "To make the humidity level uniform, they put the particles into giant dryers whose combustion chambers are fueled by leftover dust from the chopping mill.", "After 15 to 25 minutes, the humidity level drops to 1.5%.", "From here, they'll send the dried-out particles to a screening machine, which will separate them by size.", "Pieces too big for particleboard are fed through the mill again.", "Sawdust will become fuel for the dryers.", "Larger particles go into the rougher core layer of the particleboard, smaller pieces into the smoother surface layer.", "Meanwhile, the factory's glue department gets to work mixing resin, water, wax, and chemical hardeners.", "Machines mix the glue and the particles, then push out a long, continuous mat.", "A cold compressor forces the air out of the mat.", "Then a hot press activates the glue and forces it all together.", "Next, a saw cuts the continuous mat into large sheets called master boards.", "They're still hot from the hot press, so they're put aside to cool for about a half-hour.", "Once the master boards are cool, they're sanded.", "Then a stacking machine piles them about 80 sheets high.", "A saw cuts them into a smaller, more manageable size to be sent off to a furniture factory.", "At the furniture factory, the first step is to laminate the particleboard panels with a decorative covering.", "First, the glue spreader covers the board's surface with glue.", "Then another machine sticks on a 4- to 5-foot strip of decorative paper fortified with resin, varnish, and other chemicals.", "This covering comes in many different colors and designs, from solids to imitation granite or wood.", "A blade cuts the paper between each board.", "Then a machine stacks the boards to prepare them for cutting.", "The saw cuts through six to eight boards at a time, depending on their thickness.", "The next step is to cover the edges of the particleboard.", "They take a strip made of pvc plastic that matches the laminate.", "They glue it over the edges, then trim it for a neat finish.", "Next, they prepare the pieces for assembly.", "A multiple-head drill makes screw holes in the panels.", "Meanwhile, they prepare the bag of hardware.", "There's a separate bin for each screw, nut, bolt, and connector.", "The machines count out the exact number of hardware each piece of furniture requires.", "Then the hardware is automatically bagged and weighed to make sure nothing's missing.", "Every so often, a worker assembles a sample to make sure everything fits together properly.", "If it does, production continues, and they can proceed to packaging.", "They put together the particleboards for each piece of furniture, add the hardware bag and instruction booklet, then seal everything in plastic film.", "From here, it goes into a box to be shipped to the store.", "Getting your first pair of ice skates is like getting your first bicycle.", "It's a childhood rite of passage, and one that leads to another well-known ritual-- landing on your backside the first time you try them out.", "How long have we been ice-skating?", "An iron skate found in scandinavia dates to 200 a.d., but people likely put blades made of bone under their shoes even earlier than that.", "Skaters tied on their blades with straps until the advent of the skate boot in the early 1900s.", "Today, skates are lightweight and high-tech and are designed for specific sports-- figure skating, speed skating, and hockey.", "It takes 145 steps to make this high-end hockey skate.", "The skate boot is made of a synthetic material that looks and feels like leather.", "Once they've cut the pieces that will make up the boot, they shave the edges, thinning them out so the boot won't be bulky, particularly where there's overlap at the seams.", "They position a reinforcement piece onto what's called the quarter-- the main structural piece that will form the sides and back of the skate boot.", "They glue it on with a hot press.", "The boot pieces now go to the sewing department.", "They stitch together the tongue piece, then, using a sturdy zigzag stitch, they attach the quarter and the heel piece.", "They spray glue on the quarter...", "And on the ankle support...", "Then stick on a foam ankle pad designed to mold to the contours of the skater's ankles.", "Next comes the lining.", "They must center it perfectly for the skate to be properly aligned and balanced.", "The eyelet machine works like a hole punch, punching out eyelets in the quarter.", "They reinforce each eyelet with an aluminum washer.", "The last step in the sewing department is called forming.", "They place the boot over a metal foot form.", "A hot press laminates the boot to give the back and sides of the quarter their shape.", "In the assembly department, they put the parts together using a foot form.", "They tack on a white plastic insole and a black plastic toe cap.", "They brush on a layer of glue...", "And attach the boot.", "They sand the bottom of the boot to roughen up the surface for better adhesion.", "An automated machine applies a layer of glue along the contours of the boot's underside.", "The boot then goes through a heat machine for a couple of seconds to evaporate the solvent in the glue, making it tackier.", "As with the lining, they must position the sole perfectly, or they'll throw the skate off-balance.", "An 8-ton press presses it onto the boot.", "The sole is made of strong carbon or carbon composite depending on the skate model.", "Once the glue is dry, they drill two holes through the sole for attaching the skate blade.", "The blade sits in a plastic holder.", "They screw it in place through the holes, then secure it with five steel rivets and four more resistant copper rivets.", "Like the lining in the sole, the blade's alignment is crucial.", "Roller hockey skates are made almost the same way as ice hockey skates, just instead of a blade, they attach an aluminum chassis with rollers.", "In the finishing department, they inspect the inside of the skate, checking the blade holes and rivets in particular.", "They plug the blade holes.", "Then they lace up the first three sets of eyelets.", "Finally, they install what's called the footbed-- the high-density foam padding that lies under the foot.", "Last, but not least, they clean the skate, trimming excess threads and removing any glue residue." ]

{ "things": [ "Laptops", "Panettone", "Saxophones" ] }

[ "The first computers used to be the size of an entire room.", "Then they were built to fit on your desk.", "The newest design is a portable device that sits on your lap, and today's laptops are made even smaller and more powerful than ever.", "With its lightning-fast processor and impressive graphics, this laptop is designed for high-performance gaming.", "The computer's brain, called the motherboard, begins as a printed circuit board.", "Its pattern of lines and pads and copper is the wiring for the electronic components that will be soldered to the board.", "This machine places a stencil of the component layout onto the board and applies solder paste through the openings.", "A quality-inspection camera photographs the solder paste and sends the images to a computer.", "The computer analyzes them, looking for any missing paste, misalignment, or other mistakes.", "If the board passes inspection, it passes through 15 robotic machines, each of which places up to 150 components on the correct locations on the board in just 30 seconds.", "Then the board runs through an oven that melts the solder paste, connecting the components to the board.", "Another camera inspection ensures that the internal processor is correctly soldered, and that no component is missing or shifted out of position.", "After function testing and a visual inspection, the motherboard moves to the assembly line and is set aside for the time being.", "Next, technicians manually assemble the top half of the laptop called the panel kit.", "They place protection film on the 15-inch lcd screen.", "Then they plug in the cable that will connect the lcd to the motherboard.", "They insert the lcd screen into a frame with a web camera and microphone already embedded.", "Then they attach this antenna bottom cover to the screen cover and position the motherboard cable inside it.", "Next, they install the module for the webcam and microphone.", "They attach two hinges, which connect this panel kit to the rest of the laptop.", "Then they install the wi-fi antenna in the antenna bottom cover.", "All components are concealed in the antenna bottom cover behind this antenna top cover.", "They complete the panel kit by pressing in a thin metal frame around the screen.", "Next, they assemble the bottom half of the laptop.", "First, technicians attach the top cover to the panel-kit hinges and the touchpad.", "Then they install the right and left speakers in the top cover.", "Now the motherboard comes back into play.", "After inspection, a computer-guided router cuts out openings to accommodate the computer's fans, which prevent the electronics from overheating.", "A gaming laptop generates a lot more heat than a regular laptop and therefore requires two powerful fans rather than one.", "After checking that the fan screws are sufficiently tightened, they place the motherboard into the top cover.", "Contaminants such as dust or oil can impede proper contact, so as a precaution, they clean the connectors for the memory modules with solvent, then dry them with compressed air.", "Then they install the memory module, the wi-fi and bluetooth module, and the solid-state disc, which stores data.", "They connect a high-capacity battery to the motherboard.", "Batteries for gaming laptops are typically larger because the faster processor and dual fans consume more power.", "The last component is the keyboard, which fits into a rectangular opening in the top cover of the bottom half.", "A laser-etching machine marks the required information underneath.", "An automated machine tests numerous functions, and a quality-control team tests several others, including the virtual-reality feature...", "The lcd and keyboard color displays...", "And the keys.", "Not only must the keys function properly, they need to be durable, so enthusiastic gamers won't break them while playing.", "Panettone is a traditional italian sweetbread most commonly prepared for dessert on christmas and new years.", "Baking authentic panettone can take up to two days or more to make.", "A certain expertise is needed to turn these ingredients into its domed-like shape while maintaining its fluffy center.", "The baker pours high-protein flour to a mixing bowl.", "Then he adds the flour into an industrial-sized dough mixer that has hooked mixing arms.", "He adds fresh yeast, milk powder, and enough water to bind the ingredients together.", "He places the safety cage over the dough mixer.", "As the hook agitators blend the ingredients, gluten forms.", "Glutens will give the panettone structure.", "Sugar will feed the growth of the yeast.", "The agitators evenly distribute it in the dough.", "Meanwhile the baker cracks eggs and separates the yolks from the whites.", "He weighs the yolks and adds them to the mix.", "This panettone recipe calls for egg yolks only.", "Yolks provide fat to help emulsify the dough and give it flavor.", "To further enrich the flavor of the panettone, he adds a generous amount of butter.", "The mixer folds it into the dough.", "He transfers the dough to a container and leaves it to rise for 11 hours.", "This process is called proofing the dough.", "The dough undergoes multiple proofings.", "In between each proofing period, the baker deflates the dough and returns it to the mixer.", "During this process, the yeast consumes sugar, so he adds more to feed the process.", "Next, he adds more of the other ingredients, and the mixer kneads them into the dough for one hour.", "The mixer works the dough, creating bands of elasticity, so that the dough will stretch during rising.", "In the final mixing stage, the baker adds vanilla extract for another flavor dimension.", "While the dough mixer distributes it, he measures fruit by weight.", "The panettone recipe calls for two parts raisins, one part candied orange pieces, and one part candied lemon pieces.", "The mixer folds them into the dough.", "After another proofing, the baker slices the fruited dough into chunks.", "Some of the water in the dough will evaporate during baking and the panettone should end up about two pounds.", "He shapes each chunk into a uniform mold and leaves the dough chunks to rise for an hour in a warm chamber.", "Instead of metal pans, panettone is baked in these paper molds.", "The molds will also be used as retail packaging.", "After about an hour in the warming chamber, the dough chunks have doubled in size.", "The baker works them into a rounder form and transfers them to paper molds.", "Then it's back into the warming chamber for another proofing.", "As the dough rises, the round shape is contained by the paper molds.", "After six hours, he takes out the molds and carves crosses into the risen dough.", "He adds small pieces of butter to the middle of each cross.", "After 24 hours of preparation, the panettones are ready to be cooked.", "They bake for 45 minutes at 320 degrees fahrenheit.", "Once complete, he quickly spears each panettone with a metal rod near the base and hangs it upside down.", "The panettones cool for up to 24 hours in this upside-down suspended state.", "This stretches the warm breads to give them their dome shape and stops them from caving inward.", "Once cooled, the panettones are ready to be wrapped for retail.", "All that proofing has allowed the flavors to mature and the fluffy texture to develop.", "The yeast will act as the preservative, keeping this italian christmas bread fresh for up to 30 days.", "The saxophone was invented in the mid-1800s by adolphe sax, the son of belgium's chief instrument maker.", "With the saxophone, sax blended the power of a brass horn with the nuances of a woodwind instrument.", "This instrument has the ability to sound bright and edgy or dark and moody.", "Even though it's made of brass or high-copper alloys, the saxophone is technically a woodwind instrument.", "That's because it produces sound by vibrating a reed attached to the mouthpiece.", "The process of making a saxophone starts with a long brass or copper sheath.", "A hydraulic punch cuts the metal into rectangles.", "After tracing a flared pattern onto one piece of metal, a craftsman aligns the pattern with the punch to cut out the part.", "This part will now be formed into the saxophone's bell.", "The worker folds it around the metal rod and pounds it with a wooden stick to do some initial shaping.", "This takes the part from flat to three dimensional.", "After the seam has been welded, more hammering rounds the shape substantially and improves on the flare at the end.", "Next, the craftsman repeatedly pounds the flare to form it into a bell.", "Hand-hammering shapes the metal and also alters the physical properties to make the sound more resonant.", "Throughout the forming of the instrument, it is heated with a torch.", "This makes the metal flexible enough to be shaped.", "Next, he slides the bell onto a form.", "He brushes lubricant onto the metal...", "And lowers a roller.", "The form spins the curved bell against the roller, which smoothes out dents and forces the bell to conform to the dimensions of the roller.", "The rolled saxophone bell is the one on the right.", "It's dramatically different.", "Now we can see the saxophone's body take shape.", "It starts with this piece of metal that's wider at one end.", "The operator places it under a cone-shaped form.", "Using hydraulics, it descends to fold the part and imprint the cone shape on the metal.", "After more forming, another worker welds the seams to complete the cone.", "This part of the instrument is also called the tube.", "Meanwhile, the forming work on the saxophone bell has been completed.", "A worker locks the upper part of the bell into a machine and turns the punch device to cut the tone holes.", "Sound waves will be emitted through both the open tone holes and the bell's flare.", "Later, another worker aims a torch at the saxophone body to soften the metal, so that the rims of the tone holes can now be formed.", "He slides the body onto a steel mandrel with round inserts.", "He aligns the tone holes with holes on the mandrel.", "He sets a guide rack on top, aligning the holes in the rack with the holes in the instrument.", "He inserts tools through the holes and threads them into the round inserts in the mandrel.", "A support bracket props up the tools.", "Using the tools, he pulls the inserts through the holes.", "This forms a rim around each hole.", "The raised edging will allow key cups to close the tone holes effectively.", "The craftsman drills the rims to smooth and level them.", "This will prevent gaps that could affect the sound of the instrument when the key cups close.", "The next part is the bow, which will link the saxophone bell and body.", "The craftsman brushes a cleaning agent known as flux onto one end.", "He connects the two parts and applies more flux to the bell where it meets the bow.", "He then melts solder where the two parts come together, completing this critical connection.", "The solder makes the joint airtight.", "He turns over the bell and bow assembly to complete the job, ensuring that the solder encompasses the entire joint.", "He dabs water onto the soldered joint to cool it down.", "But before this saxophone is ready to make music, a few more steps must be taken for good measure.", "The saxophone has tonal qualities similar to those of the human voice.", "Its sound can range from sultry, dark tones to high-pitched exuberance.", "It's no wonder the saxophone has found a place in many music styles from jazz to pop to the classics.", "The standard saxophone has 23 different tone holes and an equal number of key cups to close them.", "At this factory, each key cup is assembled by hand.", "A craftsman arranges the parts of a key cup in a fixture to position them for soldering.", "He inserts a rod that will act as an alignment and positioning tool.", "He applies flux to clean the part and melts silver solder into the connecting points.", "To prevent the parts from sliding, the craftsman uses pincers to adjust their position.", "Other keys are grouped together on a brass plate known as a rib.", "He spaces the key posts evenly on a rod that serves as an alignment tool.", "Several overhead clamps hold the posts in place on the rib.", "He applies the chemical cleaner to the base of the post and the plate around them.", "Silver solder is melted around the post, and as it solidifies, it fuses them to the plate.", "Next, the craftsman removes the overhead clamp system.", "After sliding keys onto the ends of the alignment rod, he positions the assembly on the saxophone body.", "He closes the keys onto the corresponding tone holes and solders the base plate to the lower part of the saxophone body.", "He brushes water onto the solder to accelerate the cooling and solidification.", "He then removes the alignment rod and uncaps the tone holes for now.", "A cleaning agent is brushed onto the back of a rib that supports a second grouping of key posts.", "He solders the rib to the upper part of the saxophone body and takes the alignment rod off.", "The posts have been installed in a specific sequence to support extending keys on a hinge rod.", "Later, another worker polishes the bow and bell assembly against a buffing wheel, which polishes the instrument to remove smudges or fingerprints and give the brass parts a mirror finish.", "They dip the brass saxophone parts in a bath where sound waves help remove residual dirt and grease.", "There's also a chemical primer in the bath that will help a lacquer bond to the brass.", "A technician sprays the lacquer onto the brass to protect it from corrosion and tarnish.", "Floral artwork will add visual flair to this copper saxophone bell.", "The copper has been painted black to make the art stand out.", "The artist follows the stencil with an etching tool, rotating it using a twirling motion technique, etching in fluid movements.", "He doesn't stop until he's completed a line to prevent any inconsistencies in the engraving.", "After he completes the pattern, he does detail work.", "This exposes the copper metal and makes the art pop.", "Returning to the brass saxophone now, a technician screws long hinge rods to the posts.", "He attaches the keys, which have been equipped with pads in the cups.", "A tiny screw secures this grouping of keys.", "He turns the saxophone over, inserts a light, and looks for escaping rays, making adjustments if needed.", "He installs needle springs under the key rods and main hinge rod.", "They'll enable the keys to spring back after they're pressed.", "He tests the spring action and, again, checks for light leaks.", "He now fits the bell bow to the main body.", "There's a connecting ring that holds them together, but he'll also lock them in place with a screw.", "From start to finish, it takes about a month to craft this saxophone.", "Whether it's made out of basic brass or something a little showier, the look of the instrument can reflect the saxophonist's playing style, but the tone of the instrument defines it." ]

{ "things": [ "Technical Glass", "Washing Machines", "Playing Cards", "Crossbows" ] }

[ "A traffic intersection, a hollywood movie set, the outside of an airplane-- it's hard to imagine any common ground among them until you flip a switch, a light switch.", "Traffic lights, movie lights, and aircraft lights are all made of the same type of special glass.", "It's called technical glass.", "Borosilicate glass has a low thermal expansion and is very durable.", "It's used in high-temperature applications and when abrasion resistance is important.", "It begins with a mix of silica sand and chemicals called batch.", "Workers shovel the batch and recycled glass, called cullet, into a pot furnace, where they melt for two days.", "A variety of colorants are added to make hundreds of different colors.", "Next, it's on to the molding process.", "Workers heat a ring and transfer it to the top of a mold.", "Then they twist and turn a stick called a punty to gather some melted glass and carefully string it in the mold.", "A plunger squeezes the molten gob into shape.", "The glass solidifies in seconds.", "This glass lens is used as a landing-light cover on an aircraft.", "They extract it from the mold for a quick inspection.", "Any imperfections, and it gets recycled.", "If the lens is acceptable, it's held in a forming device to finalize the shape.", "The burner maintains the proper temperature of the ring.", "Once formed, the lenses are cooled in an annealing oven, which relieves unwanted stress in the glass.", "This circular mold makes theatrical and landscape lighting.", "Again, a gob of molten glass is dropped in the mold, and the plunger is depressed, forming the lens.", "Heat-resistant tongs enable workers to handle the hot lenses.", "Red and yellow lenses need a high-temperature anneal for the color to appear.", "This is called striking.", "Back on the molding line, special tools are used to ensure this aircraft lens maintains its shape.", "A quick spin on the light wheel illuminates any defects.", "After a trip through the annealing lair, the lenses are ready for further processing.", "The molding process for larger lenses can be more complicated.", "This large convex lens requires several gobs of molten glass placed carefully on top of one another.", "The plunger enters into the molten glass, forming the lens.", "Deep ridges located in the plunger of the mold create the circular prisms on the glass lens.", "Within seconds, the lens is ready for extraction and inspection.", "Using heat-resistant mitts, workers scrutinize the glass from every angle, checking for small fractures or imperfections in the glass.", "Next, they inspect for flatness using a paper-thin plastic feeler.", "If it slides underneath, the lens is warped and unacceptable.", "They check the glass thickness in many locations, using a calibrated thickness gauge.", "Any major defects, and they discard the lens.", "In the factory's finishing shop, they use a diamond saw to slice away excess glass around the periphery.", "A special sanding belt is used to smooth the surface to perfection.", "Then, with a cloth buffing wheel, they polish the glass to a shine.", "At last, the final inspection.", "Using calipers, they measure the lens's ridged edges, called the flange, to make sure the dimensions are correct.", "Producing such a colorful assortment of technical glass takes a lot of work, but at least there's light at the end of the tunnel.", "In the days before electricity, doing laundry was just plain hard work.", "The first electric washing machines were little more than a bucket with a motor attached.", "Fully automatic machines came about in the 1960s.", "But with rising concern for the environment, there are new designs that need less water and electricity to get the dirty job done.", "Most washing machines contain a circular tub to hold the laundry.", "But this model has a unique feature-- a hexagon-shaped tub made from panels of laser-cut, perforated stainless steel.", "The operator separates the cut panels and places one on a bending machine called a press brake.", "It forces the panel against a die, bending the edge.", "The operator repositions the panel for the next bend, repeating this until the six-sided shape is complete.", "Then an assembler attaches a hinged door to the tub's opening.", "That's where the laundry goes in.", "This inner tub is contained by another outer tub.", "To assemble it, a welder sets a stainless steel plate onto a welding fixture.", "Then he places the tub's main frame and slides in another steel plate to close it up.", "He clamps the tub firmly in place then spot-welds it on each side so the pieces hold together.", "Next, he takes the tub over to a machine called a seam welder.", "There, an electrode wheel travels all along the tub's edge, welding together the front and back panels to the main frame.", "There's still more welding to do with the use of a robotic welding arm to build the machine's 24x27-inch steel base.", "A concrete counterweight mounted on the outer tub's side prevents the machine from shaking too much when it's in operation.", "Next, an assembler attaches a pressure tube and a sump hose to draw the used water out of the machine.", "He seals both tubes with a watertight adhesive.", "Now he can install the suspension struts that support the outer tub, one at each corner of the base.", "A single electric motor powers the whole machine.", "It's set on the machine's underside on an adjustable pivot shaft.", "With the motor in place, assemblers now turn over the completed outer tub and lower it into position on its base.", "They connect the support struts on all four sides and then push the tub to make sure the struts align properly and keep the machine balanced.", "Next, the inner tub is set into the outer tub.", "Workers insert a stainless steel shaft right through both tubs.", "A strip of watertight foam is set along the outer tub's perimeter to seal it before workers install a plastic bezel that keeps water from splashing out of the machine.", "Next, assemblers install the drive pulley onto the shaft that supports the inner tub.", "A drive belt connects the motor to the pulley, which rotates the shaft and the inner tub that it supports.", "Now they slide a stainless steel outer cabinet onto the base that covers the tubs.", "It contains a control board, the brain of the washing machine.", "The assembler sets the lid into place, and the machine is complete.", "The control-board wiring is located on the underside of the lid.", "That's also where the valves that dispense detergent, bleach, and softener are.", "Before it leaves the plant, a member of the quality-control team tests it out with a load of soiled laundry.", "According to the manufacturers, the unique shape of the inner tub is the key to making this a lean, green washing machine that requires less water, less detergent, and less energy to get the job done.", "There's been a lot of water under the bridge since the days of those first machines.", "They've sure come a long way.", "The playing card traces its roots back more than 1,100 years to 9th century china.", "Since then, generations young and old lay down their true colors in a variety of games, each as unique as the traditional 52-card deck and as timeless as the four famous suits.", "Whatever the hand, a winning combination of technical features makes these playing cards durable and cheater-proof.", "Industrial humidifiers control the moisture level of the card stock.", "This prevents the cardboard from drying out and warping.", "Technicians regularly monitor the cardboard's temperature and humidity by inserting a flat probe 4 inches from the top of the 3,000-sheet stack.", "Card stock arrives from the paper mill ready-made-- two layers of cardboard bonded with colored glue.", "This construction makes the playing cards impossible to see through.", "Before making printing plates, a technician checks the artwork for the deck, then prints out a low-resolution sample to confirm the sequence and layout are correct.", "There's absolutely no room for error, so she carefully double-checks every card for suit, sequence, color, and layout.", "A signature on this sticker confirms these cards are good for print.", "The next step is to make a digital proof.", "This printer's internal laser heat-transfers dots of colored foils onto a clear film.", "These dots perfectly reproduce the content and color of each card.", "Next, a laminating machine bonds the exposed films onto a sheet of the same cardboard used to make the cards.", "This produces a printed proof showing exactly what the finished playing cards will look like.", "Here, graphic artists adapt hand drawings of the face cards, adding color and a touch of regal class wherever needed.", "The next step is to make the printing plates.", "A computer-guided laser etches the design into the polymer surface of the printing plate.", "Entirely automated, this machine produces 30 plates an hour.", "To set up for a print run, workers pour several cans of thick cyan ink into the ink duct.", "The three other colors-- same setup.", "When the printing press gets rolling, each fountain will disperse ink evenly via 16 rollers.", "Feeders transport the cardboard sheets one by one into the press.", "Each printing plate is mounted on a rotating drum.", "Rollers transfer the ink onto the plate, which then transfer onto a rubber blanket, which presses against the passing cardboard as it moves through the press.", "At the end of the machine, the printed sheet is flattened and stacked.", "They feed the same sheets back through the press, this time upside-down.", "The sheets now move through a cutting machine called the combi, where rotating blades divide the sheet into columns, then into individual cards.", "The cards get grouped into decks.", "Then the deck heads into what they call the cornering station.", "A die descends and, in one fell swoop, cuts off all four corners.", "Next, a robotic arm nudges each deck onto a conveyor destined for the cello wrapper.", "Grippers pull a cellophane reel downwards while a knife then cuts the film.", "A heated bar descends and seals the film, which forms an envelope.", "With a simple pull, the red tear strip removes the wrapper.", "The traditional english deck is the international standard for games such as poker.", "But there are many more types of playing cards.", "This set of spanish cards, for example, has no numbers, just symbols.", "Whether at the casino blackjack table or the kitchen table, playing cards are the real deal.", "A crossbow is a modern bow and arrow that you shoot like a rifle.", "It's popular for both target shooting and hunting.", "With a rifle, you can shoot from 200 yards away.", "But using a crossbow is more of a challenge.", "You have to be at least four times closer to your target.", "A crossbow consists of the bow and the stock.", "The bow shoots the arrow, while the stock houses the trigger and the aiming scope.", "A plate of fiberglass is the starting point for the bow's limbs, the two curved arms that pull back and release to shoot the arrow.", "A vacuum holds the plate steady as a computer-guided grinder does some initial shaping.", "Workers measure the plate with micrometers to ensure it meets strict specifications.", "This is a special type of fiberglass.", "The fibers all run in the same direction, meaning they can bend repeatedly without weakening over time.", "Workers mount the plate on a computer-guided cutter.", "It carves out the limbs with a high-pressure water jet-- the most precise way to slice fiberglass.", "Each plate yields four limbs-- two bows' worth.", "The severed fibers make their surface rough, so a little polishing is in order.", "The limbs go into a vibrating tub filled with ceramic stones that rub against the limbs, wearing down the coarse fibers.", "Now the limbs are ready for decoration.", "The design is printed on plastic film.", "This machine uses heat and pressure to transfer the design.", "The next bow component is called the riser.", "They machine it out of aluminum, then jazz it up with an ink transfer.", "To assemble the bow, they bolt a limb to each side of the riser.", "It acts as a spacer, separating the limbs so that the arrow can pass between them when you shoot.", "The riser and limbs go into a press, which applies more than 660 pounds of pressure, bending the limbs into an arc.", "Next, workers mount a set of aluminum pulleys on each limb tip.", "These are called compound cams.", "Next, the yoke.", "A yoke is a string with a loop on each end.", "They anchor one loop to one side of the limb tip, pass the other end through a loop on a steel cable, then anchor it to the other side.", "This forms \"y\" shape that distributes pressure on the limb evenly.", "They repeat the same process with a second yoke on the other limb.", "Now for the bowstring.", "On each limb, they attach the bowstring end to one side of the cam.", "Then they anchor the cable coming from the yoke to the other side.", "Next, two rubber silencers go onto the bowstring.", "When you shoot, these silencers absorb the string's vibration, reducing the sound.", "These components make up what's known as a compound bow.", "This design enables the bowstring to propel the arrow farther.", "Now the bow is finished and ready for testing.", "This scale measures how much strength it takes to draw the bow.", "Elsewhere, the stock is coming together.", "First, the trigger mechanism.", "It undergoes extensive testing in a specially designed device that applies air pressure to simulate the bowstring tension.", "They pull the trigger six times to ensure it fires properly.", "Then they apply the safety catch.", "And with a strap to get maximum strength, they pull some more.", "This makes absolutely sure the trigger won't fire accidentally in the safety position.", "After attaching a connecting rod that fits in the bow's riser, they install the trigger in the barrel.", "Then they bolt these components into the stock housing.", "They attach a bridge and rail on which the scope will mount.", "Now they test the trigger again to check the installation.", "Connecting the crossbow's two sections is simple.", "You insert the stock's rod into a slot in the riser and tighten the mounting bolt.", "Then you attach a foot stirrup.", "To cock the bow, you stand the crossbow on the ground, put your foot in the stirrup, and pull the bowstring upward until it locks into the trigger mechanism.", "Then you pick up the crossbow, aim, and fire." ]

{ "things": [ "Steel Bistro Sets", "Letterpress Printing", "Bamboo Ceramic Lights", "Asphalt Compactors" ] }

[ "The metal bistro set is a fixture in european-style cafés and small restaurants.", "The set consists of a small dining table and two chairs.", "A bistro set is also popular in homes with limited outdoor space as there's usually enough room for one on a balcony or small patio.", "The small restaurant bar known as the bistro originated in 19th century france.", "Its iconic dining sets are still being produced today in both traditional and modern styles.", "This french factory makes them out of strips of flat steel with rounded edges.", "The first step is to flatten the strip with pressure-applying rollers.", "The steel then enters a press which does three operations simultaneously.", "It cuts pieces to the required length, rounds their ends, and punches out holes where required.", "These are parts for the table legs.", "Meanwhile, this computer-guided machine bends a 1/2-inch steel rod into a circle to form a ring that will support the tabletop.", "This table is collapsible, allowing it to fold flat for storage.", "Therefore, two of the legs are hinged.", "A pin and notch lock them in the open position.", "After putting together the folding legs, a worker positions all the parts for the base on an assembly fixture.", "Then he operates a welding robot, which welds all the crossbars, reinforcing the legs and the legs to the ring.", "It only takes about 2 minutes to weld all these parts into a folding table base.", "The manufacturers make the tabletop from a square piece of sheet steel.", "This machine first sheers off the corners, transforming the square into a circle.", "Then it draws the edge upward to form a 1/2-inch-high rim on what will eventually be the underside of the tabletop.", "It also cuts a hole in the center for an umbrella pole and draws that edge, as well.", "A worker mates the tabletop to the folding base.", "He inserts the ring into the tabletop's underside rim.", "Then he opens the base and uses spreading pliers to pull apart, then butt the ends of the ring.", "Next, he shields the underside of the table with a scrap piece of metal and welds the butted ends.", "The table is now fully constructed.", "The chair parts are cut on the same press as the table legs.", "Each chair has two long legs and two shorter legs.", "This machine simultaneously folds and twists the two shorter ones and folds the two longer ones.", "The operator then connects them with a crossbar.", "The next operator places these connected short legs in another machine.", "He adds washers to the protruding ends of the crossbar, then the two long chair legs, connecting them lower down with the crossbar.", "The machine welds that crossbar and forms each end of the other crossbar into a rivet, which creates the folding point for this collapsible chair frame.", "The next operator places the frame on another machine, positioning three holes on each side onto upright steel pins.", "He lays two steel slats for the chair back on these pins, then five more for the seat onto identical pins riveted to a pair of steel bars.", "The machine then forms the pins into rivets, attaching all the slats.", "He then assembles the seat to the frame, completing the construction of the chair.", "The tables and chairs go on to the paint line.", "The first station washes and dries the furniture.", "Next, a worker opens each one to spray paint the articulation points.", "Then, automated nozzles paint the rest.", "This is industrial-grade powder paint known as powder coat.", "A 10-minute trip through a tunnel oven at 370 degrees fahrenheit bakes it on.", "Workers apply product information stickers, cushion protruding parts with plastic covers, and enclose foot protectors.", "The bistro set is now ready.", "Just unfold and unwind.", "In an electronic world where a few taps on a device keyboard sends an invitation or greeting card, it's not all that common anymore to receive something printed the old-fashioned way.", "Yet there's nothing quite as elegant as the crisp, recessed print that traditional letterpress printing produces.", "Letterpress printing is a centuries-old method that's making a comeback.", "The printing press makes an impression in the paper with raised type as it applies the ink.", "The printer first sketches out some design ideas.", "Then he detours into digital technology, finalizing the colors and composition and choosing the font in traditional metal type.", "He cuts paper to the size of the greeting card he's making.", "The paper is 100 percent cotton, which is more pliable than standard wood-fiber paper, thus enabling a deeper impression.", "Cotton paper is more delicate, so he has to cushion it while cutting.", "Otherwise, the clamp holding the stack would dent the paper.", "Now it's time to set up.", "He locates the selected font in the type cabinet.", "Each individual character, called a sort, is backwards because backwards type prints forwards.", "He finds the sorts for the first line of text and lines them up left to right and upside down in what's called a composing stick.", "Once he completes the type of the line, called a form, he clamps it in position.", "Then he takes a metal frame, called a chase, and mounts the form at a specific position inside the frame, filling the excess space with blocks of wood called furniture.", "Just below the piece of furniture that's underneath the form, he places a compression device called a quoin and expands it with a key.", "This locks the form in position.", "He chooses each ink color from a fan deck, then follows the recipe to mix it.", "This is color extender, which works like paint thinner, diluting a dark color to a lighter shade.", "He mixes the color extender into the ink, blending the two ingredients thoroughly.", "When the color matches the fan deck sample, he places a glob on a piece of cardboard and takes the mixture over to the printing press.", "He applies it in dots all over the ink disc.", "Then he pumps on the treadle to run the rollers back and forth across the disc.", "This spreads the ink over the disc and onto the rollers.", "He inserts the chase containing the form into what's called the bed of the press.", "Now for the test run.", "The printer pulls the lever to bring the bed and platen together so that the form, inked by the rollers, creates an ink-filled impression in the paper.", "If the print is off a bit, he marks the correct position by pencil and installs gauge pins, which will hold the paper there.", "Now he's ready to start printing.", "There's no automation here.", "He manually places one sheet at a time in the gauge pins.", "The ink dries quickly because it's rubber based and because cotton paper absorbs well.", "This printer's technique is a hybrid of traditional and modern approaches, as he uses computer-generated graphics.", "He sends the digital file to a company that makes a polymer printing plate, which he mounts on an aluminum base that fits in the chase of the press.", "He switches plates to do the next graphic in a different color, layered over the first.", "The polymer plates marry the old and new technology by making it possible to print computer-generated graphics by traditional letterpress.", "After printing the inside of this greeting card, as well, he uses a scoring rule mounted in another press to make a perfectly straight fold line down the middle of the paper.", "The result is beautiful, textured print on elegant cotton paper just like the good old days before ink-jets, e-cards, and e-vites.", "Bamboo-ceramic lights add a touch of zen to any space.", "Made of ceramic and inspired by bamboo, they resemble bundles of tropical grasses, but they're not exact replications.", "These light fixtures offer an artistic interpretation of an exotic element from the natural world.", "Trying to create a tropical ambiance?", "It's all in the lighting.", "These ceramic lights celebrate the natural beauty of bamboo and set the mood.", "Making the ceramic casing starts with a slurry of clay and water known as slip.", "A propeller mixer evenly distributes the particles.", "The slip flows through a hose and into plaster molds.", "The artisan controls the amount going in, ensuring that each one is filled just below the brim.", "Over 3 hours, the clay thickens and congeals along the edges.", "After pouring out the remaining slip, he trims the clay casting, which has a putty-like consistency.", "After leaving it to solidify a bit more, he carefully disassembles the mold, revealing the clay casting with a bamboo-like detail.", "After curing overnight, the casting further solidifies, and the color lightens.", "Using a knife, he adds more definition to some of the detail and cleans up the rough edges.", "He also shaves off protrusions formed where the mold parts came together.", "He lightly sands the entire bamboo ceramic casting to smooth over any remaining imperfections.", "Using a wet sea sponge, he washes the entire casting.", "This softens the clay on the surface and gets rid of any minute scratches left by the sanding.", "The artisan then cuts holes in the back of the casting.", "One is for installing the light socket, and the other is to run wires to the electrical junction box.", "With the clay surface still moist, he carves nodes, or joints, into the bamboo canes.", "He also cuts wide vertical lines to create the effect of cracks that occur in bamboo naturally when they dry out.", "After firing the clay casting in a kiln and then cooling it overnight, the material has become a strong, durable piece of ceramic.", "This craftsperson examines it for imperfections and then begins the painting process.", "She sprays a very light yellow paint onto the bamboo ceramic.", "This gives the piece just a hint of color, but it provides the desired undertone.", "Next, she mixes a green oil paint with thinner and then brushes the mix into the grooves and notches.", "This accentuates these areas.", "She also brushes it onto the edges of the bamboo ceramic light box to better define the profile.", "Using a soft cotton cloth, she blots up some paint from the palette and wipes it on the ceramic.", "This softens the brush strokes and gives the ceramic cane structure a hint of green.", "She sets the light casing on a revolving stand and inspects the coverage.", "She then applies a liberal amount of brown paint to the entire piece, and the brown color completely overpowers the green and yellow paints.", "She rubs off a lot of the brown paint.", "This tones it down and subtly brings out the other colors.", "This produces color variations that evoke the different tones of dry bamboo.", "The paint transforms the piece.", "A technician inserts the socket and pulls the wires through one of the holes and out the back.", "He secures the socket in the light box from the back with a washer and nut, and that completes this bamboo ceramic light fixture.", "Making it takes roughly 1 week, but the final result is very unique.", "While providing illumination, it may also be an object of conversation.", "Asphalt compactors are the heavy rollers of paving.", "They're equipped with vibrating drums that weigh several tons.", "The sheer load, in combination with the mechanical vibrations, compact new pavement.", "This locks the aggregate particles together in order to provide a strong and stable road.", "The asphalt compactor vibrates as it applies its weight to fresh pavement, and this process removes air pockets that could ruin the newly laid road.", "To make this critical piece of road-building equipment, a computerized plasma torch cuts through heavy-gauge steel.", "The operator selects the programs that guide the cutting.", "The torch cuts out the compactor's body panels, the plates for the rollers, and many other parts.", "A worker welds the front of the compactor frame together, and he attaches bracket plates for a pivot-hinge steering system.", "Another worker guides a steel plate into a rolling machine.", "The machine shapes the thick steel into the shell of a compactor roller.", "The machine requires a few passes to establish the correct radius.", "A crane then transfers the rolled steel to a fixture that positions bulkheads within the shell.", "It then lifts the shell with the bulkheads and fixture onto a table, and a worker wraps cables around it.", "He adjusts the length of the cables with a thick steel pin.", "He tucks brackets behind the cables at the seams to protect them during the welding that will come later.", "He installs chains and tightens them to hold the shell steady on the table.", "He then activates what's called the squeezer.", "Hydraulically powered, this machine pulls the cables to close the gap in the shell, and while the cable keeps the seam tight, the worker tack welds the seam and bulkheads from the inside.", "With the tack welds holding everything together, a robot does the full welds on both the seam and the bulkheads.", "The seam weld is large and protrudes from the shell...", "So the next worker grinds the seam flush to the rest of the shell, allowing the roller to operate smoothly.", "After a thorough wash, the roller goes into a paint booth to be sprayed first with epoxy primer and then urethane paint.", "The rollers spend about 50 minutes in an oven to bake on the coatings.", "An electric tug transfers them to the assembly line.", "Here, the rear half of the compactor frame is taking shape.", "A worker bolts the hitch to the frame.", "He attaches a hydraulic steering cylinder to the hitch and secures it with a thick steel pin.", "The next worker screws guide pins to the hitch.", "He runs hydraulic hoses to the front section and links the rear structure to the front.", "Next, workers lower the diesel engine into the front frame.", "They anchor the engine by driving thick bolts into substantial engine mounts.", "A center pivot link provides a second connection between the front and back parts of the compactor.", "A worker torques the bolts that secure the link to the back.", "Moving forward, workers lower the operator platform into place, complete with a seat and the controls.", "They secure the control base to the frame with bolts in each of the four corners.", "The compactor is now ready for the two rollers.", "They've been equipped with vibrating mechanisms since we saw them last.", "The team bolts the back roller in place and then connects the lines to the hydraulic systems that drive it.", "They install the second roller and connect the hydraulic and electrical lines.", "They calibrate the rollers to ensure they operate at the same speed.", "They adjust the pivot steering if needed, and then it's time to roll." ]

{ "things": [ "Fresh Cut Flowers", "Adhesive Tape", "Tofu", "Lottery Tickets" ] }

[ "Today on \"how it's made\"...", "Fresh cut flowers...", "Adhesive tape...", "Tofu...", "Tofu...", "And lottery tickets.", "And lottery tickets.", "To wish condolences, congratulations, or for romance, there's no shortage of occasions for sending flowers.", "Whether made up in a splendid arrangement or simply placed in a vase, fresh cut flowers rarely go unappreciated.", "Roses are a perennial favorite.", "Florists buy them from commercial greenhouses.", "Those greenhouses have sophisticated sprinkler systems positioned to irrigate the soil rather than the plants because watering directly on the rose bushes would grow harmful fungus.", "The hotter the weather, the more watering is required-- up to seven times daily for about five minutes each time.", "The greenhouse climate is computer-controlled.", "If it gets too humid, the computer automatically triggers the roof to open, bringing down the temperature.", "The ideal greenhouse temperature for most flowers is about 70 degrees fahrenheit during the daytime and 60 degrees at night.", "With every watering, the roses get a low-level dose of fertilizer, the botanical version of taking a daily vitamin supplement.", "It's a mix of nitrogen, phosphate, and potassium.", "The proportions are determined by ongoing soil analysis.", "If the pest specialist detects a bug problem, he applies an insecticide treatment to target the particular pest, but first, they close the roof so as not to pollute the outside environment.", "Workers handling the chemicals wear masks and protective wear masks and protective clothing.", "Clothing.", "The roses grow through the openings of horizontal trellises positioned one above the other.", "This ensures the stems grow tall and straight.", "Crooked roses, after all, are worthless.", "Cutting the roses is tricky and prickly.", "Workers have to wear thick gloves to protect them against the thorns.", "They cut the stem at a 30-to-45 degree angle just above the second set of 5 leaves.", "The cut must be precisely at that spot for a second rose to bloom about 40 to 55 days later, depending on the season.", "Growth is slower in winter because there's less sun.", "The growth period also varies somewhat according to the variety of rose.", "The fresh cut roses go into a bucket of lukewarm water with a few drops of bleach to kill off any harmful bacteria.", "Workers then check each and every rose to make sure the blooms and foliage are free of blooms and foliage are free of defects.", "Defects.", "Then they classify the roses by length.", "The longer the stem, the more the longer the stem, the more the rose is worth.", "The rose is worth.", "They make a bundle of each length...", "Then trim the bottom of the stems to equalize the height.", "They wrap the roses in newsprint so they won't dry out during shipping.", "The transport trucks are refrigerated in summer and heated in winter to keep the roses at a safe temperature, about 40 degrees fahrenheit.", "To make a bouquet of dried roses they select open blooms for a nicer look, then hang them upside down in a room cooled by fans.", "They leave lots of space between bouquets so the air will better circulate.", "The roses take a week to dry out.", "Fresh cut flowers are striking, whether part of an arrangement or in a vase.", "They can last in water for about a week, provided you trim half an inch of the stems to open up the water channels.", "Fill the vase with lukewarm water, never cold water.", "Pour in a bit of bleach to ward off stem-clogging bacteria.", "Change the water every three days, and be sure to keep the flowers away from the heat of a flowers away from the heat of a sunny window.", "Sunny window.", "Adhesive tape was invented in 1925 as a painter's masking tape for auto-body shops.", "That led to transparent tape, designed to seal the cellophane wrap used by the food industry.", "Then tape was introduced as a household item, and the idea just stuck.", "These rolls of plastic film called polypropylene are on their way to becoming shipping tape.", "The rolls go on a machine called the unwinder.", "Workers then position a strip of adhesive splicing tape along the end of each roll.", "This will enable them to connect one roll after another, creating an uninterrupted feed to the production line.", "Now watch closely.", "Once a roll unwinds completely, its end sticks onto the splicing tape at the beginning of the next roll.", "Once that roll's unwound, its end will stick to the beginning of the next, and so on.", "An automatic tension adjuster ensures that the machine pulls the film evenly to prevent ripping.", "The unwinder also applies a solvent to the film's surface.", "This prevents the film from sticking while unrolling.", "To transform this film into tape, they coat one side with a hot adhesive known as hotmelt, made from several ingredients.", "Synthetic rubber gives it flexibility.", "A u.v. protector keeps it from drying and discoloring, while an antioxidant prevents aging.", "Synthetic resin makes it sticky, while pigmentation oil provides a choice of color-- in this case, tan.", "They load the hotmelt into a preheated holding tank, which keeps the melt at a piping 390 degrees fahrenheit to prevent it from hardening.", "The tank pumps the adhesive to a machine called the gluer.", "They wipe away the excess, then roll the film.", "And there goes the adhesive.", "A cooling roller-- that black one on top-- immediately hardens it.", "A computerized sensor ensures there's an even coat of adhesive.", "If not, it automatically signals to the pump to adjust the output.", "Now a machine called the rewinder rolls the tape onto spools.", "Remember the unwinder that spliced the rolls together?", "Well, the rewinder unsplices them.", "When a spool fills, a knife separates the tape at the splice point so that winding can begin point so that winding can begin on the next spool.", "On the next spool.", "The tape on just one of these spools would run the length of 85 football fields.", "The spools feed a row of sharp razor blades called the slitters which divide the 5-foot-wide tape into several strips.", "Shipping tape is almost 2 inches wide, so they get 31 strips per spool.", "Each strip winds onto a cardboard core, and its end is cardboard core, and its end is sealed with a tab.", "Sealed with a tab.", "The length of tape per roll varies according to the customer's specifications.", "As the machine ejects the finished tape rolls, in comes the next batch of cardboard cores.", "Then it's off to the packaging department.", "Nothing's shipped out, however, before a quality-control check.", "They test a sample roll from each spool.", "In one test, they unroll the tape sticky side up, then release a tiny, stainless-steel ball down an incline, measuring how far the ball rolls before it sticks and comes to a stop.", "To pass the test, the ball has to adhere within a certain distance.", "The stopping distance varies depending on the type of depending on the type of adhesive tape.", "Adhesive tape.", "Some people just can't get past that rubbery texture, but tofu enthusiasts say it's all in how you prepare it.", "Tofu is a great source of protein, low in saturated fat, and cholesterol-free.", "And it's versatile, absorbing whatever flavors surround it.", "Tofu is made from soybeans, the seeds that grow in the pods of the soybean plant.", "They contain 40% protein, more than double the protein in beef or fish.", "They start by soaking the soybeans in cold water for 18 to 24 hours, depending on the season.", "In winter, beans are stored in outdoor silos and take time to warm to room temperature.", "Here's what the beans look like before and after soaking.", "As they absorb the water, they double in size and soften up a bit.", "The bloated soybeans go on to a conveyor belt where a rotating device transports them to a crushing machine.", "The machine crushes them into a thick and grainy soup of soybean milk and pulp.", "It does this by forcing the beans through an internal filtering screen.", "Next, they transform the soup into a paste by heating it in a steam cooker for 3 to 4 minutes.", "Then it's into a centrifuge machine.", "As the chamber spins, the centrifugal force separates the milk and pulp.", "The milk passes through a cone-shaped filter, while the pulp, called soy meal, sticks to the sides of the chamber.", "The soy meal goes off to be sold for cattle and pet food.", "The milk stays behind to be transformed into tofu.", "Still piping hot, it goes into a coagulation tank to be thickened into curd, but first, they add different herbs and spices, because this batch will be sold as flavored tofu.", "Then they add the coagulant, magnesium chloride...", "Along with water to activate it.", "Then more stirring.", "It takes about 15 minutes for the soybean milk to congeal into soybean curd, otherwise known as tofu.", "When it's ready, it's still steaming but pretty soggy, so they run it through a perforated cylinder to drain as much liquid as possible.", "By the time the tofu comes out the other end of the cylinder, it's relatively dry and roughly the consistency of scrambled eggs.", "Now it can be processed into those familiar blocks you buy at the supermarket.", "They transfer the tofu into large rectangular molds lined with cheesecloth.", "Then it's into a press that applies 130 pounds of pressure.", "This squeezes out most of the remaining liquid and molds the lumpy, loose tofu into a firm rectangular block measuring 15 by 29 inches.", "They cut the block lengthwise and widthwise into 54 blocks of 10 1/2 ounces each.", "Tofu is pretty tasteless, but like a sponge, it absorbs the flavor of whatever it comes into contact with.", "They drench this batch in a spicy marinade to make jalapeño-flavored tofu.", "After verifying the weight of each block, they package the tofu with a sprinkle of spices for garnish.", "Then, to kill off any bacteria, the blocks go into a pasteurizer at 230 degrees fahrenheit for an hour.", "When they come out, they drop into a cooling basin filled with water just above freezing temperature.", "They stay submerged for about an hour.", "Tofu comes either preflavored or plain.", "It also comes in different textures.", "Firm tofu maintains its shape in soups and stir-fries, while soft tofu and silken tofu are ideal tofu and silken tofu are ideal for blended dishes and desserts.", "For blended dishes and desserts.", "The odds of winning big in a lottery are slim to say the least.", "Still, we keep hoping that lottery ticket will become our one-way ticket to extreme wealth.", "Experts say your odds of picking the winning numbers never change no matter how many people buy tickets.", "Lotteries are by no means a modern invention.", "The emperors of ancient rome held them for entertainment.", "European monarchs used state lotteries to help fund their extravagant lifestyles, and the american colonies held lotteries to finance roadwork and construction projects.", "Pressure from the church and widespread fraud led many countries to ban lotteries during the 1800s, but governments eventually reconsidered.", "They just couldn't resist they just couldn't resist milking that cash cow.", "Milking that cash cow.", "Eye-catching lottery tickets are designed by graphic artists.", "A technician takes the design, separates it by color, then sends the information to a machine called an image setter, which generates one negative per color.", "Next, they place the appropriate colored film under each negative and expose it to ultraviolet light.", "This hardens the color not shielded by the dark portions of the negative.", "When they wash away the unhardened color, they're left with a color image.", "They layer the films to make the client a mockup of the finished lottery ticket, in this case a scratch-and-win type.", "Now they make the printing plates-- one for each color of the design-- first for the non-playing area, everything outside the scratch zone.", "Each negative goes onto a paper-thin aluminum plate coated with a u.v.-sensitive emulsion.", "They expose the plate to u.v. light for about 20 seconds.", "This hardens the unshielded emulsion.", "The rest is washed away in a chemical bath, leaving the design in relief on the plate.", "For the ticket's playing area, a similar process is used, but instead of an aluminum plate coated in emulsion, they use one made of photo polymer, a light-sensitive plastic.", "The finished plates are now ready to go on to the printing press.", "Their raised service will work just like a rubber ink stamp.", "The non-playing area goes on first.", "This method is called offset printing.", "The press applies up to nine different colors, one after another, from lightest to darkest.", "High-intensity u.v. lights dry the ink in the mere half-second between color applications.", "Next comes the playing area.", "A high-speed ink-jet printer first applies the game numbers, chosen randomly by computer.", "Infrared lamps dry the ink in a split second.", "A strobe light enables the press operator to do spot checks as the tickets whiz by at a rate of 16 feet per second.", "Then the printer gives each ticket a unique bar code.", "This enables ticket vendors to scan your ticket to see if you've won.", "It also shows whether a winning ticket is genuine or a forgery.", "The next machine seals the game numbers with layers of varnish and applies six coats of scratchable ink.", "An electronic scanner checks the positioning of the scratchable ink, making sure it hides the numbers.", "The first three scratchable-ink coats are black.", "The next three are white.", "All those layers are used to keep cheaters from holding the card up to the light to see the numbers.", "Now they can finally print the playing area design onto that white background-- in this case, a crossword design.", "A machine now perforates the rolls of tickets so they can be folded.", "It processes almost 10 feet of tickets per second.", "Here's what that looks like in here's what that looks like in slow motion.", "Slow motion.", "The next machine folds the tickets along the perforation lines into piles called fan folders.", "Goodbye, slow motion.", "Goodbye, slow motion.", "Here's the actual speed.", "Here's the actual speed.", "Before the lottery tickets are shipped out, several samples undergo a quality-control inspection.", "The company checks that the tickets are properly printed.", "It also performs a series of scratch tests and chemical tests to make sure they're absolutely to make sure they're absolutely cheatproof.", "Cheatproof." ]

{ "things": [ "Screwdrivers", "Compact Track Loaders", "Physician Scales", "Carbon Fibre Bats" ] }

[ "Bit by bit, the screwdriver makes the life of a handyman a whole lot easier.", "The screwdriver first showed up in the early part of the 19th century.", "It evolved from a flat-bladed bit used in a carpenter's brace, and its invention was a definite turning point.", "These trusty tools come with different bits to fit a variety of screwheads, so all you have to do is apply the right torque, and it's mission accomplished.", "The job of making screwdrivers starts with coils of specially formulated steel.", "Wheels straighten a thick wire, and then it travels through an aperture.", "On the other side, a machine rocks back and forth as it cuts the wire to length and forces it through four dies.", "The first die narrows the steel to the required diameter.", "The others form a hexagonal bolster partway down.", "This bolster will allow a wrench to be applied to the screwdriver to increase its turning power.", "A quick shower washes away the lubricant, and these screwdriver shafts are ready for inspection.", "The technician examines them for defects and measures the length and the dimensions of the hexagonal bolster.", "Once he confirms that everything is to specification, the screwdriver shafts head into a machine that will transform the tips into a slotted shape.", "At the first two stations, the press flattens the tip.", "The third one trims it and stamps the part number onto it.", "The flat blade is probably the most common of screwdrivers.", "Its chiseled tip turns a standard slotted screw.", "After the screwdrivers are heat-treated to increase their hardness, they sand the tips to shave off .", "1 of a millimeter.", "They confirm that with this slotted guide.", "Then they insert the screwdrivers into a different slotted device.", "This one shuttles them over to a grinding wheel.", "This wheel trims them to their final dimensions.", "Visually, the change is subtle, but this fine-tuning will make a big difference in the screwdrivers' performance.", "Now they twirl in a machine that blasts the tips with mild abrasive.", "This texturizes the surface to allow this screwdriver to really grip a screwhead.", "The texturized tip is the one on the right.", "Over at another station, a different kind of screwdriver is taking shape.", "This is a phillips.", "Its tip has a beveled cross point to correspond with a phillips screw.", "This machine carves ridges into the bevels of the cross point to give it extra gripping power.", "A press then slams into the other end of the screwdriver to create flanged grooves.", "These grooves will allow them to lock the screwdriver shaft into its handle.", "It's time for some positive vibrations.", "This vibrating feeder causes the screwdrivers to chafe against each other, and the action removes any waste material.", "After they texturize the cross-point tip, it's over to a laser machine.", "It etches the part numbers onto these polyurethane handles.", "And now for the gripping part.", "The assembler attaches the handle to the screwdriver blade.", "He then places the screwdriver in a machine that applies mechanical force to solidly entrench the shaft in the handle.", "With the screwdrivers now on a tray, they move through a curtain of plastic.", "A machine heat-seals the plastic around the edges.", "The loosely wrapped tray then enters a special furnace, and the heat shrinks the plastic around the tray to neatly wrap up this job.", "It has taken several days to make these screwdrivers, and now they're ready for the twists and turns of any job.", "Tools like these screwdrivers are really an extension of the human hand.", "A quality tool will enable you to work with more precision, but, of course, you have to grasp the fundamentals of your project.", "And depending on what kind of handyman you are, that could be a whole other story.", "Compact track loaders move materials like dirt, gravel, and even snow into a dump truck or any other type of machinery.", "The rubber tracks give them the traction to work hard while treading lightly over soft ground conditions like grass.", "Compact track loaders can be used year round.", "Compact track loaders give a smooth and stable ride over all sorts of terrain.", "Their rubber tracks and suspension allow them to turn on a dime and work in places where other machines can't.", "To start, technicians attach four sets of mid wheels to a frame rail.", "The wheels are made of plastic and rubber.", "Then they assemble the axle suspension using rubber cords so the wheels can flex up and down.", "They tighten the bolts and mark them as done.", "After they attach two more sets of mid wheels, what's called the frame-rail assembly is complete.", "Technicians then attach a turnbuckle to the frame rail.", "The turnbuckle will be used to tighten or loosen the rubber track.", "Next, they put together the drive sprocket assembly-- the part that drives the track.", "They put a drive motor into a housing, add the sprocket assembly, then put on a heavy-duty bearing.", "Finally, they install a support plate which completes the drive-motor assembly.", "A technician then mounts the drive-motor assembly onto the frame-rail assembly.", "Technicians install the rubber track onto the frame-rail assembly.", "A little lubrication makes the track go on easier until its molded lugs interlock with the drive-sprocket assembly.", "Next comes a larger idler wheel, which they install at the end of the track, securing it on the axle.", "He tightens the turnbuckle to give the rubber track the correct tension, completing the undercarriage assembly.", "The track loader will ride on two of these undercarriages.", "A technician installs the machine's main suspension onto the chassis, then connects the hydraulic-valve assembly.", "It's the hub to which they connect all the hydraulic lines and hoses used to control the machine.", "Using a crane, the technician mounts the engine to the chassis.", "Once the engine is secure, he puts on the integrated fuel tank.", "He installs a hydraulic cylinder and connects its two fluid lines.", "One cylinder goes on each side of the machine.", "They are used to move the loader bucket up and down.", "He then connects the undercarriage assembly to the chassis using an undercarriage pin and pneumatic wrench to secure it in place.", "A technician now installs the loader assembly-- the part that holds the bucket or other attachment.", "Once installed, this machine can lift more than 3 tons.", "He secures the assembly in place using heavy-duty pins.", "Then technicians install the operator's station that helps protect the driver from the elements and from debris.", "A technician makes sure the loader arm works properly, then drives the track loader on a treadmill to test all the systems.", "He runs the engine at full speed until it reaches the appropriate operating temperature.", "This shows that everything is working as it should.", "Finally, he affixes the company logo.", "Compact track loaders are strong and agile machines.", "They work just as well on dry surfaces as they do in wet and muddy conditions.", "Stepping onto the scale at the doctor's office is a moment of truth not everyone enjoys.", "Little has changed in the simple design of these scales since the early 1900s.", "Cast iron has given way to steel and aluminum.", "That means they've actually gotten lighter over the years, unlike some of us.", "This scale compares the weight placed on the platform with a standard weight known as a poise that slides along an off-center waybeam until it balances.", "A punch press forms sheet steel into the head, or top of the scale's column.", "Workers form the column from another piece of steel using this press brake.", "Then they spot-weld the head and column together.", "Another machine stamps out lengths of steel that will form the frame for the scale's base.", "Workers use the press brake again to bend both sides of the steel lengths.", "Then they fold it by hand to form the frame.", "They clamp the frame onto a base, and this robot welds them together.", "The robot moves on to weld other components to the scale, such as the lever mechanism and the baseplate.", "Now workers place steel bearings at each corner of the base, where the lever mechanism will rest then add the base frame.", "Next, they install the long lever...", "Then the short lever.", "A c-clip joins them together.", "Once it's right-side up, the lever mechanism hangs off the platform.", "The columns receive a coat of electrostatically charged paint that evenly coats the metal for a flawless finish.", "Once it's dry, a machine silk-screens the brand name onto the column.", "Now for the final assembly.", "A worker inserts a 4-foot steel rod that will tie the waybeam to the levers.", "He works the rod up through the column, then, at the column's head, he screws it to the waybeam's shelf.", "Another worker hammers the large poise into position on the waybeam, then the smaller poise.", "They screw on to the beam in two parts so they can glide freely.", "She applies a gauge onto the beam that indicates the weight measured in pounds from 0 to 350.", "Now she takes a zero-adjustment screw and spring-loads it onto the beam.", "This allows the beam to balance when the poises are set at zero and the scale is unweighted.", "A retaining ring holds the screw in place.", "At the assembly line, workers fasten the scale's column to its base.", "They cover the pivot to protect it from wear and set down the waybeam that balances on it.", "Then they connect it to the steel rod that comes up through the column from the base.", "Once the waybeam connects to the lever mechanism at the base, the scale is functional.", "Now it's time to make sure it's accurate.", "Each scale goes to a weigh station where workers check the readings in 44-pound increments.", "If the readings are off, workers go back and remove some lead from inside the large poise so the scale calibrates perfectly.", "Just a few grams of lead can make all the difference in accuracy.", "Finally, they place a plastic cover over the working parts, and the scale is complete.", "When the competition is stiff, sometimes it helps to be a little flexible, and that's the idea behind the carbon-fiber softball bat.", "Manufacturers can tweak the stiffness of carbon fiber to produce a bat with some elasticity.", "It's a striking innovation.", "Carbon bats are a high-tech way to improve your game.", "Incredibly, these hard-hitting bats start with pliable sheets of carbon-fiber infused with a special resin.", "They crisscross the sheets and then iron the side with a paper liner to melt the layers at the seams.", "A hot steel roller then applies some serious pressure to fuse the carbon-fiber layers together.", "They slice it to size.", "Now they peel away that paper liner and spiral the carbon fiber around a steel bat form.", "By changing the angle of the weave, they can fine-tune the bat's elasticity to a league's specifications or to an individual player's performance level.", "They wind polypropylene tape around the carbon layers to squeeze out the air between them.", "They bake the carbon in an oven for two hours.", "This cures the resin impregnated in the carbon so the many layers become one.", "After they slice away the tape, they slide braided weaves of carbon and fiberglass over the fused carbon form.", "They secure the braided tubing with tape.", "They pull a layer of thick carbon over that, followed by a superstrong synthetic weave called aramid.", "One last taping, and this softball bat is ready to take shape.", "They place the carbon-wrapped forms in a mold.", "As the mold closes around them, they prepare an epoxy resin.", "They then inject the resin into the mold.", "It permeates the many layers wrapped around the steel form.", "The mold applies hot pressure to bake the layers together and define the contours of these bats.", "It takes just a few minutes in the mold to transform the many layers into a solid bat.", "This 5-ton puller now extracts the steel form on which the carbon bat was built.", "They use this pneumatic equipment to test its flexibility.", "A lathe now spins the bat as a cutter moves in and carves the hardened resin base into a knob.", "The knob on the right now meets league specifications.", "Now this carbon bat goes for another spin so they can sand it from every angle.", "They dip the bats two at a time in black primer and hang them to dry.", "The bat then takes on a more colorful appearance with a variety of spray paints.", "They transfer decals with production information onto the barrel of the bat, and a laser burns the company logo and serial number into the painted carbon.", "They cap the bat by press-fitting a polycarbonate plug to the barrel.", "Resin completes the seal, and they add extra to adjust the bat's weight to league specifications.", "They pump the resin in through a hole in the knob, and it flows up to the barrel plug.", "Then they weigh each bat to verify that it's within an acceptable range.", "Using a hydraulic ram, they drive a steel pin into the hole on the bottom of the knob to achieve the correct balance point.", "And it's time to wrap this carbon bat with synthetic leather, making it easier to grip.", "These high-tech bats are now ready to team up with raw talent, and they could blow the competition out of the ball park." ]

{ "things": [ "Carbon" ] }

[ "Today, on \"how it's made\"...", "Carbon-fiber masts...", "Fortune cookies...", "Imax projectors...", "And roller chains.", "In the world of sailing, lightweight ideas are the best kind.", "This carbon-fiber mast is a good example.", "At the half the weight of aluminum or wood, it allows the boat to move faster, and it's a pillar of strength, easily holding up a full sail.", "Whether you're a sailor or passenger, it's nice to know you can count on its support.", "They launch production of a sailboat mast with a strip of carbon fiber.", "They wrap it around a long mast form, which will serve as a mold.", "They trim the material and peel away the paper backing.", "Between 20 and 100 layers will be wound around the mold, depending on the size of the mast.", "They apply some layers in a crisscross manner to give the mast more structural integrity and help it hold its shape.", "They cut away the overlap so that the edges meet perfectly.", "The material is a bit creased and bulky at this point, so they wrap it with plastic pull tape to compress it.", "Then they remove it.", "This temporary taping is done after each layer, but they leave it on after the final one and tape a breather cloth around it.", "Then they pull a long plastic vacuum bag over the entire thing.", "They seal the ends with tape.", "They attach the vacuum connector and hose and turn it on.", "It sucks air from between the carbon layers, compressing them further.", "Next, it all heads into an autoclave to be baked under pressure.", "This will squeeze more air from the layers.", "At the same time, the heat will activate glue impregnated into the material, permanently fusing the layers.", "They make this fitting in a similar fashion.", "It's called a gooseneck plate, and it will connect a boom or spinnaker pole to the mast.", "Back to the mast.", "They pull the big aluminum mold out of the mast tube.", "Using a disk sander, they rough up the surface so paint will stick.", "They drill two holes.", "And using a jigsaw with a special blade, they connect them, making one wide slot.", "And remember the gooseneck plate?", "They trim it using the jigsaw so that it will fit snugly on the mast.", "Next, a worker maneuvers a plastic pipe with a string on the end.", "He threads the string through the mast tube, then hooks it and pulls it out of the slot made earlier.", "It's a messenger line, and it will be used to install the rope halyard that will raise the sail.", "They also use messenger strings to install electrical wiring, connecting such things as radar, horns, and lights.", "They're all funneled through the inside of the mast.", "The mast has now been painted, and a worker installs the upper end of the pulley system for the halyard.", "He slides in a pin that holds the halyard pulley and bolts on a guard to keep the rope from fraying.", "Next, they screw on a device that will let the captain know which way the wind is blowing-- the wind indicator.", "He twist-locks a signal light to the top of the mast.", "It will indicate the boat's direction to passing vessels.", "Now they attach a piece called the toggle.", "It's a connector piece between the gooseneck plate and the boom.", "This carbon-fiber mast is now seaworthy and will soon make its debut on the water.", "The fortune cookie is a snack with a message, and the message is usually as sweet as the sugary shell.", "But there is one surprising thing about the fortune cookie.", "It wasn't invented in china, but in california in the early part of the 20th century, and people in china have never really developed a taste for it.", "Yes, the fortune cookie is about as american as apple pie.", "But more than pie, it gives you something to think about.", "To make a batch of fortune cookies, they start with a sack of sugar.", "They empty the whole thing into a big steel mixer.", "Fortune cookies are about 20% sugar.", "They add some food coloring, just enough to turn the cookies that distinctive gold shade, then some melted vegetable shortening.", "They pour in some starch as a thickener.", "Pipes spray water into the mix.", "And then they add pastry flour.", "This soft wheat flour will give the cookies their texture.", "They add a bit more water, because too little of it would make for a crumbly batch.", "Then it's time to mix it all up.", "After a few minutes, they check the consistency.", "Then they pour in more melted shortening and a soy-based lecithin.", "Once that's blended in, the cookie mix ebbs from the bowl as a hose pumps it out from the bottom.", "Next, ejector nozzles squirt the batter onto hot moving trays, making precise little patties that look like regular cookies.", "You could call this \"the wheel of fortune cookies\".", "Hot molding plates revolve.", "Each one descends and presses onto four fortune-cookie patties, flattening and shaping them.", "They travel through an oven that's almost 30 feet in length and bake for about a minute.", "They come out of the oven piping hot and are given no time to cool down, because these fortune-cookie patties need to stay soft so they can be easily manipulated in the next step.", "Steel prongs push little paper fortunes into each cookie as they fold it into that distinctive butterfly shape.", "There are about 5,000 different fortunes in the mix at this factory, so it would be rare to get the same fortune twice.", "This plant makes a truly astounding number of fortune cookies every day-- about 4 million.", "The folding molds open as the track descends.", "The fortune cookies, now cooled and crispy, drop to a conveyor below.", "It takes each fortune cookie through a wrapping mechanism, which envelopes it in plastic.", "Then a hot blade cuts and seals the package in one fell swoop.", "The packaged fortune cookies transfer to another conveyor, which transports them to an inspection station where many production lines converge.", "A worker checks to make sure there are no breaks in the package or the cookie.", "He tosses out any rejects.", "After all, a broken fortune cookie could be bad luck.", "A box moves into position, and hundreds of cookies fall into it-- 350 cookies, to be precise.", "They're portioned out by a scale overhead.", "Then a plastic ram gently presses the cookies into the box to reduce the bulk.", "A conveyor belt moves the box full of cookies under a metal bar, which pushes the flaps down to close it.", "And now the time has come to crack open the cookie in the proverbial ritual.", "Hope our fortune is a good one.", "So, you want to be on the big screen.", "You won't get there without a movie projector.", "It was invented over a century ago, and the concept is the same today.", "Film revolves in front of a light which projects an image onto a screen.", "But the latest technological advancements allow for much bigger screens.", "Its film is 10 times larger than normal, and the projector magnifies it 400 times as it moves in a sideways-rolling loop, rather than the traditional vertical feed.", "And instead of the usual sprockets, registration pins retract as the film loads and then reach out to steady it as it rolls.", "A vacuum sucks the film to the aperture lens.", "This is how they keep the gigantic image perfectly steady.", "To make an imax projector, they bolt two prisms together and mount them on a part called the lower illumination module.", "The prisms and a mirror will reflect the projector's light to a similar part called the upper illumination module, which will relay the light to the lens.", "It's a fly's-eye lens, a collection of many lenses on one glass.", "Each will focus to a single point, ensuring an even distribution of light.", "A technician screws two fly's-eye lenses together and then places them in a fixture to align the two halves.", "He switches on a light and places an alignment guide over the lenses.", "There are red and green filters on this guide, and he brings them into focus.", "He adjusts them until the red and green lines merge.", "It means the two fly's-eye lenses are now aligned.", "Next, they install the upper illumination module in the projector frame, and then they flip it.", "They remove the protective cap from the back.", "Then they attach it to the lower illumination module which we saw assembled earlier.", "Here, they bolt together the rotor support and motor.", "The rotor is this big wheel.", "It's the heart of the projector.", "It drives the film forward in that distinctive wavelike action.", "This piece, called a stader, will act as a guide for the film.", "He fits the aperture block on the front of the frame.", "Using a crane, they lower it onto the base.", "They screw in spacer bars and install the second projector assembly.", "These two assemblies will enable the system to run three-dimensional movies.", "Now it's time to position the main lens at the front of the projector.", "They remove the lens cap, and it's time for the film.", "The film wave happens 24 times a second.", "We've slowed down this footage so you can see it all happen.", "The film of a test chart ripples in front of the aperture, and then vacuums pull it down for a 1/24 of a second.", "This eliminates any shakiness in the projected image.", "Now we're showing it in real time.", "You get the picture.", "There's also nothing ordinary about the lamps the imax projector uses.", "They're very powerful, but they use the light very efficiently.", "And now it's time to enjoy the show.", "Roller chains are used all over.", "We're all familiar with them as the chains that move energy to the wheels of our bikes.", "But roller chains also transfer energy in industrial and agricultural machinery.", "They really keep things moving, and without them, a lot of important equipment would be powerless.", "To make a roller chain, a punch press pulls steel from a giant spool.", "Using 500 tons of force, it cuts shapes out of the steel.", "These shapes are the link plates that will join all the parts of the roller chain.", "The plates travel on a series of conveyors.", "An arm positions them as they head towards the next punch press that makes two holes in each link plate.", "A worker then pours them onto a tray and spreads them evenly across it.", "A vibratory mechanism shuffles them into a blazing furnace.", "This heat treatment toughens the steel.", "Then they cool down slowly in a tank of oil.", "After that, they go for a tumble in the washer, to get rid of the oily residue.", "Meanwhile, another machine uncoils some steel to make bushings, or sleeves, for the chain pins.", "The blade slices the material to the correct length.", "Then mechanical arms fold the steel around a mandrel.", "Here's the action in slow motion.", "In real time, it all happens faster than you can blink an eye.", "The bushings fall into a bin, and now they're ready to be heat-treated.", "They open the furnace and stand away from the blast.", "A railcar takes the bushings into the flames.", "This may look destructive, but the bushings will come out stronger.", "Now it's time to make the pin that will hold everything together.", "This machine shoves a steel rod into a jig, and a saw cuts it to size, which varies, depending on the chain it will be used for.", "A mechanical arm then picks up the pin and transports it to rotating heads, which machine down the ends.", "The pins then travel across a grinding wheel, which reduces them to a specific diameter.", "Next, they go through a wash cycle.", "A special mix of lubricant and solvents rinses away the residue from the grinding.", "These are the pins before and after grinding.", "Now it's time to put the pieces together.", "This is a breakdown of what happens at a blurring pace on the assembly line.", "The link plates and bushings go into an assembly device.", "A ram presses them together.", "They remove them and place two more link plates in the device.", "They position rollers on top of them and slide the bushings and link-plate assembly into place.", "They press-fit it all together.", "And now they have links for the roller chain.", "The next step is to fit the roller links together.", "They clamp them into a fixture and slide in pins.", "A hydraulic ram presses the pins to the base of the assembly.", "Then they connect the pins with another link plate and press it in place.", "This is repeated as they lengthen the roller chain.", "They can also widen it to enable it to handle more horsepower.", "To do this, they stack single strands of roller chain.", "They use longer pins to hold all the layers together.", "Again, a fixture holds it in place while the ram does its work.", "This produces heavy-duty roller chain.", "The one shown can handle 400 horsepower.", "Finally, they lower the roller chain into a vat of hot grease to lubricate the joints.", "And that's the end of the production process for the roller chain." ]

{ "things": [ "Downhill Ski Bindings", "Immersion Parts Washers", "Mining Ventilation", "Pencil Sharpeners" ] }

[ "The binding is the most important component of a downhill ski.", "It attaches the ski boot to the ski.", "It prevents injury by releasing the boot if the skier falls.", "Also, an integrated brake engages upon release, stopping the ski from sliding down the hill.", "Every downhill ski binding has a toe and heel piece.", "The toe usually releases sideways in a fall, and the heel releases upward.", "The earliest bindings were made of heavy stamped steel and had no safety release.", "Today's bindings are made of lightweight material, such as extruded aluminum and fiberglass-reinforced plastic.", "Using 3-d software, the research and development team designs the binding along with the molds and dyes used to manufacture the components.", "The team produces a prototype of each component and uses three-dimensional measuring tools to verify the specifications.", "Workers paint the visible aluminum and plastic components then cure them in an oven for 40 minutes.", "They also dry them at room temperature for 24 hours.", "This company produces high-end racing models, as well as less expensive models for beginner to intermediate skiers.", "This aluminum housing is for the toe piece of a racing binding.", "They screw on plastic tabs to keep the metal from damaging the plastic ski boot.", "Then workers assemble the indicator, which is used to adjust the release setting.", "The release setting determines how much torque is needed to trigger the binding to release the ski boot.", "The torque is generated by the weight of the skier falling.", "They place a bronze and aluminum ball joint in the metal base.", "The ball joint acts as the rotational center of the toe piece when it releases.", "They lubricate the ball joint with grease before putting the base in an assembly fixture.", "Then they add the toe piece housing...", "And a plastic cap with a white line on the side.", "As they screw down the cap, it compresses the spring underneath.", "They test the finished toe piece.", "This machine stamps the company logo on the heel piece of a binding that's designed for beginner to intermediate skiers.", "This one is made of fiberglass-reinforced plastic with a clear polyurethane protective cover.", "You press the heel piece with the ski pole to get in and out of the ski.", "Next, they mount a heel piece to a base and assemble the internal mechanism.", "This includes a screw-down cap that sets the internal spring to a specific release setting.", "An automated machine tests each heel and toe piece to make sure the mechanism functions correctly.", "Another machine unscrews the cap halfway to lower the release setting to the midpoint.", "Next, a metal pin connects the pivoting top of the heel piece to the base.", "This setting tool locks the pin in its lateral position.", "Now, workers mount the ski brake to the heel piece.", "The ski boot maintains pressure on the brake to keep it in the off position.", "In a ski accident, the fall releases that pressure, triggering the brake.", "After the binding has been adjusted to the length of the ski boot, workers insert a notching pin that locks the heel piece to the mounting plate of the ski.", "These plastic caps hide the heads of the lateral metal pin.", "Finally, workers connect this lever to the notching pin.", "You simply pull it up and back to disengage the pin and adjust for boot length.", "The company subjects random samples from the production line to rigorous quality control tests.", "Bindings are made to international standards.", "These standards dictate how they're supposed to react to falls.", "Provided the binding is correctly set for the skier's weight, boot size, and skiing ability, these standards ensure the ski boot releases in an accident but doesn't inadvertently release if the skier hits a big bump.", "Removing oil, heavy soils, scale, or rust stains on a piece of metal can be tough.", "This is where industrial cleaning technologies come in handy.", "Immersion parts washers use degreasing and descaling compounds to clean metal.", "They also use ultrasound to literally shake off the muck.", "An immersion parts washer agitates water mixed with an industrial detergent to clean a mechanical part or piece of metal.", "A pneumatic lift mechanism moves the platform up and down inside the tank as the water heats to about 150 degrees.", "A robot loads stainless steel into a laser cutter, using suction cups to manipulate the sheet metal.", "A cnc cutter uses a 2,500 watt laser to cut the steel, following a layout entered in a cad system.", "The layout maximizes the number of parts made out of a single sheet.", "The machine parts come out on an unloading platform where an operator performs a visual inspection.", "He takes the parts to a cnc folding table.", "The machine bends the sheet metal to form the outside shell of the immersion parts washer.", "This is also called the tank skin.", "A hydraulic bending machine makes flanges in the sheet metal to reinforce the tank walls and provide a surface for welding.", "This high-end sheet metal-forming technique allows workers to produce a series of parts for multiple units.", "A worker assembles the machine parts on a welding fixture.", "He uses clamps to hold the pieces in place as he welds them together using an electric mig torch.", "Welding such a thin sheet of stainless steel is a tricky job because it's more susceptible to warping from the heat.", "The tank goes through a 24-hour leak test before painting.", "A painter applies epoxy and acrylic hybrid electrostatic powder coat.", "The coat combines the protective strength of epoxy and the resilience of acrylic.", "The painter places the tank in a massive curing chamber...", "And sets the oven time and temperature.", "The baking process gives the powder coat a grainy, textured finish.", "A worker grinds down the weld profiles and polishes the top tank walls with fine sandpaper.", "Another worker brings in the lift arm and inserts it in the tank.", "He puts the bearing support mechanism in place and bolts it onto the tank.", "He inserts the rollers that will support and guide the lift arm...", "Then drives a shaft through the bearings.", "He installs the pneumatic cylinder behind the bearing support and pins it on top of the lift arm.", "He brings in the agitator pump and installs its 3/4-horsepower electric motor next to the bearing support.", "A plumber installs the fittings for the tank filter.", "The filter removes contamination and debris from the cleaning solution.", "A worker installs the platform and bolts it on the lift arm.", "He installs a rack on the platform.", "It's made of grainy fiberglass to prevent the pieces from shifting during a cleaning cycle.", "After testing the movement of the lift arm and platform assembly, workers install the steel lid on the tank...", "And attach its hinge.", "Then they check the fit of the lid.", "An electrician makes the connections for the heat and timer controls...", "And screws the electric panel onto the side of the tank.", "He closes the electric box, then tests the lift arm, the lid, and the agitator pump.", "As the lift arm moves up, the platform lifts clean parts out of the water.", "Washers like this one can clean anything from automotive castings to printing press parts.", "In an underground mine, ventilation is critical for the safety of the miners.", "Above-ground fans can either blow in fresh air or they can suck out toxic gases using ventilation ducts suspended from the ceiling of the mine shaft.", "The black ventilation ducts are made of fiberglass.", "The yellow ducts are made of vinyl reinforced with steel wire.", "Both are designed to withstand negative pressure when drawing out gases and positive pressure when blowing in air.", "To manufacture sections of fiberglass duct, they use a steel mandrel.", "Workers wrap plastic around the mandrel to prevent the fiberglass from sticking.", "They also wrap cardboard around one end of each duct section to increase its diameter.", "Next, they start up the fiberglass winding machine.", "It draws 29 strands of fiberglass roving through a bath of resin, then winds them in a helical pattern up and down the mandrel, building up a layer between 3 and 10 millimeters thick, depending on the application.", "The regular end is called the spigot.", "The wide end is called the bell.", "The spigot of one duct section fits snugly inside the bell of the next.", "This way, multiple sections can be connected to each other.", "Workers embed d-rings at regular intervals along the top.", "These rings are used to suspend the ducts from the mine shaft ceiling.", "Once the winding is finished, workers cut the roving...", "And roll the fiberglass-covered mandrel into a large oven for curing.", "It takes about 30 minutes to cure the resin on a duct this size.", "Once it's cured, they extract the mandrel.", "They saw through the middle of the fiberglass duct to divide it into two shorter ducts of equal length.", "Each has a bell end and a spigot end.", "Workers use a hand saw to cut and shape some pieces into fittings.", "Fittings are angled or \"y\"-shaped pieces that connect two straight pieces, allowing the route of the ducting to turn or branch out.", "They connect the cut pieces with galvanized metal tape, then they seal the gaps with strips of fiberglass cloth saturated with resin.", "To make spiral duct, they weld together sheets of vinyl to create a wider sheet.", "On one end of the tube, they weld in a ring made of galvanized wire rope.", "At the other end of the tube, they weld in an adjustable coupler.", "To connect duct sections, the ring of one section fits into the coupler of the next one.", "They mount the tube on the guide bar of the spiral winding machine.", "The machine applies steel wire to reinforce the vinyl.", "It also enables the duct section to collapse into a compact hoop.", "As it works its way down the tube, the machine covers the wire with a strip of vinyl.", "It welds the vinyl to the tube, forming a pocket that both locks the wire in position and protects it from wear.", "When the machine reaches the opposite end of the tube, they cut the wire and remove the duct section.", "The last step is to attach hangers at 2-foot intervals.", "The hangers are used to suspend the ventilation ducts from the mine ceiling.", "Spiral ducts are the easiest type of ventilation to transport and install because they're collapsible and lightweight.", "However, they can get damaged in high-traffic work areas, so mines prefer to use sturdier fiberglass ventilation ducts.", "Before the pencil sharpener, people used knives to sharpen the tips of pencils.", "It was in the mid-19th century when a french inventor came up with a clever tool-- a little box with a blade and a cone-shaped opening.", "Just twist the pencil into it, and it makes a very precise point.", "The pencil sharpener has been a favorite of pencil pushers for over 150 years.", "With a few twists, it can hone the graphite tip of a pencil to a very fine point.", "To make pencil sharpeners, they start with high-carbon steel for the blades.", "The steel unwinds through a straightener, then a feeder serves it up to a punchcutter.", "It cuts out five blades in one action, complete with assembly holes in the center.", "It also embosses the company logo onto it.", "This machine can generate well over 100,000 pencil sharpener blades in an hour.", "A worker distributes the blades onto a conveyor that will take them to an oven.", "The temperature inside is 1,500 degrees.", "The blades slowly circle in the oven.", "This step takes 15 to 20 minutes.", "Exposure to the intense heat and a quick cooldown in oil harden the blades, but it also leaves them tarnished.", "So they drain the oil by spinning the blades in a perforated drum.", "Then they add a mix of dried corn and polishing paste to the blades.", "The drum tosses the blades in the polishing medium for six 6 to 12 hours.", "This restores them, as we see in this before-and-after shot.", "A circular feeder sorts them into a single file and racks them on a metal rod.", "Once on the rod, a machine grinds a cutting edge into all of the blades at once.", "Next, they manufacture the housing for the pencil sharpener blades.", "A circular saw cuts a ridged magnesium bar to the correct length.", "The magnesium blocks tumble into a feeder, which funnels them into a stamping machine.", "The machine stamps the company logo onto the top and lower side of the blocks.", "Machinery moves the pencil sharpener bodies forward to a drill that bores cone-shaped, pencil-sized holes into them.", "A second drill carves holes in the top for screwing the blades into the pencil sharpener bodies.", "A little metal rod shoves the pencil sharpener bodies out of the machine and into a bin.", "A worker plunges the pencil sharpener bodies into five chemical baths.", "Each bath has a different formula.", "The chemicals soften the edges of the magnesium bodies, making the surface shinier.", "A worker spreads the pencil sharpener bodies across a mesh conveyor.", "The conveyor takes them through a dryer to remove any residue left behind by the chemical solutions.", "These pencil sharpener bodies are now ready to receive blades.", "A feeder system delivers them to an assembly station.", "The screws funnel into an automated screwdriver at the assembly point.", "A mechanism slides the blades into the pencil sharpener bodies as they arrive.", "The pencil sharpeners fall into a bin, ready for retail.", "It's taken many different processes to produce these magnesium pencil sharpeners.", "Here's a recap of the process.", "Over a century and a half after its invention, the manual pencil sharpener is still making life easier.", "And in modern factories, the concept has been honed to a fine point." ]

{ "things": [ "Petanque Balls", "Biologic Medicines", "Asphalt Pavers", "Basque Espadrilles" ] }

[ "today on \"how it's made\"-- pétanque balls...", "Biologic medicines...", "Asphalt pavers...", "And basque espadrilles.", "the french game of pétanque is somewhat similar to the italian game of bocce and the british game of lawn bowling.", "It's played with hollow steel balls called boules on a dirt or gravel surface.", "The object of the game is to toss the balls as close as possible to a small wooden ball.", "The first pétanque players carved their balls from wood.", "By the late 1800s, players hammered in nails to make their balls heftier and less likely to crack when hitting other balls.", "Then came brass balls and later the hollow steel balls used today.", "Manufacturing begins with long bars of carbon or stainless steel, about 1 1/2 inches in diameter.", "This is stainless steel.", "An automated saw cuts pieces about 1 3/4 inch long.", "Workers place the pieces on a conveyer, which moves them into an induction oven.", "The oven heats them to between 1,650 and 2,190 degrees fahrenheit, softening the steel.", "As soon as a piece comes out of the oven, the forging press strikes it three times, first flattening it into a disk.", "Next, thinning the disk, then stamping the disk into a half sphere.", "Workers mill the forged half sphere on a lathe to refine the shape and to create a gap they later fill with metal wire when they weld this half to another half to form the ball.", "A worker drops the milled halves down two separate chutes and deliver two halves at a time to an automated welding machine.", "The machine clamps the halves together and welds them to each other.", "A robot removes the ball from the welding machine and transfers it to a computer-guided milling machine.", "As the machine's lathe spins the ball, a knife shaves off thin layers of steel to smooth the ball and make the weld invisible.", "This also puts the ball within a specific diameter and weight range in accordance with international rules governing the sport.", "The machine also engraves a pattern to help identify whose balls are whose.", "International pétanque rules require a ball to have four items engraved into its surface-- the brand name, the pattern name, the weight of the ball, and a serial number for the set to which it belongs.", "Once the brand, pattern and weight are engraved, the balls move along a conveyor toward the tempering station.", "Cutting, heating, forging, and machining steel makes it brittle and weak.", "Tempering is the process of hardening it to restore its strength.", "After heating the ball to between 1,470 and 1,830 degrees fahrenheit, they immediately cool it in water that's about 104 degrees, a process known as quenching.", "After tempering the steel, manufacturers polish the ball with an automated sander.", "The finished balls do vary slightly, so this last automated machine weighs each one and sorts it in rows of identical weight.", "Then, equal weight balls are grouped in sets of three and are engraved with the same serial number.", "These pétanque balls are made of carbon steel.", "To prevent oxidation and corrosion, the factory electroplates its carbon steel balls with a protective layer of chromium.", "It submerges the balls in a series of chemical baths and water baths to prep the surface for the final dip in an electroplating tank in which an electrical current draws chromium particles through the water and deposits them onto the ball's surface.", "The chromium treatment leaves a white film.", "This brushing machine removes it and restores the shiny finish.", "International rules require pétanque balls to be 2 3/4 to just over 3 inches in diameter and weigh between 1 1/2 to 1 3/4 pounds.", "The retail box contains three identical balls engraved with the same serial number, along with the wood target ball, a cleaning cloth, and a warranty card.", "The goal of the game is to toss the balls as close as possible to the target ball while knocking the opponents' balls away from it.", "And the player's feet must remain planted inside a small circle when tossing.", "You can play pétanque indoors in a venue known as a boulodrome or boule bar, or you can play outdoors anywhere there's a patch of relatively flat ground.", "Biologic medicines are proteins produced inside living cells, which are mini factories generating the genetically engineered protein treatments.", "It's a different approach from traditional drugs, which are manufactured using chemical synthesis.", "Biologics offer hope where other therapies have failed.", "To mass-produce these biologic medicines, scientists use the molecular machinery inside living cells.", "The process starts with the insertion of genetic material into chinese hamster ovarian cells.", "They're known as cho cells.", "They keep them frozen in liquid nitrogen until the next step.", "In the seed lab, a technician thaws the cells in warm water.", "He transfers them to a glass flask that contains growth media.", "The growth media is comprised of hundreds of nutrients, including vitamins and minerals.", "It's a recipe to help the cells multiply.", "A worker transfers the flask that contains the cells to the production side of the plant.", "The team injects the mixture into a 5-gallon-capacity bioreactor.", "Inside, a propeller agitates the mixture to stimulate growth.", "Over a 3-week period, the number of cells increases exponentially.", "Each new cell is programmed to produce the target biologic protein.", "A worker sterilizes this 21-gallon-capacity bioreactor to prepare it to receive the cell mixture.", "Under precisely controlled conditions in the bioreactor, the cells multiply substantially.", "Over several weeks, the team transfers the cells to progressively larger bioreactors.", "The cells grow until there are trillions, each producing the target protein.", "Next, a technician measures salts and other dry ingredients.", "He's preparing a recipe for purifying the protein liquid once it's been separated from the cells.", "He labels the bag and records the information separately as required by government regulations.", "He adds the ingredients to purified water in a mixing tank.", "An automated system keeps tabs on the condition of the purification solution.", "After separating cellular material from the protein mixture, the team pumps it through steel and glass columns.", "Here, the purification solution works with resin beads to separate the protein from the impurities.", "The purified protein is stored in steel tanks at -4 degrees fahrenheit.", "It keeps the biologic medicine in a stable state.", "Meanwhile, in the quality control lab, a technician injects a sample into glass capsules.", "She places the capsules into a robotic analytical instrument.", "This sophisticated equipment measures the potency and purity of the biologic medicine.", "Once the biologic medicine passes the tests, they prepare glass vials to receive it.", "That means an intensive cleaning.", "The automated system loads the vials into individual slots, and sprayers rinse them.", "The system then transports the vials through a heat tunnel that sterilizes them to remove any potentially harmful toxins.", "Moving through an isolated sterile zone, the vials funnel into a fill station.", "Nozzles dispense a specific dose of biologic medicine into the vials.", "Here, plungers insert stoppers in the vials.", "A camera then takes a picture, and a computer instantly analyzes it to confirm that the stoppers have been correctly installed.", "The system then caps the stoppers to completely seal them from contaminants.", "This machinery hygienically fills and caps over 100 vials per minute.", "A worker visually inspects each vial.", "He carefully swirls the contents as he looks for impurities.", "If he sees any, the vial of medicine will be rejected.", "Finally, this technician takes a sample and conducts a test to ensure the medicine is sterile.", "Grown in living cells, these biologic medicines are now on their way to potentially making a difference in people's lives.", "The development of the asphalt paver in the early part of the 20th century changed the way roads were built.", "The paving machine took over from large crews who paved surfaces manually using picks and shovels.", "This invention has made it a lot easier to pave the way.", "The asphalt paver transforms rough roads into smooth ones.", "This paving machine distributes asphalt, levels it, and also provides the initial compaction.", "Making one starts with a computerized plasma cutter.", "The operator programs it to cut out all the parts of the paver structure from heavy-gauge steel plates.", "It also configures the cutting to minimize waste.", "The plasma tooling also cuts and threads holes for bolting the parts together.", "Once the parts have been cut, a crane transfers them to a welding fixture.", "The fixture holds the parts for the paver frame in tight alignment while a welder tacks them together.", "He also tack welds smaller parts like engine mounts to the structure.", "Once the tack welds are done, he does full welds throughout, creating strong, thick seams.", "A team loads more steel into a computerized press break.", "It clamps the steel plate between a matching punch and die.", "Then, using hydraulic power, the press break makes precise bends to shape the steel into a section of the paver hopper.", "With the first bend done, one of the workers measures the angle with a digital level to confirm that it's exactly right.", "The team then moves the steel plate into position for the next bends.", "They make a total of three in the hopper part.", "Those three bends must be perfectly angled and positioned to fit the rest of the hopper.", "It's why precision is critical.", "They do a final check of the three bends using a template.", "Next, a welder joins a side panel to the hopper part with the three bends.", "These two parts form the left side of the hopper.", "After an acid wash, it's into the paint booth to coat the steel with an epoxy primer and urethane paint.", "The parts then spend time in an oven to accelerate the paint cure.", "Then it's over to the assembly line, where construction of the paver tractor is already underway.", "A worker bolts gear systems to the sides.", "These gears will drive the paver wheels.", "With the help of a crane, the team guides the engine into position.", "The engine's mounting structure mates to bushings in four locations.", "They now assemble the hopper to the front of the paving machine.", "Hinge tubes on the hopper part intermesh with tubes on the center conveyor framework.", "They'll run a long pin through these hinge tubes to complete the assembly.", "With everything in good working order, they're ready to build the screed, beginning with the base plate.", "The screed is a critical apparatus.", "Its system of vibrating extenders both levels and compacts the asphalt once it's deposited on the road.", "They're also equipped with heating elements to keep the asphalt workable.", "They run a battery of tests on all these components to confirm that the screed is fully operational.", "The screed is now ready to be mated to the paver tractor.", "They put the tractor in reverse and back it up to the screed until brackets on both meet in perfect alignment.", "Once the brackets have been bolted together, the asphalt paver is ready for work.", "The road ahead will be long and potentially winding, but it should be pretty smooth, thanks to this asphalt paver.", "Espadrilles have been a popular style of casual footwear for decades now, yet most people likely don't know the origin of this comfortable cloth shoe.", "Europeans have been wearing espadrilles since the 1300s.", "The basque region in northern spain is still famous for them.", "Espadrilles are fashion forward and a step back in time.", "The people of the basque region have been making these cloth and jute shoes for hundreds of years.", "They began reinforcing the soles with rubber in the early 1900s.", "Jute is a plant fiber that's spun into strong, coarse twine.", "For traditional basque espadrilles, they use twine that's about 1/10th of an inch thick.", "Large jute spools feed an automated braiding machine.", "Its five bobbins move in a circular pattern that produces a neat braid measuring roughly 3/4ths of an inch wide by a quarter of an inch thick.", "Right after exiting the braiding machine, the braid enters a calibration machine which applies tension to make the dimensions uniform.", "Each espadrille sole is hand-crafted by an artisan.", "He winds the braid on a form that's more than a century old.", "The positioning of the metal pegs in the holes correspond to the size of the shoe he's making.", "The closer the pegs are to each other, the smaller the shoe size.", "After nine rotations for this shoe size, he cuts the braid, then, using a large needle, ties off the end.", "He places the wound braid into a press which, as we see here in slow motion, compresses it into the shape of the sole.", "In real time, this step takes just a couple of seconds.", "Then he picks up the sole with a comb and feeds it into an automated sewing machine.", "Two large needles, one above, one below, simultaneously stitch all the way through the sole with thick jute thread, binding the wound jute braid.", "This machine sews more than 100 pairs of soles per hour.", "By now, the espadrilles' signature jute sole is formed and sewn, but it's not quite finished yet.", "To prevent it from wearing out, it needs a protective layer of rubber.", "The artisan now opens a mold for the corresponding shoe size and fills the sole-shaped cavities with a pre-measured quantity of colorless rubber granules.", "Then, he places the jute soles on top.", "He closes the mold and places it in a press for 6 minutes.", "The press heats the mold to 300 degrees fahrenheit, melting the rubber granules.", "The liquid rubber spreads throughout the cavities, penetrates the jute fibers and vulcanizes, meaning it hardens and cures.", "This produces a rubber outer sole about 1/6th of an inch thick that protects the jute inner sole.", "The espadrilles' uppers are made of 100-percent-cotton canvas.", "The artisan stacks about 20 pieces and cuts them simultaneously with a razor-like blade.", "Each upper is comprised of a front piece and a back piece.", "A seamstress sews the upper entirely by hand.", "She wears a glove that has a copper cup built into the palm, which she uses to force the giant needle through the tough jute.", "After stitching the front and back pieces to the sole, she sews them to each other along the sides.", "She closes and reinforces the toe with three rows of stitches.", "All this with strong, thick thread made of braided cotton.", "This maker of basque espadrilles prides itself in using only natural materials, even in the paper packaging.", "The rubber used for the soles contains no colorants but is infused with citronella, a fragrant plant oil believed to help repel mosquitoes." ]

{ "things": [ "Motorcycle Goggles", "Handbuilt Jukeboxes", "Vacuum Excavators", "Pewter Shaving Sets" ] }

[ "The inuit and yupik native alaskan tribes invented specialized goggles to prevent snow blindness.", "In the early 20th century, a new kind of eyewear was created for airline pilots in order to protect their faces from wind.", "Soon, motorcyclists started wearing the eyewear for the same purpose.", "This manufacturer uses the same tooling process used to produce the iconic eye protection worn by the ace pilots of the royal air force during world war ii.", "Production begins with a coil feeder, which feeds a strip of soft-coil brass into a press tool.", "The tool stamps out a series of flat blanks.", "The press simultaneously punches two guide holes that will help position the blanks on the other tools.", "Two raised press tools form the blank around a left and right die.", "The press tools add new folds and contours to the blanks.", "Another press tool stamps out the center aperture.", "A device punches out stitching holes that will allow an attachment to connect to a leather face pad.", "A different press tool punctures the stitching holes located along the goggle frame.", "Due to the age of the machinery, the distance between the holes has become slightly uneven, giving the goggles their distinctive character.", "Next, the nose-bridge bracket is positioned on a rivet shaft.", "With the eyepiece in place, the craftsman triggers the device to rivet the components together.", "Before he attaches the two eyepieces, the craftsman polishes each piece against a grinding wheel.", "This is a two-step process starting with an operation called scarfing, which prepares the surface, followed by polishing with a special compound.", "The goggle lenses will be installed into the frames at a 45-degree angle, so a grinding wheel casts a 22.5-degree angle on each section of glass.", "The craftswoman removes the slight burr left by the grinding process with a sanding wheel.", "The lenses are made out of shatterproof laminate for additional protection.", "The lens frame is made out of a painted brass channel.", "The brass has been annealed for strength and to remove any internal stresses.", "A small rod is inserted as a temporary support.", "She places the assembly in a clamp and secures the channel in place with a brass cleat.", "She uses a manual hand press to bend the channel to 45 degrees.", "The craftswoman removes the support rod and applies epoxy glue to the seam between the two sections of glass.", "She inserts a brass cleat to hold the assembly in place, and this time the cleat is permanently fastened to the assembly.", "Now the eyepiece is ready for the next phase of production.", "The eyepieces are attached to a leather face pad made from lamb nappa leather.", "A craftsperson starts the process by using a custom die and a 10-ton press to stamp out the required shape.", "Then she uses a leatherworking sewing machine to stitch the two layers of the face pad together.", "With exactly 1.5 millimeters between each stitch, the attachment is durable without overperforating the leather.", "She sews the inner perimeter of the face mask with an overlocking stitch.", "This operation is not easy.", "It takes a skilled leatherworker up to seven months of training to become truly proficient.", "Before sewing the nose-cover section of the face pad, the craftswoman glues the layers together to ensure they're assembled correctly.", "After the glue has cured, the goggle eyepieces are placed in position over the face pad, and the components are stitched together by hand.", "The goggle assembly is almost complete.", "The goggle lenses are placed into position in the channels of the eyepiece frames.", "Now they just need to be secured in place.", "The headband clips attach to the goggles and lock in the lenses.", "Not only do these handcrafted goggles protect your face, you can be assured they will never go out of style.", "Today we can listen to music instantly from a smartphone or in our car, but to enjoy a bit of nostalgia, you can still enjoy a more tactile and visual musical experience by pushing down a button and waiting for a jukebox to load and play a song on a vinyl record.", "This classic 1940s dome-top jukebox is built by hand.", "It plays vinyl records, which are loaded into the machine after purchase.", "A technician builds the cabinet out of thin, flexible sheets of plywood.", "Once five sheets of wood have been glued together, the technician places them in a dome-shaped mold.", "After glue is applied to the inside of the cabinet, team members insert the wood back panel.", "The layers are then held together by hydraulic rams for 24 hours.", "Then workers remove the cabinet from the mold and install shelving and brackets.", "The brackets, or knuckles, are made out of zinc and will hold the cabinet door together.", "When a knuckle comes out of the mold, the edges are rough and contain excess metal, so a technician smoothes the knuckle with a belt sander and then uses a guide to drill screw holes.", "The factory sends the knuckles out to a specialty metal plater, who plates them with chrome.", "The cabinet door consists of a front hoop and a front panel.", "Technicians place both parts in an assembly jig to ensure they are positioned correctly.", "Then eight knuckles are connected-- two at the top and three on each side.", "Every jukebox is uniquely handmade, so a technician verifies that the door and cabinet are aligned accordingly.", "Next, both components are moved to the cabinet-finishing area to be painted or stained, depending on the wood.", "The customer selects the color and any options, such as programmable l.e.d. lighting or bluetooth connectivity for streaming digital music.", "The bubble tubes are handcrafted from standard glass tubing.", "An artisan seals the tube at the bottom then passes a probe to check for any small cracks.", "If the tube is intact, tiny silicon crystals are placed at the bottom, and fluid that turns from liquid into gas is poured into the tube at very low temperature.", "The artisan melts the glass with a torch to seal the top of the tube.", "Each jukebox has four straight bubble tubes and four curved ones.", "Making a curved tube requires two artisans.", "One heats the tube, while the other bends it around a form.", "Next, the tubes are placed in a tester, which heats the fluid, turning it into gas.", "The silicon crystals at the bottom disrupt the gas as it rises, creating hundreds of rising bubbles.", "As the bubbles reach the top of the tube, they cool and turn back into liquid.", "A technician installs the tubes inside transparent protective covers.", "He connects each tube to a heating plate hidden inside the cabinet.", "Another specialist wires the jukebox electrical systems and speakers.", "The speaker assembly is located behind the front door of the cabinet.", "A 1950s-style jukebox is made with shaped glass and chrome.", "It has a curved, see-through front door, which allows the user to watch as the vinyl system finds, pulls, and plays the selected record.", "Each machine contains a 70-slot circular basket that holds a two-sided record.", "The motor in this reproduction jukebox is guided by computer software.", "The motor rotates the basket to bring the selected record to the lift arm.", "Another motor rotates the turntable to play the song.", "The software reads the position of each record via an optical sensor and a rotating slotted disc.", "The software calculates the quickest route to the requested record, then spins the basket to bring the record to the lift arm.", "So when your jukebox arrives, all you have to do is drop in your favorite records, make title cards using the labeling software, and insert them in the title display.", "This jukebox is ready to provide the listener with good times and good vibes for many years to come.", "Standard excavators shovel and dig, but due to their size, they can sometimes break underground utilities.", "Vacuum excavators dig with a technique that doesn't cause damage, softening the soil with a high-pressure stream of water, then sucking up the mud into a debris tank.", "A vacuum excavator functions as a pressure washer and shop vacuum.", "Using a high-pressure water jet, the excavator removes materials with a vacuum hose and deposits it into a debris tank.", "The tank holds up to 1,188 gallons of debris and is made from high-strength sheet steel.", "A steel rolling machine curves the sheet under pressure.", "A welder clamps the ends of the sheet together and tacks them to form a cylinder.", "Next, he transfers the cylinder to a welding fixture and fully welds the seam.", "Then the welder mounts a steel dome to the front end of the tank.", "Using an assembly jig, he clamps the dome into position.", "He strikes the dome with a mallet to close any gaps between the dome and the cylinder.", "He tack-welds the parts to each other.", "He removes the cylinder from the jig and fully welds the exterior seam around the perimeter.", "Another machinist welds the inner seam.", "Other components are welded to the tank.", "These include a large hinge for the tank's rear door, side pins that allow the tank to tilt when emptied, a pair of windows, storage hooks, and an inlet for the suction hose.", "Once all the steel parts have been cleaned with hot water and a chemical that inhibits rust, a technician sprays them with primer.", "Then a coat of durable, epoxy-based paint is applied.", "The paint takes a couple of hours to dry.", "The vacuum excavator is built into a welded steel trailer that has upright steel posts on each side to hold the water tanks.", "A technician installs l.e.d. brake lights and side indicator lights.", "Next, wiring is run along the length of the trailer.", "The wires control the machine's trailer brakes and safety lights.", "Then the wiring is connected to the lights.", "A technician covers every connection with heat-shrink plastic.", "This will ensure the connected wires are water-resistant.", "Next, the hydraulic pump is installed, as well as rubber cushions to protect the bottom of the debris tank, and reflective red-and-white safety tape, as required by law.", "A technician installs two industrial tires on each side of the trailer.", "He runs hydraulic lines from the hydraulic pump to the lift cylinders that tilt the debris tank and to its rear-door mechanism.", "The empty debris tank weighs more than 1,500 pounds.", "Using an overhead crane, a team lifts and positions the tank over the rear part of the trailer, lowering it into the hydraulic lift system.", "Next, the power pack is installed on the front of the trailer.", "The pack contains the gas or diesel engine, the vacuum and water pumps, the battery, and belts that connect the pumps and engine pulleys.", "After the first of two polyethylene water tanks are assembled, technicians install an air-filtration unit.", "The unit protects the inner components of the vacuum pump.", "Two technicians install the second water tank, placing it in between the trailer's support posts.", "Then the tank is secured with two crossbars.", "To dig with a vacuum excavator, the suction hose is attached to the debris tank while the other end digs.", "Then the ignition, water, and vacuum pumps are started.", "The water pump pressurizes the water flowing from the tanks through the hose and out the nozzle of an attached wand.", "The water pressure turns the soil into mud, and the suction hose removes the material.", "Thanks to this shovel-free process, operators can now dig without damaging underground utilities.", "Inside a pewter shaving set is a double-barreled mug called scuttle.", "In one compartment, it keeps shaving water hot, while holding soap in the other.", "The set's badger-bristle shaving brush is used to work the soap and water into a hot lather.", "With a pewter shaving set, the user employs nostalgic tools to shave.", "It's elegant, and it helps get the job done.", "Pewter of made of tin, with a small amount of copper and antimony.", "Tin is a soft metal, while the other metals add strength.", "A metal worker places a filter gate at one end of the mold.", "He scoops up molten pewter and pours it in the mold in front of the filter gate.", "The filter gate captures impurities as the pewter flows to the other side.", "Heat causes any air pockets to rise to the surface and dissipate.", "Spraying the pewter with cool water accelerates the solidification.", "After 10 seconds, the pewter has hardened into a thick slab called an ingot.", "A metal worker breaks off the excess material left by the filter gate.", "The pewter is now in a workable form.", "A technician places the ingot in a machine with steel rollers and adjusts the space between the upper and lower rollers.", "Using 66 tons of pressure, the rollers flatten the ingot.", "It takes several passes through the rollers to reduce the ingot to its desired thickness.", "Additionally, the rolling stretches the ingot, transforming it into a large sheet.", "Later, the sheet will be used to make the shaving scuttle and brush handle.", "Now it's time to construct the beard combs.", "A technician ladles molten pewter into a rubber mold.", "The centrifugal force forces the liquid pewter into the mold's crevices.", "After 2 1/2 minutes, the mold is removed, producing seven pewter beard combs.", "The technician extracts the combs from the runners formed from the molten pewter.", "After sanding, the combs are dipped in a specialized solution.", "In a vibrating machine, the ceramic pellets shake off most of the excess solution.", "But the solution that's seeped into the embossed logo remains, adding definition.", "Back to the shaving scuttle and brush assembly, a large sheet of pewter is cut into discs.", "A technician pours resin into a mold to create the shaving-brush handle.", "After the handle's cured for 25 minutes, the resin transitions from a liquid to a solid.", "Now he has a handle form to work with.", "As the handle spins in a lathe, the technician shaves off imperfections with a cutting tool.", "A sharp, circular die cuts out discs from the pewter sheet.", "With the handle core still spinning, the worker shapes the pewter disc, essentially giving the part a pewter skin.", "Using the same spinning techniques, the scuttle shaving mug are now complete.", "Using a natural abrasive mixed with oil, the pewter parts are buffed.", "This step removes flaws and provides an initial polish.", "Then the maker's mark is carved into the shaving-scuttle base, stamping the logo into the pewter.", "Now that the scuttle-mug parts are assembled, a technician solders the base to the scuttle body.", "A decorative cured handle adds visual interest and will provide the user a place to grip.", "A technician adds more solder to seal the handle to the scuttle body.", "This shaving scuttle is now complete.", "All the parts will undergo an extensive polishing, giving the pewter a mirror finish.", "Using a buffing wheel, a technician polishes the shaving scuttle one last time.", "Finally, this pewter shaving set is ready to take on stubble." ]

{ "things": [ "Traditional Bows", "Coffee Machines", "Mascots", "Hammocks" ] }

[ "Today on \"how it's made\"...", "Traditional bows...", "Coffee machines...", "Mascots...", "And hammocks.", "When some innovative caveman invented the bow and arrow, it was a huge breakthrough.", "The discovery turned the homo sapien into an efficient hunter-gatherer.", "These days, archery has made a comeback in the hunting community, and it's even been reclassified as an olympic sport.", "Today's bows are definitely not primitive devices.", "Crafted with calculated precision, they make it easier for you to take your best shot and hit your intended target.", "To make a longbow, a craftsman cuts six strips of cherry wood just under a quarter of an inch using a band saw.", "Then, with a belt sander, he repeatedly thins the wood strips on both sides, tapering the ends a little each time.", "The tapering gives the wood some flexibility, which the bow will need to launch arrows into the air.", "With this band saw, he now carves a handle from a piece of wood.", "Next he brushes superadhesive glue onto fiberglass strips and the tapered strips of cherry wood.", "He works swiftly because the glue will start to dry in less than an hour.", "Now he layers the strips.", "The fiberglass strips buttress the six glued wood strips on either end.", "This process is called lamination.", "Next he glues the wood handle to the fiberglass and wood lamination.", "And he tops it with a piece of masking tape to protect it from scratches and glue smudges during the next steps.", "Now the laminates are squeezed together.", "He places them on a carved plywood shape called a bow form.", "He positions a steel heat strip, a rubber hose, and another plywood form on top of the laminates.", "He clamps it all together, then inflates the rubber hose with an air compressor.", "The pressure from the hose combined with the heat from the metal strip mold the wood to the bow shape as the glue sets.", "One hour later, he removes the laminates, nicely pressed and glued into more bow-like curves.", "Now he draws the bow form onto the newly curved lamination, following a template made of fiberglass.", "With his band saw, he cuts the wood along the lines he's just drawn.", "He cuts an arrow shelf.", "That's the notch for the arrow to rest as the archer aims.", "Then he trims the handle, making it a little wider at the center for comfort.", "Next, using a coarse-toothed file, he hollows out little grooves in the upper and lower limbs of the bow.", "They're called string nocks and the string will loop around them.", "To strengthen the tips, he glues little pieces of fiberglass and moose horn over them and the freshly filed nocks.", "He clamps it in a vise grip to set.", "When it's dry, he files through the horn and fiberglass to bring back the nock groove.", "He smoothes it with sandpaper.", "Now he glues another piece of wood over the handle to improve the look and feel of it.", "He clamps it together while the glue dries, and three hours later, he sands it.", "Next he wraps the handle in a piece of leather and stitches it together with nylon thread called artificial sinew.", "Many years ago, they used the tendons of an animal for thread.", "The leather will make the bow easier to grip.", "With a gel pen, he writes a serial number on the back of the bow, along with the draw weight.", "This bow will hold about 44 pounds of pressure in check when it's drawn.", "This is a flemish string jig-- a wood fixture with posts on it.", "He loops nylon string around the posts.", "This is how he measures the string.", "It's always four inches shorter than the bow.", "He cuts it with a utility knife, then rolls wax onto it to make it easier to work with.", "He measures some string.", "Then he twists 16 strands of nylon-- 8 black and 8 white-- into a braid with loops on the ends.", "He hooks the string on the nocks and it's time for target practice.", "As he bends the bow, energy is stored.", "He releases it, and the energy propels the pointed projectile right on target.", "Coin-operated coffee machines are a staple in offices and public places.", "Years ago, these machines just weren't able to produce consistent brews.", "And there also wasn't much choice in brewing style.", "But today, even finicky java junkies drink machine coffee because the latest machines have mastered the art of making delicious coffee one cup at a time.", "This office coffee machine actually makes several different types of hot beverages.", "And if your employer prepays, you don't have to insert any coins.", "Production begins with a sheet of steel about 6 1/2 feet long by about 1 1/2 feet wide.", "This flat, as it's called, will become the top and side sections of the machine's casing.", "A computer-guided punch press makes dozens of perforations for ventilation and for the various fittings the machine will need in order to function.", "A worker puts another sheet of steel into a press.", "This press bends the metal into 90-degree angles.", "This piece will become the bottom of the casing.", "A worker uses a spot-welding machine to assemble what's called the base panel.", "This will later house a waste chute, overflow sensors, and wires.", "Another worker coats the casing with an epoxy-based paint powder.", "This process statically charges the powder and draws it to the metal like a magnet.", "Excess powder falls into a barrel below.", "Here a worker installs a fan that will vent the steam and heat generated inside the machine.", "Another worker assembles one of the two coffee-delivery mechanisms, called augers.", "When the machine's on, they move the ground coffee to the brewer.", "He installs the augers into what's called the dual hopper.", "The hopper's two sections will hold up to six pounds of different coffee blends, such as dark and light roasts.", "Next he installs what's called an agitation wheel.", "This plastic wheel helps move the ground coffee along and prevents it from getting stuck.", "The worker then aligns plastic couplings on the augers to mate with the ingredient dispenser.", "The dual hopper attaches to the ingredient dispenser with one screw in a pivoting bracket.", "Workers also connect power wires to the dispenser's motor and to a water-inlet valve.", "Next they install a heater and temperature sensor inside a plastic water tank that's nearly two gallons large.", "This 1,100-watt heater keeps the water at 200 degrees fahrenheit, just below boiling.", "That's the optimal temperature for extracting flavor from ground coffee beans.", "After applying stickers warning service technicians to turn off the machine before draining it, a worker installs three outlet valves-- one to dispense hot water for tea, one for coffee, and another for hot chocolate.", "Next come stainless-steel rods to monitor the water level inside the tank.", "They trigger an automatic refill mechanism.", "The worker connects power wires to the brewer motor.", "Then she mounts what's called the whipper mixing bowl.", "This aligns with the chocolate-syrup dispenser to prepare the hot chocolate.", "Next she installs the brewer-motor assembly into the machine's casing.", "This is the coffee machine's 15-button selection panel.", "It lets you select what type of hot drink to brew, in what cup size, and when to start.", "The panel also displays the prices when the coffee's not on the house.", "Once that's hooked up, workers test the chocolate-syrup delivery system.", "They run water through it to ensure it doesn't leak.", "They also test to see if the system dispenses the correct dose of syrup.", "One dose is a half ounce-- a tablespoon.", "A small cup of hot chocolate requires two doses.", "A large cup requires four.", "Now they install the brewer.", "It works much like a french press coffee maker, brewing a separate batch for each cup.", "To test it, they run water through it and make sure the selection panel works properly.", "By testing the panel with the coffee machine closed, they ensure the circuits are properly aligned behind the selection buttons.", "Depending on how strong you select your coffee, a dispenser releases between .", "2 and .", "6 ounces of ground coffee into a re-usable nylon filter.", "A piston then forces hot water through the filter for 10 to 20 seconds, depending on the size of the cup.", "This process extracts the flavor of the ground beans.", "The machine then scrapes away the coffee grinds and throws them down the built-in waste chute.", "Then it prepares for the next customer, and the next delicious cup.", "Mascots are supposed to bring luck, but the people who wear mascot costumes have had a few lucky breaks themselves in recent years.", "The outfits are much lighter now, and there's even an exhaust system complete with a tiny fan inside the head so it's not so hot in there.", "That helps the mascot keep his energy up for the entire game.", "This dinosaur mascot for the lung association is part of a new breed.", "It's really evolved into something that's relatively easy to work in.", "To make this dinosaur, they sketch him out.", "Then the artist modifies the figure to human proportions, targeting a height of 5'10\", which means the costume would fit performers 5'8\" to 6' tall.", "The artist designs huge eyes and a very extravagant mouth, and not just for creative reasons.", "The large openings will give the mascot performer room to see and to breathe through screens.", "Now a sculptor carves big pieces of lightweight, uncrushable foam.", "With a utility knife, he shapes the dinosaur's head, based on the design pattern.", "Traditionally, fiberglass has been used for mascot heads but foam is half the weight.", "He attaches a battery pack to the inside of the head, at the back of the neck, using velcro.", "He tests it to make sure it has enough juice to power this tiny, square exhaust fan, which is to be placed inside the head at the top.", "Then he sprays glue on the foam, sticking the sculpted layers of foam together.", "Now the dinosaur head is starting to shape up.", "He cuts out those enormous eye holes.", "Then he tries on the head for size.", "He checks visibility and ease of movement.", "Next the sculptor slices into a very dense piece of foam.", "It's dense because it will need to hold up to heavy traffic.", "This is the dinosaur's foot.", "He scoops out foam in the center of the foot, hollowing out an area.", "Then he carves out more, following a pattern of a size-12 shoe so that a human foot could fit inside this big mascot claw.", "He rounds the outside of the foam foot with a belt sander.", "Now the foot is fully sculpted and ready for the fabric department.", "There, a worker sprays heavy-duty glue onto the outside of the foot, and stretches a nylon fleece fabric over it.", "The fabric has a lot of give so that it can be tightly pulled into the grooves of the foam.", "Now she sprays adhesive onto the bottom of it and cuts off the excess fabric.", "She sews the seams with a very tough thread.", "Then a worker glues a rugged rubber sole onto the bottom of the dinosaur foot.", "This is a toenail made of nylon stuffed with polyfill.", "It takes three hours to make a foot.", "Now it's back to the other end.", "He glues an eye onto the mascot head.", "The eye is made of breathable nylon stretched over a plastic frame.", "Another worker sews on a horn, which is made of fabric-covered foam.", "Then she stitches on the nostrils.", "And now the mascot has some expression.", "But there's one more step.", "He glues a white nylon screen over the mouth and sticks black fabric strips over it to give the mascot its smile.", "Now a worker drafts a pattern for the outer body.", "It will go over an inner-body suit that will give the mascot its rotund shape.", "She cuts the liner fabric for the outer body, following the pattern...", "And then follows the same pattern for the outside fleece.", "She sews three layers-- fleece, foam, and liner-- all together.", "This serger machine cuts off excess fabric, and it sews and binds the edges.", "She hand-stitches the scales onto the back of the dinosaur mascot.", "And now it's time to give this mascot suit a test run.", "It fits like a glove.", "But what's the view like from the insideof that head?", "Hmm.", "Not too bad.", "This dinosaur mascot suit is ready to help its user excite the crowd.", "When christopher columbus discovered the new world back in the 15th century, he also discovered the hammock.", "It was in the west indies that columbus found natives lounging in what he later described as sleeping nets.", "And when hammocks were introduced to the europeans, they really caught on.", "Hammocks are still used centuries later.", "Hammocks were once called hamacks because they were woven with fibers from the hamack tree.", "Today they're made of braided polyester.", "To make a hammock, a worker measures and marks the spots for holes to be drilled in a hardwood spreader bar.", "He spaces the 22 holes almost 3 inches apart.", "He rounds the edges of the wooden bar with a shaped cutter called a router, smoothing out any sharp edges that could jab you when you climb into the hammock.", "Using an electric drill, he makes holes a half inch in size in the spreader bar.", "Then, with a countersink, he scoops out the wood around the edges of the holes, to make a gentler slope for the polyester rope.", "He adheres the company's prepasted label onto the bar.", "Next, 16 bobbins turn at a speed that could make you dizzy just watching.", "They're spinning the polyester cord.", "The bobbins twist the 16 polyester strands, braiding the strands into a herringbone pattern while electrical pulleys draw them up.", "The pulleys drop the cord in a drum.", "Now it's all in the wrist action.", "A weaver deftly intertwines the thick cord into a triangular shape.", "She's making the hammock's harness.", "It's called a clew.", "She tugs each row tightly to a ring at the top to ensure that the weave is steadfast.", "As she weaves, she drapes the long pieces of cord over a wood frame, to keep them from tangling.", "After the triangle is formed, she checks for errors in the weave.", "Now she threads the clew cords through the holes in the spreader bar.", "She snares a cord with a large crochet hook.", "Using the hook, she threads a cord through the hole at the furthest end of the spreader bar and then knots it.", "And she does the same on the other end of the bar.", "While the bar hangs by the two cords, she pulls the rest of the clew cords through all 22 holes in the bar.", "Next she positions the spreader bar under a guide bar to ensure everything's level.", "And she knots the rest of the cords tightly onto the underside of the spreader bar.", "It's a critical step.", "If there's any slack in the clew, the yarn will stretch and the hammock will be misshapen.", "This hammock harness is now strong enough to support a 450-pound person.", "Next she uses a 10-foot-long cord to make a chain of small links by pulling each link through the previous one.", "The top of the chain rope hangs from a hook, stabilizing it, and allowing the weaver to quickly turn the simple cord into an intricate-looking chain.", "Now she hooks each end of the chain onto pins on a loom.", "She weaves another cord into the chain, threading it with a crochet hook.", "She makes one loop in about every sixth link in the chain rope, and she hooks that cord onto the same pin as the chain.", "There's no rest for the hammock weaver.", "She takes a shuttle, which is a piece of wood with 656 feet of cord wrapped around it.", "She pulls it from below up through the available loops and then back down, expertly weaving the web that is the hammock bed.", "She hooks a second chain rope on the loom, and threads the edge of the woven bed to this chain.", "Now she places the spreader bar of a finished harness on one end of the loom.", "She lines up the pins of the loom with the holes of the bar.", "She knots the cord on each pin to a cord from the spreader bar.", "She repeats the process at the other end of the loom, binding the second harness to the hammock bed.", "She makes one last knot in the chain...", "And then removes the excess cord with the heat gun.", "The heat gun makes a clean cut with no ragged edges to unravel.", "With high-quality construction, this hammock will surely provide years of relaxation." ]

{ "things": [ "Electric Baseboard Heaters", "Moulded Pulp Containers", "Chicken", "Video Games" ] }

[ "Today on \"how it's made\"...", "Electric baseboard heaters...", "Molded pulp containers...", "Prepared chicken...", "And video games.", "Electric baseboard heaters are inexpensive, easy to install, and practically maintenance-free.", "Unlike radiators, they're inconspicuous and they take up very little space.", "And best of all, you can control the temperature room by room.", "A baseboard heater is simply wires and a heating element in a steel casing.", "They make the element using a strip of paper-thin aluminum 7 inches wide.", "It's lubricated with soap, then goes through a forming machine.", "A die punches the strip into little squares called fins.", "They measure half an inch by three-quarters of an inch and have a circle in the middle.", "The machine pierces the circles and cuts the fins apart.", "This machine churns out 600 fins per minute.", "It stacks them on steel tubes, the lengths of which vary according to the length of the heater.", "As each tube fills to capacity, a worker takes it away to be wired up.", "Elsewhere in the factory, they make the heater's casing using what's known as cold rolled steel, a flexible type of steel that can be worked without using heat.", "After a squirt of oil for lubrication, the first die cuts holes for attaching the baseboard to the wall.", "Then the second die cuts holes for attaching the heating element to the casing.", "Now the steel travels through what's called the roll former-- a machine whose series of rollers successively bend a flat strip of metal, one fold at a time, into the shape of the casing.", "From start to finish, 20 rollers make 20 bends.", "The process takes about 150 seconds per casing.", "After the last fold, a computer-controlled die cuts the casing to the required length.", "The higher the heater's wattage, the longer the casing has to be.", "Models range from 300 watts-- about 2 feet long-- to 2,500 watts-- about 8 feet long.", "Next, they put a steel junction box on each end of the casing.", "These hold the wires that the electrician connects to the house wiring.", "Workers spot-weld both junction boxes simultaneously.", "After a thorough washing, computer-controlled sprayers coat the casings in paint powder.", "Then it's into an oven for 20 minutes at 365 degrees fahrenheit.", "This transforms the powder to liquid, drying it instantly.", "After running a red wire for the electrical current the length of the casing, they rig up what's called a linear high limit temperature control-- a safety device that prevents the unit from overheating and catching fire.", "Gas inside the temperature control expands under intense heat, triggering the device to cut the current.", "Now they install supports to hold the heating element in place.", "They're made of satin-coat steel, a rust-resistant metal.", "As the element heats up, it naturally expands.", "To prevent it from scratching against the metal casing and making annoying noises, they install a heat-resistant plastic bushing.", "Now they connect the red wire that will carry the electrical current to the heating element's black wire, capping it with a wire connector.", "They clip it to the cover of the junction box-- easy access for the electrician installing the baseboard.", "Then they close the junction box cover.", "At the other end, they connect the red wire and the black wire to the temperature-control wire.", "This runs the electrical current through the safety device at all times.", "After a voltage test, they close it up and snap on a panel to cover the element.", "Being toasty warm is now just an installation away.", "\"molded pulp\" isn't exactly a household word.", "But it is a household item.", "Chances are, you've got an egg carton in your fridge that's made of it.", "This thick, cardboardlike material can be shaped into a variety of containers, like those drink carriers they give you at the fast-food restaurants.", "Farms ship out their eggs in trays called filler flats.", "These flats begin as recycled paper-- old phone books, newspapers, magazines, cardboard-- pretty much any product made of paper fibers.", "The factory even recycles its own flats that had been rejected by quality control.", "The raw materials go into what's called the pulper-- a giant blender that mashes everything up and blends it with hot water that's 110 to 150 degrees fahrenheit.", "The hot water swells the fibers, causing them to break apart.", "After 20 minutes, they become pulp, a watery mixture roughly the consistency of hot oatmeal.", "The pulp exits out the bottom of the pulper through a filter that screens out plastics and other contaminants.", "Shaping the flats is a fully automated process.", "Formation molds descend into a vat filled with pulp.", "A vacuum sucks the mushy mixture onto them.", "Water jets rinse of the excess.", "Rotating above are transfer molds.", "They grab the flats off the formation molds and move them onto a conveyor.", "Before the transfer molds grab the flats, though, a brush applies a water-based lubricant.", "This ensures the flats won't stick to the molds.", "It's just like greasing a baking pan.", "The molds themselves are made of bronze, plastic, or aluminum, depending on how long the factory intends to use them.", "They're covered with a stainless-steel mesh.", "This mesh ensures an even vacuum through the mold so the pulp spreads over it evenly.", "The soggy flats now go into an oven for 12 minutes to dry out.", "The 400-degree-fahrenheit heat evaporates the water.", "This bonds the fibers together, forming a rigid material.", "After they exit the oven, a device appropriately called an up-ender flips them up so that they stack into each other.", "A built-in counting mechanism triggers the machine to section off the required number of flats per package...", "Then compresses them...", "And seals them in plastic film to keep the dust out.", "The factory uses the same molding process to make four-cup drink carriers.", "These, too, go into an oven to dry out the pulp, but only for six minutes-- half the time the filler flats need because this product is smaller and lighter.", "Automated compactors stack the finished drink carriers.", "Then workers compress them for packing and shipping.", "The factory also makes disposable urinal bottles for hospitals.", "They add chemicals to the pulp to make the bottles liquid-tight.", "These molds are three-dimensional and lined with mesh on the inside.", "When they submerge into the pulp vat, a vacuum sucks in the pulp.", "When they resurface, water jets rinse the excess pulp off the bottle necks, and the vacuum sucks out the water.", "A spiked conveyor belt transports the bottles to the drying oven.", "They dry at a lower temperature than the flats and drink carriers do-- 350-degrees fahrenheit-- and for longer time-- a half-hour.", "This ensures the chemicals that make the bottles liquid-tight cure thoroughly.", "While urinal bottles can't be recycled for sanitary reasons, drink holders and filler flats are recyclable, making them extremely environmentally friendly.", "In the year 2001, the average person ate 61 pounds of chicken.", "Given that rate of consumption, if we had to process the poultry ourselves, chances are, we'd be in a rather foul mood by dinner.", "Thank goodness for chicken-processing plants.", "The chickens arrive at the factory with their feet, legs, and heads already cut off.", "What's left are the breasts and wings.", "The slaughterhouse also removed the internal organs.", "A conveyor belt transports the chickens to the cutting and deboning zone, a bustling assembly-line operation.", "Workers prop each chicken on a cone-shaped stand, in order to have both hands free.", "Cutting up a chicken properly isn't as easy as you might think.", "The workers get special training.", "It's crucial they keep their knives well-sharpened and wipe them after every five or so chickens.", "The first cuts remove the wings.", "Starting on one side and positioning the knife horizontally, in line with the top of the cone, the workers make an incision where the wing joins the shoulder, then cuts downward, across the back of the chicken, then a quick cut and twist to detach the wing.", "It's the same procedure on the other wing.", "The incisions at the wing/shoulder joint must slice through the tendon completely, otherwise, detaching the wing is difficult.", "And struggling with a slippery wing while holding a knife in your hand can result in a serious injury.", "The next cuts remove the skin and breasts.", "They peel off the skin, then pull on the two breasts, and make a quick incision to release them.", "They slice the breasts apart, carefully checking for bones that might have broken off from the carcass and could be hiding in the meat.", "The next cuts remove the tenders-- the meat located under the breast.", "Workers make an incision in the middle, just under the wishbone, and down the length of the carcass.", "This detaches the tenders, enabling the next worker on the line to pull them off.", "Meanwhile, waiting in the wings are the wings.", "Workers load them onto a machine appropriately called the wing-cutter-- a mini ferris wheel that takes the wings for a little ride, right into a sharp knife that chops them into three sections-- the drumette, the chubby part with the most meat; the winglet, the middle part; and the wing tip, the pointy part with barely any meat.", "This factory transforms the meatier drumettes and the winglets into frozen, ready-to-eat chicken wings.", "The first step in that process is seasoning.", "Workers load the pieces into a giant drum.", "As the drum rotates, they inject the seasoning-- barbecue or honey garlic, for instance.", "After about an hour, the chicken wings come out evenly coated.", "Now these freshly seasoned wings go into a gas-fired oven, where they bake at approximately 480-degrees fahrenheit for 8 to 11 minutes.", "They come out fully cooked and ready to eat.", "They go into a freezing mechanism for about a half-hour, then to the automated-packaging department, where they're sealed in a bag.", "These chicken pieces-- wings, tenders, and breasts-- are prepared differently.", "After seasoning, they travel through a rotating drum that coats them in a flour-and-bread-crumb mixture, then into a second drum for a second coat.", "Next stop, a 40-second deep fry in canola oil, just long enough to adhere the coating.", "Then from the frying pan into the fire, as they say-- well, into the oven, actually.", "After 20 minutes at about 480-degrees fahrenheit, these chicken pieces are fully cooked and ready to be frozen and packaged.", "They started out a generation ago as simple black-and-white ping-pong games on a tv screen.", "Today's video games are vivid, sophisticated, and fast-moving, driven by state-of-the-art computer software featuring the latest in high-tech graphics.", "It all started in 1952 with a cambridge university phd thesis on human/computer interaction.", "The student invented a primitive tick-tack-toe game on a vacuum-tube computer-- the very first computer game with graphics.", "A team at m.i.t. designed the first recognized computer game in 1962.", "Then, in 1972, a stanford student invented the arcade game \"pong,\" which later became a home video game you could play on your tv set.", "It all begins with the people who form what's called the core team.", "They brainstorm in meeting after meeting to hammer out the concept-- how the game will look, how it'll work.", "Then they plan out the production schedule, assigning who will do what when.", "They break down the game on paper and color-code the components.", "Then they post them on a bulletin board that'll act as the production's nerve center.", "Now work on the artistic concept begins.", "Artists sketch out the characters and backgrounds on paper in a scene-by-scene storyboard.", "Meanwhile, graphic artists recreate those storyboard drawings three-dimensionally on the computer.", "This step enables the development team to use the latest in computer-animation technology to bring the game elements to life.", "They add colors, textures, shading, and of course, movement.", "After developing a preliminary version of each character, the animators superimpose a skeleton.", "By manipulating the skeleton, they make the character move.", "They experiment with different movements until they decide which ones they'll use for the game.", "The animators have to design every movement each character can potentially make in the game.", "That's 700 movements for this main character alone.", "Once that's done, they flesh out the character's features and costumes.", "The evolution of the characters from the first pencil drawing to the final version is quite remarkable.", "Other animators work on the backgrounds, the game's playing field.", "Once they have a rough version laid out, they refine it by adding details, colors, and textures.", "To give it depth and dimension, they use virtual lighting to create shading and shadows.", "To advance the story line, this particular video game is interspersed with one-minute animated movies.", "These segments, called cinematics, are animated in high-resolution to produce a top-quality image.", "The interactive game, on the other hand, is in low resolution because computers can't process high-res images quickly enough for fast-moving play.", "The animators have to create every character twice, in both high and low resolution.", "Meanwhile, for the cinematics, they animate the storyboard using rough-draft characters.", "This is simply to calculate the timing and to map out a clear path across the backgrounds so the characters don't collide with the scenery.", "To make the cinematic's action look realistic, they use a technique called motion capture.", "The animators videotape themselves performing the action, then use animation software to reproduce it on the computer.", "Computer programmers create the video game's menu settings, among other features.", "Computer engineers design the artificial intelligence, the brain that runs the game.", "It's made up of thousands of computer codes.", "For the cinematics, actors record the characters' lines in a sound studio.", "An audio technician mixes the voices with music and sound effects and synchronizes everything with the action.", "Now they take the video game out for a test-drive.", "Do the characters move the way they're supposed to?", "Do they go where they're supposed to?", "Or do they run into trees and walk through walls?", "This is the development team's last chance to rid the games of any bugs.", "After that, the company can finally market the video game and hope it becomes a hit." ]

{ "things": [ "Flying Water Bikes", "Throttle Position Sensors", "Cinnamon Cordial", "Handmade Rasps" ] }

[ "Looking to get high on a new water sport?", "Well, you literally can riding a flying water bike.", "It attaches with a long hose to the back of a jet ski, elevating you up to almost 40 feet above the water where you can perform aerial flips and spins.", "The jet ski's water thrust feeds three jet nozzles on the flying water bike.", "One propels the bike upward.", "The other two feed jet control nozzles that maneuver the bike.", "The bike's frame is made out of aluminum parts because it has to be lightweight as well as relatively corrosion-resistant, especially if it is going to be used in saltwater.", "This curved tube will become the lifting jet.", "To build each jet control nozzle, a worker places a housing on an alignment fixture then hammers an endcap into position.", "Holding the housing steady with a clamp, the worker welds on the endcap.", "This housing will cover the bushing at the heart of the jet-control nozzle.", "He inserts an elbow into the opening in the endcap and welds the parts together.", "After welding a jet nozzle cone to the other end of the elbow, he welds a handlebar to the housing.", "These five welded parts make up the body of the first jet control nozzle.", "To prep for painting, the manufacturers rough up all the aluminum parts by tumbling them with abrasive stones.", "This component splits the portion of the water thrust that bypasses the lifting jet, sending it in opposite directions to the jet control nozzles.", "The lifting jet tube now has a nozzle cone welded to one end, a coupling for attaching the fire hose to the other, and an oval hole in the curve, which aligns with the angled end of a straight tube in the middle, called the backbone.", "After positioning parallel support bars between the lifting jet and the splitter, the welder fuses all the parts together.", "Then he flips the assembly jig and welds on the seat support.", "The seat support attaches where the lifting jet and backbone meet.", "After masking the ends of the splitter, a worker sprays the completed frame, jet control nozzles and other aluminum parts with powder coat.", "This helps protect against corrosion.", "The parts go into an oven for up to a half hour to bake the powder coat to a shiny finish.", "Then workers install an aluminum camlock to securely fasten the fire hose to the coupling.", "Another worker attaches the remaining components to the frame.", "First, he screws in the pair of footplates on which the rider stands.", "Then he bolts the bottom half of each plate to the parallel support bars and the top half to just ahead of the camlock.", "He mounts a padded knee rest to the support bars.", "It can be easily repositioned to accommodate the rider's height.", "On each unpainted end of the splitter, he installs an internal support ring, then a precision-fit nylon bushing and an external support ring, which he screws to the splitter.", "The worker slides the jet control nozzle housing over the bushing and screws it to the internal support ring.", "The two control nozzles maneuver the water bike.", "To ascend, you pull back gradually on both of them, simultaneously.", "To descend, you push forward on both.", "To spin, you move one forward and one back.", "And to do a backflip, you yank both control nozzles all the way back.", "He assembles the water bike's body.", "It's made of molded polyethylene with a waterproof urethane pad to cushion the front of the rider's body.", "The seat is made of the same padded material.", "Both pad and seat attach with plastic clips.", "The hollow body is completely watertight, which is why the bike floats.", "The final step is to mate the body to the frame.", "The completed water bicycle weighs 30 pounds.", "Once connected to a jet ski with the fire hose, this water bike flies at a speed of up to 20 miles per hour.", "By maneuvering the jet nozzles, it does backflips, multiple spins, and even dives 20 feet underwater.", "A throttle position sensor reports the position of the throttle plate to the engine computer so that it can decide how much fuel to inject into the engine and many other things.", "Without this critical sensor, the ratio of the air-fuel mix would be compromised, and the engine would likely stall.", "In internal combustion engines, the throttle position sensor is on constant alert, sending the necessary power demands to ensure a smooth ride.", "Making these sensors starts with printed circuit boards.", "These boards will ultimately process physical data and convert this into information the engine computer will understand.", "A robot transfers the boards to a conveyor which takes them to a solder screen printer.", "The printer squeegees solder through a stencil to deposit it in specific locations on the boards.", "The squeegee and stencil then retract, and the conveyor shoves the boards forward to the next operation.", "Here, a robot retrieves electronic components from tape on a reel and deposits them on the soldered spots on the boards.", "It collects multiple parts from the reel at one time and installs them on the boards faster than you can blink an eye.", "Moving forward, the printed circuit boards arrive at a camera station.", "The camera clicks away and sends pictures of the boards to a computer.", "The computer analyzes the placement of each component.", "With the computer's okay, the boards head into an oven with different heating zones.", "The oven melts the solder and then cools it down to fuse the components to the boards.", "The oven then ejects the sensor boards.", "Next, a technician serves them up to automated test probes.", "The probes energize the components on the boards and, in the process, collect information.", "They send the data to a computer, which analyzes the function of the components on the board and to make sure they're fully operational.", "Then the boards move to a pneumatic punch.", "It separates the 18 sensor circuit boards by cutting the tabs that hold them together.", "A worker assembles a metal spring to a plastic magnet holder.", "He places a high-wear washer over the neck the magnet holder.", "Then he inserts the magnet holder assembly into the throttle-sensor housing and places the unit in a tray.", "After glue has been injected in the holders, a robot moves in.", "It scans the holders and confirms that there is glue in each cavity.", "It then inserts magnets in the holders.", "A worker installs a torsion spring in the housing.", "It will hold the magnet holder tight to the throttle body.", "He now inserts the printed circuit boards into the sensor housings.", "Terminals in the housings mate to slots in the boards.", "He solders the terminals to the boards to establish the connections.", "All the parts are now in place for throttle position sensing.", "A worker places covers over the sensor board compartments.", "An ultrasonic welder then melts the plastic at the interfaces.", "Once it hardens, the weld bonds the cover to the sensor body.", "A robot pipes silicone adhesive on the welded seam to create a double layer of protection.", "The sensors ride on a conveyor that goes through an oven.", "This cures both the silicone on the welded seam and the glue inside to secure the magnet to the holder.", "Out of the oven, the sensors travel through a cooling station.", "Probes then power the devices and calibrate them for use in specific vehicles.", "A robot holds the sensor in front of a laser, which etches the date of manufacture.", "Back on a conveyor, the throttle position sensor travels under a magnifying glass so that the laser-etching job can be scrutinized.", "This throttle position sensor is now ready for detection duty.", "Cinnamon cordial marries the pungent flavor of one of our favorite spices with alcohol.", "Think of it as the liqueur equivalent of a cinnamon bun.", "On its own or as in ingredient in a specialty drink, cinnamon cordial can add some serious spice to cocktail hour.", "Cinnamon cordial is the distilled spirit that is both sweet and spicy.", "It's this complexity of flavor that is at that heart of its appeal.", "This particular cinnamon cordial starts with a blend of california grape brandy that's been aged for 2 years.", "The distiller measures the amount the recipe calls for and pours the brandy into the main production vessel.", "He then pumps neutral grain spirits out of a big holding tank and into the measuring bucket.", "This spirit is 190 proof, which means that it is 95 percent alcohol.", "He adds it to the grape brandy.", "Together, the brandy and the neutral spirits will serve as the alcohol base for the cinnamon cordial.", "The brandy contributes color and a little flavor while the clear spirits add potency.", "Next up are the spices that provide a first layer of flavor.", "Using a scale, the distiller measures the amounts for the recipe, beginning with whole coriander, a spice that will impart a citrusy zest to the cinnamon cordial.", "The next ingredient is cloves.", "This spice has a sweet and peppery essence.", "Finally, he adds dry bay leaves.", "He crumbles them to release their herbal fragrance.", "These three spices will ultimately provide background flavor, while the cinnamon that's to be added later will be the main event.", "The distiller reopens the production tank and drapes a mesh nylon sachet over the opening.", "He pours the carefully measured spices into the bag, and they become immersed in the alcohol.", "He draws the bag of spices shut and leaves it in the alcohol for 2 weeks.", "During this time, the alcohol extracts flavors from the spices.", "Staying true to the recipe is critical.", "Adding too much of one spice or leaving the spices in the alcohol for too long could ruin the batch.", "After steeping, the liqueur is ready for the cinnamon spice.", "He adds two kinds-- cassia, which is from indonesia, china, and vietnam, and ceylon cinnamon, which originates in sri lanka.", "He breaks up the cinnamon tree bark to increase the surface area for steeping.", "He also adds two different powdered cinnamons for extra flavor and color.", "He now makes simple syrup from organic sugar and water and adds it to the mixture.", "This syrup provides sweetness and dilutes the alcohol content substantially, bringing it down to 68 proof.", "He leaves the blend to steep for a week.", "During this time, he samples the beverage daily to confirm that the drink is developing correctly and that the cinnamon flavor is properly balanced.", "The color change during this week is dramatic, and it's an indication of the cordial's deepening flavor.", "When the taste and color seem just right, he removes the spices and pumps the cinnamon cordial into 25-ounce bottles.", "This bottling system is equipped with a filter to remove any impurities.", "Once full, he corks the bottle.", "Using a special labeling machine, he rolls on the label that identifies the product for marketing.", "He then heat-shrinks a plastic seal around the cork.", "He puts a signature on it, and this cinnamon cordial is ready for the cocktail circuit.", "Tour the workshop of a cabinetmaker or woodcarver, and you're sure to come across a collection of rasps.", "A rasp is a hand tool with teeth that you push forward with pressure over wood to shape it.", "Rasps come in various textures, called grains, ranging from coarse to fine.", "Machine-made rasps may suffice for hobbyists, but fine woodworking requires premium rasps like these, which are made entirely by hand.", "A rasp starts out as a steel bar, called a blank.", "First, a worker heats one end of the blank in an oven at a temperature of approximately 1,500 degrees fahrenheit.", "When the steel glows somewhere between orange and red, he immediately cuts the end to a crude point with a press.", "Then he places the end under a spring hammer which strikes it repeatedly against a die, forging the crude point to a refined one.", "After repeating these steps on the opposite end...", "He inserts the blank into a shearing machine.", "This cuts across the middle, dividing the blank into two flat rasps, each with a pointed end and a flat end.", "The worker puts the flat end into the oven.", "Once it reaches working temperature, he places it in a press.", "The first strike tapers the end.", "The second cuts off steel to form the tool's handle, called the tang.", "The rasp shape is fully forged.", "An experienced craftsman now begins refining it.", "First, he runs it against a grinding wheel to remove excess steel.", "Because steel warps in the forging process, he hammers along the tang, point, and length to straighten the rasp.", "This step is critical for structural strength because if the grain of the steel isn't perfectly straight, the rasp will warp when the craftsman later hardens the steel by tempering.", "Once the rasp is straight, he grinds the flat surfaces on a grinding belt.", "Then he returns to the grinding wheel to remove excess steel around the point.", "By the time he completes this step, the point is transformed from this to this.", "After additional grinding to polish away the marks, it's time to give the rasp some teeth.", "This process, known as stitching the rasp, is a highly specialized skill that requires exceptional dexterity.", "The stitchers form every single tooth by hand with a single hammer strike on a punch.", "The punch shape and size determines the tooth shape and size.", "The hammer size determines tooth height.", "A heavier hammer forces the punch deeper into the steel, forming a taller tooth.", "The larger and deeper the teeth, the coarser the grain of the rasp.", "The artisans stitch the rasp a quarter section at a time to set the teeth at the proper angle.", "The tooth angle differs when they're making a left-hand rasp versus a right-hand rasp.", "The expert craftsman now hammers a slight curve back into the rasp.", "If left straight, it would curve when they temper it.", "By preemptively curving it, the rasp will straighten when tempered.", "He submerges the rasp in a molten salt bath inside the tempering furnace.", "Salt prevents contact with oxygen, which burns off the carbon in the steel, thus destroying its properties.", "After removing the rasp from the salt bath, he gradually cools it in a quenching tank filled with saltwater.", "Cooling steel at just the right speed and direction is critical.", "Too slow, it doesn't harden sufficiently.", "Too fast, it twists or warps.", "He does a final straightening in a press.", "The final operation is a very soft sandblasting.", "This removes residue from the salt bath and transforms the surface from shiny to matte.", "These handmade rasps come in a multitude of shapes and 15 different grains ranging from coarse to fine, so the woodworker can always select the right rasp for the task." ]

{ "things": [ "Seatbelts", "Windows", "Wax Figurines", "Hot Air Balloons" ] }

[ "Today on \"how it's made,\" seatbelts...", "Windows...", "Wax figurines...", "And hot air balloons.", "It's an indisputable fact that seatbelts save lives.", "When a car comes to a sudden stop, the seatbelt prevents you from hurling forward.", "It spreads the stopping force across the sturdier parts of your body, namely your rib cage and pelvis.", "This spreading action dilutes the strength of the stopping force, minimizing injury.", "Before production can begin, the factory has to adjust the seatbelt design to fit the specific car model, to make sure the belt path is clear, that there's enough room for rotating parts to move, and so on.", "On the factory floor, robots assemble most of the mechanical components.", "This plastic disk, containing a spring and a weight, is part of the locking mechanism.", "It's what stops the seatbelt straps, called the webbing, from lengthening when you jerk forward due to a sudden stop or hard deceleration.", "The locking mechanism goes into the seatbelt's retractor mechanism, the component that lets the webbing extend and retract.", "The webbing will wind onto this aluminum spool in the retractor, a rewind spring keeping it taut.", "Sudden deceleration will cause this silver ball to trigger the locking mechanism.", "This will stop the spool from rotating and lock the webbing.", "This next robot assembles what's called the pretensioner mechanism.", "While the locking mechanism stops the webbing from lengthening, the pretensioner sharply pulls the webbing back, tightening any slack.", "The pretensioner kicks in only in the event of a crash.", "The sudden deceleration on impact triggers sensors which signal the air-bag control module to send an electrical charge to the pretensioner.", "This charge sets off a tiny explosion that deslacks the belt.", "This worker installs the explosive device, called the micro gas generator, or mgg.", "After lubricating the inside of its aluminum cylinder with grease, she inserts a piston and the mgg.", "The mgg contains a chemical called nitrocellulose.", "The electrical charge coming from the air-bag control module ignites this chemical, causing a tiny gas explosion.", "That generates pressure within the cylinder, driving the piston upward at high speed.", "This triggers a gear that winds the retractor spool backward, taking up any slack in the webbing.", "After capping off the micro gas generator's housing, a robot transfers the completed pretensioner mechanism to the retractor's frame.", "Then it screws on a steel cover plate to hold the pretensioner in place.", "They install the rewind spring onto the spool of the retractor mechanism.", "This spring is what provides resistance when you pull out the webbing to buckle up.", "Then, when you unbuckle, it rotates the spool to rewind the webbing.", "The car company decides what type of spring to use.", "The thicker the spring and the more coils, the greater the tension, and therefore the faster and smoother the belt retracts.", "But the greater the tension, the less comfortable the seatbelt is on the body.", "The webbing is made of woven polyester fiber.", "This machine sews one end over into a loop for the pin that'll anchor the webbing to the spool.", "The pin is made of either plastic or steel, depending on the type of retractor they're using.", "A worker now threads the end through a machine that automatically winds the webbing onto the retractor spool, making sure the pin is properly attached.", "At the same time, the machine checks the overall belt length to make sure it conforms to the client's specifications.", "At this factory, every single seatbelt component has to pass a thorough quality-control check.", "Here a machine checks a key safety feature, a lever-and-ratchet mechanism that prevents the webbing from extending after you've belted in a child car seat.", "Now for the final assembly.", "Workers load all the seatbelt parts in a jig, a holding device that arranges them in the proper configuration.", "A worker feeds the webbing through the shoulder loop, from which the belt hangs, and through the tongue plate, the part that clicks into the buckle.", "Both these components are made of steel for strength, with plastic coverings matching the car interior.", "The last step is to sew the anchor to finish off the other end of the webbing.", "Every seatbelt design goes through extensive testing before going into production.", "This machine assesses how much pull the webbing and retractor can withstand before breaking.", "This machine tests the webbing's durability, running it through 50,000 abrasion cycles to ensure the material doesn't wear out.", "The earliest windows were merely holes cut into the walls.", "People living in warm climates left them uncovered, while people in harsher climates used animals skins to keep the cold out.", "In the far east, people covered the opening with paper.", "Then came glass panes in sashes that swung in or out or hung one above the other.", "This type of window is called a casement window.", "A crank mechanism opens it at an angle.", "To build the window frame, the factory begins with 16 1/2-foot lengths of extruded pvc, a type of plastic.", "As clamps hold the pvc steady, a computer-guided circular saw cuts the sizes required for the frame.", "The same machine also cuts the pieces for the sash, the inner frame around the glass.", "Each frame is made from four pieces, whose ends are mitered at a 45-degree angle.", "Now workers load eight pieces onto a computer-guided welding machine-- eight, because it welds two frames at a time.", "First a heating block, whose temperature is 446 degrees fahrenheit, melts the ends.", "Then the machine pushes them together.", "They fuse, forming the frame's four corners.", "Here's the same process, viewed from above.", "As the melted ends bond under pressure, excess pvc oozes out at the joints, then hardens.", "The next machine will clean that up.", "A robot reads the profile of the specific frame style.", "Then it uses one of several cutting heads to shave the excess off the corners.", "From here, the sash and frame go to another area to receive hinges.", "Meanwhile, workers cut the glass to size.", "They start with a huge sheet, measuring about 6 1/2 feet by 10 feet..", "It's very heavy, about 200 pounds.", "So, they lay it on a specially designed table.", "A blower sends up air through tiny holes.", "This floats the glass just above the surface, making it easy to move around.", "They score the glass using a sharp carbide cutting wheel.", "This window will have what's called a thermopane, two panes of glass with argon gas in between for insulation.", "One of the panes has a transparent metallic coating to reflect the heat back into the house.", "They adhere a strip of silicone foam around the perimeter of the first pane, notching it for a good fit around the corners.", "The foam is covered in a thin, strong polyester film to prevent the gas from leaking through.", "The strip is a spacer, creating a gap between the two panes that's just over 1/2 inch wide.", "That's where the gas will go.", "They cut a hole at the top of the spacer and another at the bottom.", "You'll see why shortly.", "This window features decorative grid work called muntin bars.", "They're made of aluminum and go between the two panes.", "A worker lays the bars onto the first pane, then uses this guide to line them up perfectly straight.", "Then she puts the second pane on top.", "It sticks to the exposed adhesive edge of the spacer.", "Now the double-paned glass goes through a press, whose rollers apply pressure to ensure a strong and thorough bond to the spacer.", "After the glass exits the press, workers pump in argon gas through that hole at the bottom of the spacer.", "The speed of the gas flow is critical.", "If they pump it in too fast, it'll mix with the air in between the panes, rather than push it through the hole at the top of the spacer.", "After plugging the holes, they coat the spacer in a polyurethane sealant.", "This makes the thermopane completely airtight.", "Now it's ready to go in the sash.", "A piece of pvc called the glazing stop holds it there.", "They snap it in place using a roller.", "A little pvc cement to seal off any miniscule gaps in the corners, then the sash goes into the window frame.", "Their respective hinge parts simply snap together.", "The last step is to snap the frame's crank arm onto the sash.", "Making religious figurines out of wax is a tradition the french brought to the new world.", "For hundreds of years, this delicate craft wasn't open to just anyone.", "The technique remained a closely guarded secret, practiced only by monks and nuns within the confines of their monasteries and convents.", "This artisan uses a centuries-old technique to restore antique figurines and to make new ones.", "She begins with pure beeswax, paraffin wax, some powdered chalk to make the waxes less transparent, and a bit of solid animal fat to make the wax less fragile once it hardens.", "She heats the can of ingredients in a pot of water for about two hours, until everything's melted and homogenous.", "Then she tints the mixture using oil-paint pigments.", "There's no exact recipe.", "She goes by gut feeling, fiddling with various colors until she creates the exact skin tone she's looking for.", "Once she's certain the color is uniform throughout, she pours the mixture through a stocking.", "This filters out any contaminants or undissolved particles.", "Now she pours the mixture into a plaster mold.", "There's a different mold for each figurine model.", "This one's a baby jesus.", "The wax takes about 10 minutes to solidify.", "The figurine comes out easily, because she had greased the mold cavity beforehand with filtered sheep fat.", "The figurine at this point is firm enough to extract from the mold but still soft enough to sculpt.", "With a very fine blade that she heats over a flame, the artisan now scrapes away the seam left by excess wax that oozed out of the gap between the mold's two halves.", "Then she runs the figurine through the flame just long enough to melt off any wax particles left behind by the scraping.", "After smoothing the surface with a solvent, she signs the back of the figurine with her initials, then uses the flame once again to melt off the scraped-out wax.", "Now that the figurine's body is finished, she can begin the detail work.", "She melts pine resin with beeswax to make glue, then brushes it on the figurine's head.", "Then she takes strands of human hair-- clients often supply their children's hair-- and soaks them in water.", "She wets strips of fabric, as well.", "Then she rolls the hair around a knitting needle to make curly locks.", "She winds the fabric over the curls to hold them in place until they air-dry.", "If she's pressed for time, she'll dry them in the oven on low heat.", "To make bigger curls for a larger figurine, she simply uses a thicker knitting needle.", "Now, using a hot blade to reheat and activate the glue, she applies each length of curls individually.", "Once she's finished covering the head, she attaches a little halo made of brass wire, heating the end so that the wax melts on contact and holds it in position.", "Now, using a small, pointed tool that she repeatedly heats on the flame, she sculpts the fine facial details-- the figurine's eyes, eyelids, nostrils, and lips.", "Again, a little solvent cleans off the wax particles.", "Now she brushes the figurine head to toe with powder made of pumice and pigment.", "This will help the watercolor paints adhere to the wax.", "She paints the eyes, lashes, brows, and lips.", "Once the paint dries, she applies a touch of varnish to the eyes to make them shiny and bright.", "Once the varnish dries, she dresses the figurine and positions it in its setting.", "The first passengers ever to ride in a hot air balloon were a sheep, a duck, and a chicken.", "That eight-minute flight took place in france in 1783.", "Today's hot air balloons work on the same principle-- the burner heats the air, the balloon envelope holds the air, and the basket carries the passengers.", "Hot air balloons fall under government aircraft regulations, so their engineering has to meet very specific performance and safety standards.", "Once the technical design gets approval, the factory works on the graphic design.", "The computer renders the graphics into plans that resemble a giant jigsaw puzzle.", "Each piece has a code number.", "The computer generates a paper template for each one.", "Balloons usually fly in the early morning, when there's still dew on the ground.", "So, the nylon fabric with which they make the balloon envelope has a silicone coating to repel moisture that would generate mold and mildew.", "After tracing each template with grease pencils, they cut the fabric by hand and mark the corresponding code number on the back of each piece.", "Then, following the plan, seamstresses sew the pieces together like a giant quilt, using heavy-duty thread.", "The type of seam they stitch is the strongest possible-- what you typically see on jeans.", "They sew the seams to nylon straps, called webbing.", "These run both horizontally and vertically, forming a giant grid.", "Should the fabric rip, the seam and webbing combined prevent the tear from spreading.", "Hot air balloons often carry a corporate logo.", "Workers divide the design into components, project each one onto a piece of fabric, trace it, and cut it out.", "They first glue, then sew the components to the balloon in one of two ways either into the fabric, or on top of it, as we see here.", "Stainless-steel aircraft cable connects the balloon envelope to the basket below.", "Workers slip a plastic sleeve, then a copper sleeve over one end, then loop the cable.", "They line the loop with a stainless-steel thimble.", "This thimble will protect the aircraft cable from damage due to wear and tear.", "They crimp the copper sleeve to lock the loop.", "After taking various measurements to ensure everything conforms to strict specifications, they wrap tape around the sharp end of the crimp, then, using an industrial heat gun, shrink-wrap the plastic sleeve over it to seal the connection.", "The basket is made of wicker or a similar natural material woven over a stainless-steel frame.", "Wicker is flexible enough to absorb the shock of a bumpy landing.", "They cover the bottom edge with rawhide to protect the wicker when it scrapes against the ground.", "They pad, then cover the top edge in suede or leather for comfort when you're leaning on it to admire the view.", "These nylon poles, called uprights, fit into the frame.", "They support the burners above the basket.", "Hot air balloons run on propane, the same stuff gas barbecues use.", "Only a barbecue produces about 70,000 btus of heat, while a hot air balloon's two burners together generate 30 million btus, enough to warm a large building.", "After connecting the basket to the burner frame with cables, they cover the cables and uprights in protective padding.", "Then they hook up the hoses running from the burners to the propane tanks housed in the basket.", "Now for the final assembly.", "First, they tip the basket onto its side.", "Then they take those looped cables they made earlier and hook one end to the frame of the burner system.", "The other end is already hooked up to the balloon envelope-- one cable to every vertical strip of webbing.", "Depending on its size, a balloon has between 12 and 28 of them.", "They form the skeleton of the balloon, carrying the weight of the craft and its passengers.", "After laying out the balloon envelope, they use a fan to inflate it partway with cold air.", "This takes 5 to 20 minutes, depending on the size of the balloon.", "Then they fire up the burners to heat the cold air.", "It expands to fill the envelope.", "The fabric near the burners is fire-resistant.", "Because hot air weighs less than cold air, it rises, pulling the balloon upright and off the ground.", "You control vertical movement by manipulating the envelope air temperature.", "To ascend, you turn the burner flames higher.", "To descend, you pull a cord to vent hot air out the top.", "You can't really steer horizontally.", "The trick is to ride different wind currents." ]

{ "things": [ "Composite Propane Cylinders", "Salsa", "Water" ] }

[ "A composite propane cylinder is an alternative you'll appreciate if you've ever lugged a steel propane cylinder for your gas barbecue or if you've ever run out of gas in mid-grill because you couldn't tell how much propane was left in the tank.", "Composite material is 30% lighter than steel and see-through.", "Composite propane cylinders are made of transparent fiberglass encased within a plastic housing.", "Propane, a liquid under pressure, expands as temperature increases.", "So as a safety feature, the cylinder valve is equipped with an overfill-prevention device, a valve shut-off that kicks in when you've filled 80% of the cylinder.", "This ensures ample room for the propane to expand.", "Fiberglass is actual glass that's been drawn into thin fibers, then woven into fabric or, in this case, yarn.", "It's the ideal material for a gas cylinder because it's strong, lightweight, rust-proof, and nonflammable.", "A robot simultaneously winds 12 strands of fiberglass yarn over a steel form shaped like a half cylinder.", "The winding pattern is very specific, strategically designed to make the cylinder walls as strong as possible.", "While winding, the robot applies a powder binding solution.", "This immobilizes the strands so that the shape won't collapse when the robot later lifts it off the form.", "The winding process takes about 45 seconds and produces what's called a preform.", "The robot transfers the preform over to the next machine, a molding press.", "It injects liquid plastic at high pressure, impregnating the fiberglass.", "Then it heats the preform for 10 minutes to cure the plastic.", "What comes out of the molding press is a fully formed fiberglass half cylinder.", "The top-half cylinder needs to be prepped for the valve.", "First, an automated drill bores a hole.", "Then workers apply caulking around a valve fitting...", "Set the fitting on an assembly fixture...", "Position the hole over it...", "Then press the fitting into the fiberglass.", "Now they mount the top- and bottom-half cylinders on opposing lathes.", "A computer-guided grinding wheel with a fine diamond-grid surface trims the edge of each half cylinder to an exact specification.", "Then it machines a precise 3-degree taper on each edge at opposing angles.", "Next, an automated nozzle applies adhesive onto the tapered edges.", "Then the lathes move toward each other, mating the halves.", "The tapered edges slot together in a tight fit.", "After the adhesive cures nearly two hours later, this is a solid, inseparable cylinder, which, as per the certification label, conforms to the standards required by government regulators.", "Every single cylinder this factory produces undergoes safety tests.", "This one, in a pressurized chamber, ensures the cylinder can hold the required amount of pressure.", "This submersion test ensures the cylinder is gas-tight.", "If bubbles appear in the water, it means there's a leak.", "After a cylinder passes testing, workers install the valve, which is already connected to the overfill-prevention device.", "The valving machine holds the cylinder steady, while it turns the valve to the precise tightness the engineering specifications require.", "Now it's just a matter of snapping together the cylinder's two-part plastic housing.", "The housing has handles for carrying the cylinder.", "It also has a flat base to allow the cylinder to stand upright.", "Composite propane cylinders come in various sizes to fuel everything from barbecues to patio heaters, even ride-on lawn mowers and factory forklifts.", "Salsa is a staple of mexican and southwestern cuisine-- a spicy tomato-based condiment people typically enjoy as a topping on tacos or dip for tortilla chips.", "Recipes vary, as does the kick factor-- from mild to extra-hot.", "\"salsa\" is the spanish word for \"sauce\".", "This american company produces nine different flavors, from regular to roasted garlic to pineapple-mango.", "All flavors begin with fresh tomatoes delivered daily to the factory.", "Workers inspect them carefully and remove any stems, leaves, and unripe or imperfect tomatoes.", "Other workers, meanwhile, cut the stems off cilantro, a leafy herb that acts as a major flavor-enhancer.", "They wash the cilantro in a tank of ice-cold water, then transfer it to another cold-water tank for a second wash, and then to another tank for a third wash, then a fourth and final wash, this one in a machine with food-safe vegetable sanitizer, containing bacteria-killing hydrogen peroxide.", "Then they dry the wet cilantro in a giant salad spinner.", "In another area, they prep the onions, peeling the skin and slicing off the ends.", "They rinse the onions with water and the same sanitizer they used on the cilantro.", "Ditto with the tomatoes.", "This industrial-strength dicing machine chops up all the produce ingredients.", "It has interchangeable blades to adjust for different-sized cuts.", "First through the dicer-- the tomatoes.", "They enter whole and exit in pieces about 4/10 of an inch big.", "Next, the onions.", "The dicer chops them into pieces roughly 2/10 of an inch in size.", "Meanwhile, the cilantro goes into a cutter which chops it into fine pieces.", "The recipe proportions are roughly 80% tomatoes, 5% onions, 2% cilantro, 5% green peppers, then additional flavor-specific ingredients, plus salt, pepper, and vinegar.", "With the prep work done, it's now time to blend all the ingredients in a giant mixer.", "Each batch begins with 55 gallons of tomatoes.", "Next comes the cilantro.", "This and all the ingredients are pre-weighed, so as to be in the correct proportion to the quantity of tomatoes.", "The onions are next.", "This particular batch of salsa is garlic-artichoke flavor; hence the next ingredient-- diced artichokes.", "Now the combined liquid ingredients-- lemon juice, lime juice, and white vinegar...", "Followed by the combined dry ingredients-- salt, pepper, dried celery, and garlic powder.", "A final high-speed five-minute mix ensures everything is thoroughly blended and ready for packaging.", "The finished salsa goes into vats.", "From there, at packaging time, a pumping system moves it to the automated filling machine, whose nozzles squirt the required quantity of salsa into plastic containers.", "The machine then seals each container with a plastic safety film and presses on a cover.", "This is what the packaging process looks like in slow motion.", "It actually moves at about twice this speed.", "The filled containers now pass through a combination x-ray/metal detector.", "On the off chance a foreign object fell into the salsa during production, the machine flags the affected container and triggers an automated arm to eject it from the production line.", "This standard food-safety precaution ensures that every single container proceeding to labeling and then onto store shelves is \"a-olé\".", "To pump water from the ground, the windmill reaches to the sky.", "The blades catch the breeze and spin, while gears convert the spinning action into pumping action.", "This technology has been around for over 2,000 years.", "The first known water-pumping windmills originated in persia around 7 a.d. in 19th-century america, this was the wheel of progress-- a metal-bladed windmill that turned with greater force than traditional wooden ones, even in low wind conditions.", "Its superior pumping capacity made it indispensable to pioneers settling inland, away from rivers and streams.", "And today this same design continues to be a part of the rural landscape, especially when there's no electricity to run water pumps.", "Production begins with a 100-ton punch press.", "Once activated, it cuts triangular shapes from galvanized steel sheets, each with a slot in the center.", "Each cutout will be a windmill sail.", "They'll need 18 for each wind wheel.", "Once stacked, they transfer the sail shapes to a rolling station.", "The roller curls the steel to an exact curvature, producing a slightly bowed shape, which will efficiently capture the wind.", "Next, a worker wraps a metal rib around each sail.", "He taps the sides until it fits snugly to the sail.", "The rib has a tab that slots into the hole in the sail's center, allowing the two parts to interlock.", "Bands fit through the ribs to assemble the sails in groups of three.", "Next, a worker slides a metal loop over the guide wheel and drives the ends into holes in the gearbox, using a sledgehammer.", "He rivets the ends to the gearbox so that they're solidly ensconced.", "Next, he inserts the wind-wheel hub and shaft into the mainframe of the gearbox.", "He taps it to nudge it tightly into place.", "He then grinds the brake lever to shape it to the brake mechanism on the hub.", "This braking system is critical.", "It will stop the wind wheel from spinning out of control in high winds.", "He spins the hub and activates the brake several times to confirm that his machining is dead-on and that the brake system works perfectly.", "If it doesn't, he makes adjustments.", "Next, using a very toothy circular cutter, he carves grooves into steel blanks to shape the gears.", "The difference is quite obvious.", "He installs a set of these gears at the base of the metal loop and secures them with a metal pin.", "He checks their turning radius and then mates a larger set of gears to the smaller ones, ensuring that the teeth intermesh.", "This very substantial gear system will drive the guide wheel, creating the pumping action.", "Two metal parts, called pitman arms, link the gears to the guide wheel.", "A steel pin holds everything together.", "As the gears turn, the guide wheel rolls up and down the loop to complete a pumping cycle.", "Next, he screws a series of thin metal rods to the hub.", "They're called wheel arms, and they hold the windmill sails.", "The wheel arms fit into precut holes in the structure of the sail sections.", "He secures the assembly with nuts.", "Once all the sail sections have been mounted to the wheel arms, the windmill is ready for a spin.", "It's a test run to confirm the wind wheel and gears function flawlessly.", "It takes a crane to lift the 640-pound windmill to the top of its tower.", "Once it's in position, a worker guides the gearbox onto the mast pipe.", "Once it's secure, they hoist the helmet.", "It's a cone-shaped metal cap that will protect the gears from the elements.", "He bolts it to the top of the gearbox.", "With that job done, this windmill is ready to pump.", "It should last decades, providing water that is as free as the wind.", "Dragsters roar out of the starting line in a cloud of smoke, and then it's a blur.", "Traveling at speeds of up to 320 miles an hour, these hot rods rip through a quarter-mile racetrack in less than 4 seconds.", "It's why they need parachutes to slow down and come in for a safe landing.", "Blink a couple of times, and the race is over.", "Packing an incredible 8,000 horsepower, a dragster is at least 50 times more powerful than a subcompact car.", "With fat rear tires for traction and a tapered aerodynamic body, the dragster is engineered for one thing only-- speed.", "Production begins with the heart of the vehicle-- the powerful 8-cylinder engine.", "To reduce drag, the engine block is made of lightweight aluminum.", "A technician carefully installs the camshaft...", "And then fastens the timing cover to the front of the engine.", "The timing cover prevents oil leaks.", "He installs the crankshaft and hub.", "And once the eight rods and pistons have been loaded and connected, he tests their movement and function.", "Satisfied with their performance, he encases them in an oil pan.", "With the installation of the drive gears and other components, the engine block is now complete.", "They move on to the supercharger, a forceful blower that boosts engine power tremendously.", "This worker seals the seams with urethane and caps the ends.", "He slides strips of teflon between the rotors for extra sealing.", "All this sealing will ensure that the compressed air generated is directed down through the bottom of the supercharger and into the engine.", "With the supercharger now installed in its magnesium casing, he connects a cage-like starter to its drive pulley.", "It's now time for a test run.", "Blue streamers have been attached to the bottom of the supercharger.", "Their fluttering is a visual indication of the force of the air generated.", "The next employee attaches fuel pipes to the dragster's metal skeleton.", "They install the engine and the high-tech clutch.", "This racing clutch is equipped with five discs to transfer power from the engine directly to the wheels.", "Between every run, the dragster engine will be completely rebuilt.", "The rebuild should take just 22 minutes.", "So the team at the factory is on the clock to prove it can be done.", "The technician torques the cylinders to the engine block.", "He installs the fuel-distribution system and connects the hoses to the cylinder heads.", "Dragsters run on nitromethane, known as top fuel in the sport.", "It delivers more power per stroke.", "Still on the clock, the crew transfers the supercharger to the engine and connects it to the intake manifold.", "They use super-strength kevlar strapping to restrain the supercharger in the event of an explosion.", "They loop a belt over the gears that drive the supercharger.", "They adjust the engine valves...", "And then check to confirm the valves move freely.", "They cover the valves with this titanium lid to prevent oil leaks and keep all the parts in place.", "A technician connects spark plugs to the engine through slots in the cover, two per cylinder.", "With each step carefully timed and executed, it has taken 22 minutes for the crew to get this dragster engine in rip-roaring shape.", "In that 22-minute window, they also bolt the back wheels to the axle.", "They then slide the steering wheel into place in the cockpit and give it a try to confirm that it steers the tires at the front of the dragster.", "Also part of the 22-minute routine, a check of the fuel lever and the loading of the parachutes.", "They'll be tested at every pit stop before repacking.", "Finally, they fill up the tank with nitromethane fuel.", "This high-performing fuel is both volatile and corrosive, so there's a protective cover.", "This dragster is almost ready for the starting gate.", "All it needs is a sponsor to pay all the bills.", "One last test of the clutch, and this dragster is ready for the track.", "and it's off in a cloud of tire smoke." ]

{ "things": [ "Aluminum Canoes", "Wooden Stave Bowls", "Wheelchair Accessible Vans", "Marimbas" ] }

[ "When world war ii ended, an american manufacturer of fighter jets needed to land new business.", "The factory employed the same stretched-aluminum process used for shaping aircraft wings and came up with an aluminum canoe.", "No fighting machine, the aluminum canoe is designed for a peaceful day at the lake.", "Among watercraft, the aluminum canoe is the strong, silent type.", "It resists breaking and cracking when it comes up against a rock or any other underwater object.", "So this is one invention that is unlikely to sink into oblivion.", "Aluminum itself is too soft for canoe construction.", "So metals like magnesium, nickel, and silicone have been added to give it the needed strength.", "Factory employees unwind the aluminum alloy onto a work table.", "Using electric shears, they cut it to length.", "They lift the metal sheet onto a mold of of part of the canoe hull.", "They clamp the metal to a hydraulic system and activate it.", "It pulls and stretches the aluminum-alloy sheet to the mold, and it conforms to its shape.", "The molded sheet needs trimming, so they transfer it to a work table, and place a template over the contoured section.", "They clamp it into place.", "With a scribe, one of the workers etches the pattern onto the molded aluminum.", "The team then transfers the aluminum sheet to a jig and cuts out the pattern following the etched outline.", "They shape and cut a second part exactly like the first.", "The two symmetrical halves will form the hull of the aluminum canoe.", "They bake the hull halves at 390 degrees fahrenheit for eight hours.", "The heat strengthens the aluminum and adds rigidity to it.", "Out of the oven, a member of the team now aligns two halves.", "It's a perfect match, so he now lowers a large clamp.", "Once in place, he turns a crank to pull the two parts of the aluminum canoe together.", "Now tightly, clamped, he welds the two parts along the bottom.", "This joins them with a water-tight seam.", "With hand clamps, he tacks the two rounded ends together and welds here.", "He links the end welds to the one on the bottom, and the result is one continuous leak-proof weld from bow to stern.", "Next, the team positions an aluminum keel along the bottom seam.", "They reinforce it from the inside with the t-bar.", "They drive rivets through the t-bar, hull, and keel to secure the assembly.", "They install substantial aluminum guards on the bow and stern using rivets to secure them.", "These guards will protect the end welds.", "They brace the base of the canoe from the inside with six aluminum ribs.", "Welded, riveted, and with a good support structure, this aluminum canoe has really taken shape.", "They equip the rim of the canoe with aluminum gunnels, pounding them with a rubber mallet to improve the fit.", "Then a worker rolls non-skid paint on the inside so it won't become slick when wet.", "They bring incandescent heat lamps in, and the paint dries quickly in the warm glow.", "After just 30 minutes, the paint is dry.", "Then it's time to see if it will float.", "They transfer the aluminum canoe to a tank of water.", "They clamp a bar across the canoe to apply nearly 1,000 pounds of pressure-- more than the weight of two people.", "They check for leaks, especially around the rivets.", "There are none.", "Crossbars and bench seating complete the fabrication.", "There's one last bit of business, and that's the company insignia.", "This aluminum canoe is now ready for recreation.", "10 hours in the making, the fun has only just begun.", "Bowls have existed for thousands of years.", "Very early bowls, used to serve food or drink, have been found in china, ancient greece, and in certain north-american cultures.", "Modern bowls can be made from a variety of materials, such as ceramic, plastic, metal, and wood.", "Wood bowls come in many shapes and sizes.", "Many different kinds of wood are used to make bowls, such as rubberwood and teak.", "Acacia is also a type of wood used to make bowls.", "Workers cut flat planks of acacia using a large circular saw.", "The acacia was cut a few days ago in nearby plantations.", "Planks are cut to thicknesses required for bowl production and pre-dried on pallets, spaced apart for better air circulation.", "Using a table saw, a worker cuts the wood planks, now kiln-dried, into pieces long enough to make the bowl wall.", "Another worker uses a tilted table saw to cut the wood into shapes resembling a cone.", "Drying the wood eliminates water that might cause cracking later on.", "A worker trims the pieces, giving them the angle they need, so the staves can be rounded later on.", "Another worker smoothes the rough side of the staves with a spinning cutter.", "This also helps shape the wood pieces.", "Another employee lines up the staves on a table before applying glue.", "She spreads a wood-binding glue onto the sides of the staves.", "Once they're thoroughly covered with glue, she begins assembling the bowl by sticking the sides together.", "She assembles a few pieces at a time, handing them to another worker, who arranges the bowl's shape by leaning the staves against a center piece.", "They continue the process until all the staves are in place.", "Then they'll squeeze the staves tightly together.", "They stretch elastic bands around the outside of the eventual bowl.", "The elastics, held in place by a steel ring, squeeze the staves firmly against each other.", "With a hammer, she lightly taps the staves into place, making sure they are flush against each other.", "She turns the bowl over to make sure none of the staves around the top rim are sticking out too far.", "She then leaves the bowl to dry.", "About five hours later, they remove the elastics and, again, leave the bowl to harden for a full day.", "A template is attached to the eventual bowl, in order to cut a circular opening for the bottom piece.", "The template serves as a guide during the cutting process.", "A worker moves the bowl around, allowing the cutter to create a perfectly sized hole for the bottom section of the bowl.", "It's made of the same kind of wood-- in this case, acacia.", "A worker applies glue to the edges of the bottom hole...", "And to the outer edge of the round piece that goes in the bottom of the bowl.", "He inserts the bottom plate and uses a hammer to force it firmly into place.", "After another day of hardening, a worker places the bowl in a lave.", "With a variety of knives, he begins shaving off the wood.", "He starts on the inside wall of the bowl.", "Then he shaves the outside of the bowl, gradually giving it shape.", "He then uses sandpaper to smooth the surface of the bowl.", "Another worker then uses a lave to sand the surface of the bowl.", "He makes the surface as fine as possible.", "He must have a keen eye for detail in order to make the bowl surface perfect.", "A worker sprays a foodstuff varnish onto the surface of the bowl.", "Several layers are applied with drying and polishing after each one.", "If required, a stain is also applied.", "They place a sticker identifying the manufacturer on the bottom of the bowl.", "A worker then packages the wood bowl.", "With the bowl secure, the only thing tossed around will be the ingredients you put in it.", "The minivan was designed with families in mind, but it also revolutionized travel for people in wheelchairs.", "Retrofitted for wheelchair accessibility, the minivan offers unprecedented mobility.", "No need to wait for special wheelchair transportation when there's a minivan in the driveway.", "Convert a minivan and change a life.", "A wheelchair-accessibility conversion offers the convenience of a ride anytime.", "From the outside, the van will look no different.", "But inside, the modifications will be major.", "The total revamp starts with the removal of the van's middle and third-row seats.", "They pull out the carpet and completely strip the vehicle from the front seats to the back.", "Underneath, a technician saws off the exhaust system, and disassembles the rear suspension.", "The entire undercarriage behind the engine is about to be reconfigured to make way for a new lowered floor.", "The team also removes the 20-gallon fuel tank.", "They'll replace it with one of the same capacity to fit the new configuration.", "They cut out a large section of floor and relocate displaced wiring.", "They're now ready to roll the new floor framework into position below the vehicle.", "This steel structure replaces the original one and is strong enough to support the additional weight of a wheelchair.", "A motorized one can weigh as much as four adults.", "They slide the new steel floor into the vehicle and lower it into the framework.", "The new floor is significantly lower than the one the van came with, and it increases the wheelchair passenger's headroom by about 10 to 15 inches.", "After installing the new fuel tank, suspension, and exhaust systems, they return to the interior.", "A technician fits and binds carpet underpadding to the van.", "He installs the carpet and clamps it while the adhesive cures.", "With the back of the van rebuilt and carpeted, they now ready the wheelchair ramp.", "A technician applies a gritty material with an adhesive backing.", "He simply presses it to the ramp and smoothes out any air bubbles.", "This gritty material will provide a slip-resistant surface for the wheelchair to move across.", "He attaches a handle...", "And installs two cable assemblies to connect the handle to the ramp latches.", "He attaches a return spring to the handle assembly.", "He turns the handle and tests the latches to confirm that the mechanisms function properly.", "The team then links the wheelchair ramp to the new floor with a long hinge.", "They install stainless-steel trim over the hinge to protect it and also connect the counterbalance cables to the ramp.", "Hidden springs at the end of the cables provide tension to significantly lighten the load for the operator.", "The ramp weighs about 130 pounds, but the operator ends up lifting just 15 of that, due to the spring-loaded tension.", "They reinstall the interior plastic panels and repurpose the original second-row seatbelts.", "As they finish up inside, an employee puts the company name on the door of the vehicle.", "The wheelchair-converted van is now ready for a test drive.", "The operator unfolds the ramp.", "He folds away the new seats to make way for the wheelchair.", "He extends the tie-down belts and attaches them to the wheelchair.", "He wheels the passenger into the van...", "Locks the wheelchair breaks...", "And ties the chair to the floor.", "There are standard seatbelts to fasten, and then it's time to sit back and enjoy the ride.", "Seated in the converted minivan, the individual can now experience the freedom of the road.", "The marimba is a musical instrument similar to the xylophone, except with a wider and lower range of notes and metal resonators underneath the keys to amplify the sound.", "While the xylophonist uses hard rubber mallets, the marimbist usually strikes the wooden keys with a variety of mallets covered with wound yarn.", "the marimba keyboard is chromatic, meaning it includes all the semitones of a musical scale-- the equivalent of the 12 white and black keys on a piano.", "Each wooden key has a resonator, an amplification tube underneath, tuned to the same note.", "When the mallet strikes, the resulting vibration causes the resonator to hum that note, transforming the otherwise thin, muted sound into a louder, richer tone.", "They keys are fashioned from honduran rosewood, which is hard and dense, yet elastic.", "After cutting the thickness and width, they set the dial of this custom-made saw to the note they're making, which positions the wood to be cut to the correct length-- no measuring required.", "Next, using a router, they round off all the edges.", "When a key has sharp edges, it's more likely to chip or splinter when struck, even though marimba mallets are soft and frequently covered with wound yarn.", "The next step is to drill holes at the nodes, which are specific non-vibrating points on the key.", "The nodal holes are for the cord that will suspend the key over it's resonator.", "Now a computer-guided milling machine sculpts a very precise arch in the underside.", "This roughly tunes the key.", "To fine-tune the key, they must tune the fundamental note plus the first and second overtones-- the subtler notes that sound simultaneously with it.", "When the tuner strikes the key, an electronic machine reads the exact frequency of the vibrations.", "He repeatedly taps, takes readings, and sands the arch...", "Until the fundamental and overtones are pitch-perfect.", "They seal the wood with lacquer.", "This protects the key from moisture penetration, which would alter the key's tuning.", "For each key, they make a resonator out of brass tubing.", "The lower the note, the wider and longer the resonator.", "Some are so long, they must be j-shaped or u-shaped to fit under the keyboard.", "To make those curves, workers use short, angled pieces of tubing to join longer, straight pieces.", "They divide the resonators in groups then bolt each onto a painted steel rail.", "There are six groups of resonators on this full-range marimba.", "The instrument is nearly 10 feet long.", "The ends of the frame are height-adjustable.", "Between the frame ends, a center pole receives the six resonator sections arranged shortest to longest.", "Then, running over the resonators, wooden crossrails suspend the parts to support the keyboard.", "Under the lowest and longest keys are those curved resonators, fashioned from angled, soldered pieces of tubing.", "Posts mounted in the wooden crossrails support the cotton cord running through the key's nodal holes.", "At the end of each resonator is a patented tuning plug.", "After using a lave to shape a piece of hard plastic into a cylinder with a required diameter, they saw off a slice about the size of a hockey puck.", "They then quarter the slice, running the cuts just 90% of the way through.", "These slots make the plug flexible.", "Next, they drill a threaded hole through the center to the same depth as the slots and wrap the edge in polyethylene gasket tape.", "The tape smoothes the surface, helping the plug glide easily into the resonator.", "Then they thread a wing screw into the center hole and insert the plug into the corresponding resonator.", "To tune the instrument before playing, you move the plug up or down until the node is the exact same pitch as the key above.", "Then you turn the screw to push the sections outward, locking the plug in position.", "everything from this point on is in the marimbist's hands." ]

{ "things": [ "Glass Bottles", "Hacksaws", "Goalie Masks" ] }

[ "Today on \"how it's made\"...", "Glass bottles...", "Hacksaws...", "And goalie masks.", "Whether they're colored or clear, glass bottles and jars are green.", "No trees died to make this eco-friendly packaging.", "Glass is made of natural ingredients that are abundant.", "You can recycle glass endlessly, and making it uses less energy than producing metal or plastic.", "The recipe for glass combines about a half a dozen natural, raw materials, but the main ones are silica sand, soda ash, and limestone.", "Silica sand usually makes up about 45% of the batch.", "The soda ash helps melt the silica evenly.", "It comprises about 15%.", "A limestone content of about 10% make the finished glass more durable.", "They combine these ingredients with recycled glass called cullet.", "The factory's equipment feeds precise amounts of the materials into a furnace.", "Over a full day, the fiery heat-- 2,730 degrees fahrenheit-- melts everything together, producing a gooey liquid that's the consistency of honey.", "The molten glass pours out of the furnace.", "Sheers cut the flow at precise intervals to produce cylindrical gobs.", "Each gob is the exact amount required to make one bottle or jar.", "They drop to a device called the scoop.", "The scoop moves them to troughs that feed them to jar-forming and bottle-forming machines.", "A gob of molten glass goes into a preliminary mold.", "In a matter of seconds, it comes out as what's called a parison, a miniature version of the final bottle.", "Each parison then moves into a blow mold, the cavity of which is the shape of the final bottle.", "The equipment blows the compressed air into the parison, stretching the glass outward toward the wall of the mold cavity.", "This process creates the final bottle shape and hollows out the inside.", "These are amber-colored beer bottles.", "The color is produced by adding small amounts of iron, sulfur, and carbon to the glass mix.", "The factory uses a similar manufacturing process to produce other types of bottles and jars.", "In this run, the company is making 375-millimeter wine bottles out of clear glass.", "This run is producing 375-millimeter liquor bottles, also out of clear glass.", "But this mold has a special feature-- a recessed insignia on one of the walls, which produces a raised insignia on the front of the bottle.", "After the bottles leave the forming machine, they travel through flames, otherwise they would cool down too quickly and crack from thermal shock.", "A loader now gently pushes the bottles into what's called an annealing lyre.", "The bottles cool at a controlled rate as they move through the lyre.", "This releases stress from the glass gradually.", "As the bottles exit the annealing lyre, a sprayer coats their exteriors with lubricant.", "This enables them to move smoothly through the rest of the inspection and packaging line.", "The bottles now line up in single file to head into the automatic inspection station.", "As the machine spins each bottle, cameras and probes check for imperfections such as cracks or bubbles.", "The inspection equipment then examines the top to check dimensions and insure the threads for the screw cap are molded correctly.", "Before shipping, a worker does a final visual inspection.", "The proportion of cullet and glass can be as high as 90%.", "Cullet melts at a lower temperature.", "So for every 10% of cullet in the mix, the factory uses up to 2 1/2% less energy to produce its glass.", "Now that's an incentive to recycle.", "The world of saws is made up of many marvelous tools-- big saws and jigsaws, handsaws and band saws, backsaws and hacksaws.", "They all have their specific purpose.", "Hacksaws are chiefly for cutting metal or other tough materials.", "So what keeps hacksaws on the cutting edge?", "Hacksaws come in many shapes and sizes.", "Companies make hacksaw blades out of a wide range of steel alloys.", "Here a thin band of steel feeds into a machine that cuts it into blanks 10 to 12 inches long and a half-inch high.", "Workers load 300 blanks at a time into a jig.", "They lightly hammer them to compress them into a block for easier cutting.", "They then feed the block into a machine called a mill grinder.", "It cuts teeth into the upper side of the blanks.", "A water-based lubricant washes away the metal particles.", "This hacksaw model has a 24-point blade, which means there are 24 teeth to every inch.", "Workers use an ordinary paintbrush to remove any metal residue.", "The quality-control department inspects each blade for flaws.", "Then it's off to the next phase.", "Next, a separator detaches each of the 300 blades, aligns them, then sends them through a setting machine.", "The machine bends the teeth to either side at a slight angle.", "This is called offsetting.", "It'll enable the blade to clear away particles as it saws, preventing it from jamming.", "Now it's time to harden the teeth.", "The factory does this by heat-treating the metal.", "A worm gear aligns the blades to enter a heating coil.", "In this process, the electromagnetic heating coil heats the teeth to temperatures as high as 2,200 degrees fahrenheit depending on the type of metal.", "This takes no more than two seconds.", "After the blades exit the heating coil, the surrounding air cools them down over the next several hours.", "This phase is called air quenching.", "The blades are now ready for printing.", "An offset printing press applies ink to raised lettering on a cylinder.", "That cylinder transfers the ink to strips mounted on another cylinder.", "These strips then print the company name, the blade length, and the number of teeth per inch on the side of the blades.", "Now a machine inserts the blades in groups of five into slots called fingers.", "The fingers rotate the blades and place them on a conveyor belt.", "The machine raises the blades and tapes them together at one end.", "This makes it easier to transport them to another part of the factory where production continues.", "Next, the hacksaw's frame, the component that holds the blade.", "Workers place the frame components in a jig that's positioned on a rotating carousel.", "A robotic welder fuses the components.", "A press punches three holes in the handle for attaching a foam or plastic grip.", "Workers fit the two halves of the grip in a sonic welder that fuses them using high-frequency sound waves.", "The sound waves create friction at the seam.", "This generates enough heat to melt the parts together.", "Now the frame is ready for the blade.", "An automatic device tightens a wing nut to put tension on the blade.", "A final quality-control check.", "With each randomly selected blade, the testing machine cuts through a block of stainless steel.", "The machine performs this test six times per blade.", "Then the computer calculates the average number of strokes.", "If the average falls within the norms for this particular model, the batch gets the thumbs-up.", "Goalie masks are all about putting up a tough front.", "It's not just their protective shell and cage.", "Their wild paint jobs are designed to intimidate.", "Incredibly, back in the 1960s, the first masked goalies were ridiculed by fans who viewed the masks as a sign of weakness.", "It was a case of adding insult to injury.", "Today these masks allow the goaltender to play it safe, so they're far less likely to be sidelined by a serious injury.", "They start with a plaster mold of an average joe.", "They plug the mouth hole with plasticine.", "This insures that the mold won't spring any leaks while they fill it with plaster of paris.", "They let it dry for half an hour.", "Then they pull off the initial mold to reveal the solid impression.", "They press plasticine onto strategic areas.", "This mimics the foam safety guards that cushion every mask.", "The final result is called a plug, and it will be used to make a two-part compression mold.", "After applying a black sealer, they polish it smooth, eliminating imperfections that would be visible on the mold they're going to make from it.", "Over at another station, a worker in protective garb unrolls fiberglass fabric.", "He cuts and layers sheets of it, then draws patterns onto the tops one, spacing the shapes closely together to minimize waste.", "The goal is to score 100 goalie masks from one roll of material.", "Using a disc cutter, he slices through 25 layers of the fiberglass fabric.", "Then he stacks various composite fabrics-- several of the fiberglass one and patches of kevlar-- for reinforcement.", "Kevlar can absorb so much impact, it's also used to make bulletproof vests.", "He places more fabric over the kevlar.", "He spreads an epoxy resin onto each layer.", "He drapes them over a mold that's been made from the plug and smoothes the material to eliminate air pockets as he continues to layer and glue.", "He's laminating all the pieces together to form one.", "He trims away the ragged edges...", "And then places the inside portion of the mold into the outside one.", "The wet fabric is now sandwiched between two mold pieces.", "He lowers a one-ton press to compress the layers of fabric as the resins between them continue to form a bond.", "He adds some clamps to keep things tight.", "After 20 minutes, he pries the laminated fiberglass shell out of the mold.", "This is one very tough shell.", "It's the raw form of a goalie mask, but it still needs a lot of work.", "So it's over to the trimming-and-grinding station.", "He places a trim jig over the shell.", "Using a high-speed router, he cuts an opening for the cage.", "He slices off the flash with a disc grinder.", "And then he sands and grinds the edges.", "He drills holes to attach various fasteners.", "Then he carves out larger holes for ventilation and to reduce the mask's weight.", "Coming up next...", "Watch as the paint pros go to work on these shells.", "The makers of goalie masks have turned safety into an art form.", "The goalie mask has become a canvas for some very bold designs and colors.", "It's a kind of psychological tactic to intimidate the other team, and it also scores points with the fans who like the cool paint job.", "They prep the mask by roughing it up with an orbital sander.", "Then they pour a sealer into a container.", "The technician wears a charcoal respirator because the emissions are toxic.", "He adds the activator solution...", "And a reactive reducer and stirs the sealer together.", "Then he sprays the sealer mix onto the masks.", "The finish will cure and harden as the chemicals in it generate their own heat.", "Next, this system stirs up some hot hues automotive paint as the technician sprays a vivid gold base coat onto the masks.", "Computer graphics created with signlab software are sent to a plotter that cuts out adhesive vinyl paint masks.", "He pulls away unneeded vinyl around the stencil, a process called weeding.", "Then he presses the vinyl stencils against the goalie mask and peels off the paper backing.", "Applying a stencil to the crown is tricky because the surface is curved with ridges, so it doesn't lay flat.", "He lifts and cuts the pattern with a utility knife and then straightens it out.", "This mask is starting to look pretty impressive, but they cover the whole thing with white paint.", "It's a temporary cover-up.", "This process is all about layering patterns and color.", "They apply more vinyl shapes.", "And then, using a pressurized paint system, they spray everything bright red.", "Next, an artist airbrushes some shadowing onto the now barely visible image of a leaf.", "He peels away some of the paint-mask vinyl.", "And it's time for a really neat effect.", "He sprinkles the surface of the mask with water.", "Then he mists it with paint, and the water droplets catch the paint.", "He blasts it with a heat gun.", "The water evaporates, but the paint dries in droplet form, giving the mask a frosty look.", "He airbrushes a drop shadow around some lettering, dispensing with the usual safety gloves for this detail work.", "And now all is revealed as he peels away the vinyl.", "The goalie mask is showing its true colors.", "But wait-- a little touch-up job is needed.", "He traces the pattern onto see-through paper and then transfers it onto bristol board.", "He cuts it out with a utility knife.", "Then he aligns it with a shape on the mask and precisely airbrushes around it to make the smudge disappear.", "With a final clear coat, this mask has visual impact.", "It makes a colorful statement.", "And now it's time to put all the pieces together.", "She screws on the stainless-steel cage and applies a little glue to reinforce the adhesive-back foam cushioning.", "She attaches the sweatband with velcro so it can be removed and washed.", "And then she moves on to the back plate.", "She threads the harness through the back plate to the front of the mask to attach them.", "The harness is elastic, so it gives the mask some flexibility.", "Now it's ready for some ice time.", "And with their various custom paint jobs, these masks all say the \"puck\" stops here." ]

{ "things": [ "Socket Sets", "Leather Shoes", "Aluminum Water Bottles", "Bike Chains" ] }

[ "The invention of the socket wrench in 1864 put a whole new twist on fastening things.", "With the socket wrench's ratchet mechanism, the user could tighten bolts in a continuous motion without breaking to refit the wrench to the fastener.", "It was a real time-saver.", "Modern socket wrenches come with a range of sockets and extensions to handle the nuts and bolts of many different jobs.", "They start with this coil of thick steel.", "It travels through a die which straightens it to a knife that slices it into short billets.", "A machine then drives a series of forming tools into the billets.", "The tools force them into a socket shape and create the all-important hexagonal opening that matches the profile of the nuts and bolts.", "To get rid of lingering lubricating oil, the parts go for a tumble through a spiral washer/dryer system.", "A conveyor delivers them to a computerized cutting tool.", "It removes sharp edges and sculpts a bevel on the socket's inner rim so it will slide onto bolts more easily.", "It takes just seconds to improve this socket's profile.", "Different tools then sculpt the square opening in the drive end of the socket.", "That's the part that locks onto the end of the ratchet wrench.", "A powerful rolling stamp now engraves the part's size and the company name onto it.", "Once those details are out of the way, it's into a flaming oven to undergo a heat-treating process.", "A rapid cooldown follows the heat treatment, hardening the metal.", "The sockets now toss about in this rotating chamber as they're blasted with very fine steel particles.", "This cleans the parts and buffs the parts, but there's much more polishing to come.", "They clamp the sockets onto a rotating table.", "It delivers the part to a grinding belt for a very vigorous polishing.", "You can see the difference this makes in the part on the right, but these sockets need to be absolutely flawless.", "So they next go into a tub of ceramic stones.", "They rub mild acid onto the parts to get rid of any small blemishes that remain.", "The parts then receive a thorough wash and rinse, which prepares them for chrome plating.", "Now freshly chromed, the sockets look way too nice to be immersed in this brownish stuff, but it's actually a rustproofing solution to protect them from corrosion.", "They lock the tub of sockets in a centrifuge machine.", "It spins the parts to get rid of the excess rustproofing liquid.", "And now these sockets are ready to shine on the job.", "Attachable extensions improve the reach of the socket wrench.", "Forming equipment swings into action, pressing steel billets into dies to mold them into the rough shape of an extension.", "After a wash and dry, it's over to a lathe.", "And as the extension spins, cutting tools create the squared opening that allows it to be attached to the wrench.", "Cutters then go to work on the other end.", "They shape it so it will fit into various sockets and shave the shank to reduce its diameter.", "Next, a rolling stamp cuts a knurled texture into the socket-wrench extension, creating a much less slippery surface to hang on to.", "They insert a stainless-steel spring into a hole formed at the end of the extension...", "Then scoop up a steel ball so it sits in the cavity above the spring.", "A machine then press-fits it to the extension.", "This creates a mechanism onto which the sockets attach.", "It takes about three days to complete this socket set, but it will equip you to handle jobs of many sizes and just about any tight situation.", "If you're a lover of fine footwear, when it comes to dressing your feet, nothing beats leather because, unlike synthetic materials, leather lets your feet breathe.", "And high-end leather shoes feature superior construction that makes them lightweight and comfortable to wear.", "The vision originates with a design sketched on a flexible plastic sheet.", "To help the stylist perfect the design, they put it on a rigid foot form called a last.", "Exotic skins have natural variations throughout, so a specialist must hand-cut the pattern pieces to ensure the right and left shoes match well.", "They use a splitting machine to shave off a layer from the underside, equalizing the thickness of all the pieces.", "Then a skiving machine thins the edges so the pieces will be easier to sew together.", "They punch decorative holes into certain pieces with a manual press, so it's up to the operator to make sure the distance between holes is consistent.", "The top of the shoe is called the upper.", "They sew together the upper pieces, then hammer the stitches to make the seam smooth and flat.", "Next they glue a narrow leather strip along the border of the upper to hide the leather's unfinished edge.", "This also produces a decorative trim.", "Now they attach a lining made of goat leather and flax.", "This style of lining fits snugly over the last, a particular type of construction that allows for a more comfortable type of insole.", "They put the lining inside the upper and slip them onto the last.", "Then they glue on the insole.", "This type consists of a rigid section-- the black part-- and a more flexible section-- the white part.", "Now they glue the lining to the upper and put the front of the shoe, called the point, into a machine that grips the edge of the leather and pulls it straight.", "The next machine's mechanical fingers wrap the edge underneath and glue it, pulling evenly all around so that everything's symmetrical.", "The next machine does the same thing at the back of the shoe.", "They grind down the leather edge, creating a flat, even surface that's ready for the sole.", "Next they heat the leather to make it malleable and hammer until the upper assumes the shape of the last inside.", "The hammering also rids the leather of any wrinkles.", "They coat the underside with glue and carefully position the shoe's leather sole.", "The glue takes about 10 minutes to dry.", "Then they run the edge of the sole through a splitting machine.", "This separates a thin layer which they now sew to the upper.", "Durable twine and a heavy-duty loop stitch ensure the upper and sole remain inseparable.", "To hide the stitching, they glue and grind down the edge.", "A thorough polishing gives the sole a slick-looking finish.", "Every pair of shoes this factory produces is polished by a specialist, who creates just the right shading to bring out the leather's best features.", "This is the last step of roughly 200 manual operations that go into producing just a single pair of these luxurious leather shoes.", "It was swiss hikers who carried the first aluminum drink bottles in the early part of the 20th century.", "Today's lightweight bottles can be reused endlessly, meaning less waste in landfills.", "They can also be recycled, so making one is not a wasted effort.", "Some of those first trailblazing bottles still survive today, reminding us that this kind of container is made to last.", "Today's bottle starts with an aluminum puck 2 3/4 inches in diameter.", "The puck travels down a chute into a punch press.", "It uses 660 tons of force to stretch that little puck into a long cylinder with a bottom.", "A blade chops the open end down to the correct size, and then a tool pushes it onto a conveyor that sends it down the line.", "The aluminum cylinder lands on a wheel which relays it to the next station.", "There, machinery moves the cylinder's open end into position for tools to squeeze it into a bottleneck.", "The tools pinch the metal a total of 26 times to draw the open end down to half its original diameter.", "This gentle forming process results in less stress on the metal.", "The last tool presses a threaded ring into the inside of the bottle for screwing on the cap.", "The process leaves the threaded neck a lot thicker than the rest of the bottle so it will hold up to heavy usage.", "Now the bottles head into a wash station.", "They get a really good scrubbing to remove the lubricating oil from the forming process.", "They then travel through a dryer, and after a few minutes, they emerge clean and ready for the next operation.", "The interior wall of the aluminum drink bottle is about to be lined with a microthin, high-tech polymer.", "This revolving device picks up each bottle using suction and delivers it to an individual sprayer.", "The spray nozzle coats the inside of this container with a polymer.", "The liner has been specially formulated to be chemically inert, which means it won't absorb or transfer flavors.", "At this point, the coating is powdery, and you could wipe it off with your finger, but that's just temporary.", "As they bake it, the powder will solidify and bond completely to the inside of the bottle.", "The bottles move through an oven that's heated to 356 degrees fahrenheit for 10 minutes.", "The liner doesn't add much weight to the bottle.", "Here they weigh one before lining and after, and the difference is just a few grams.", "Now the bottles spin by a gauntlet of spray guns for an even coat of paint.", "Like the inner liner, this outer veneer will need to be baked on.", "When it dries, the paint takes on a glossy look.", "An automated squeegee silk-screens designs onto the bottles.", "A jet of air dries the ink between printings as they build up the artwork using different colors.", "And now it's time to screw on the cap.", "As she caps the bottle, this worker performs a final inspection of the product.", "From a small aluminum puck to a handy drink bottle-- incredibly, this transformation has taken just three hours.", "And in its various styles, this reusable bottle is sure to make a lasting impression.", "Pedaling a bicycle causes a chain reaction that sets wheels in motion.", "A bicycle chain is essentially a roller chain.", "It's designed specifically to transfer pedal power to the bicycle's rear drive wheel.", "With a good bicycle chain, you can go far or, at the very least, take a short spin around the hood.", "The chain is the driving force in a bicycle's transmission system.", "It travels over gears in a perpetual loop to keep the cyclist moving forward.", "Actions like shifting gears or braking will regularly put this critical mechanism to the test.", "It all starts with this punch press.", "It cuts and presses steel into the shape of the chain's inner links, which looks a lot like a figure eight.", "Incredibly, it generates 10,000 links per hour.", "Each of these figure-eight links has been made to interconnect, and their contours allow them to travel easily across the bike's gear sprockets.", "They send samples of the links to a measuring station to confirm the space between the holes is precisely 12.7 millimeters.", "The tester also gauges the diameter of the holes, which must be accurate to within a fraction of a millimeter.", "Then the links bake in an oven at more than 1,500 degrees fahrenheit.", "The blazing heat, followed by a quick cooldown, hardens the steel.", "They now shovel these inner links into a doughnut-shaped machine.", "They add ceramic and silica powders...", "And pour in a small amount of water.", "They then screw the lid on this machine.", "It shakes vigorously, causing the powders and water to form an abrasive paste that polishes the links.", "They load the polished inner links into a metal basket and shut the door.", "Machinery plunges the basket into a series of chemical baths to give these inner links a nickel-teflon veneer.", "The nickel-teflon surface will resist corrosion, and its smooth texture will allow the chain to travel easily over gear sprockets.", "The bike chain's outer links get a different kind of finish.", "Unlike the inner links, they don't travel over sprockets, so a simple nickel plating will do.", "They're now ready to assemble the chain one section at a time.", "Tubes feed the parts one by one into this assembly machine.", "Gripper arms adjust their position to assemble the links to other chain components, such as retainer rings and spacers.", "The machinery presses pins into the links' holes to secure the assembly.", "Then grippers move the completed section of chain down the line.", "It takes a whole lot of little pieces to build one short section of bicycle chain.", "The sections are linked together in one long chain, which now winds by an inspection station to be examined for flaws.", "After that, the chain takes a dip in hot oil, which lubricates the links to prevent squeakiness and wear down the road.", "The chain exits the lubricating station and travels by wads of absorbent material, which soaks up the excess grease.", "A laser tool then signals the location where the chain is to be cut, and a blade chops it at the exact spot.", "A standard bike chain is just over 56 inches in length.", "It consists of 114 inner links and 114 external ones, so it's got what it takes to go the distance." ]

{ "things": [ "Cookware", "Inlaid Boxes", "High" ] }

[ "A quality pot and pan has the ability to heat uniformly throughout so that food cooks evenly.", "Copper is by far the best heat conductor, but copper cookware is very expensive.", "Aluminum conducts heat well but isn't durable.", "So many cooks use stainless-steel cookware that contains aluminum.", "This high-end line of stainless-steel cookware has an aluminum core running throughout.", "Production begins with two stainless-steel sheets.", "Using a spot welder, workers tack them together along one side.", "Then they lay the connected sheets onto an assembly fixture.", "A vacuum arm pulls up the top sheet, and they insert an aluminum sheet in between.", "This metal sandwich goes onto a conveyor that takes it on a 10-minute ride through an oven.", "The heat-- 700 degrees fahrenheit-- softens the metal.", "This preps them for the bonding and shaping operations to come.", "From the oven, the metals enter the first mill, which uses electric current to heat and bond the three layers into one.", "Now it's into a second rolling mill.", "This one strengthens the bond.", "That steam you see is the water-soluble lubricant evaporating against the hot metal.", "Now the bonded metal travels to a second oven for reheating.", "This further strengthens the bond.", "From there, it's into a 110-ton press.", "It forces down a die to cut out the starting shape of the piece of cookware they're making.", "They clean off any debris from the metal cutting.", "Even a minute shard getting under the press would damage the metal.", "Now the disk goes into a 220-ton press containing a forming tool, which forms it into the shape of a 10-inch frying pan.", "A sheet of paper between each shaped pan prevents scratches.", "They install different forming tools on the press to produce different types of cookware, from saucepans to stockpots.", "Now that they've formed the shape, they need to do some refining.", "This trimming press first removes excess metal around the perimeter.", "Next comes what they call edge conditioning.", "The perimeter trimming left the rim rough, so now they smooth it by running it against a cutter at high speed.", "The next stop is a polishing machine with an abrasive belt.", "The pan's interior surface rotates at high speed against the belt.", "The result is a high-gloss finish.", "Now for the exterior.", "The pans go onto a rotary buffer.", "Each pan runs against 10 progressively finer buffing wheels.", "By the end of the circuit, the stainless steel has a mirror finish.", "It's time to get a handle on this cookware.", "First, they use a press that's essentially an industrial-strength hole puncher.", "It applies nearly 20 tons of force to perforate the metal.", "Workers position rivets in the holes, then use another press to squeeze them flat.", "As the rivets spread outward, they secure the handle firmly in place.", "This company's top-of-the-line stainless-steel cookware contains a copper core within the aluminum core-- a structure designed specifically for induction cooking, the latest culinary technology.", "A thin cut along the perimeter exposes the copper within, giving this high-end cookware a signature look.", "After all, performance and style are everything in an industry where the competition's always heating up.", "For centuries, people have stored their possessions in special boxes-- jewelry chests, watch cases, music boxes.", "Although designed for storage, they're often as beautiful and as treasured as the goods they hold-- truly ornate, handcrafted works of art in their own right.", "These wooden boxes are handcrafted and decorated with beautiful wooden inlay designs.", "To build the box structure, the carpenter uses linden, a soft wood that's ideal for carving.", "He begins by cutting slots in each end of the four sides.", "Then he glues wooden inserts, called biscuits, into one side of each piece...", "Leaving the slot on the other side empty.", "Then he assembles the sides by fitting the biscuits of each side into the empty slot of the connecting piece.", "After clamping everything firmly together, he checks the size by tracing a template of the final shape.", "Once the glue is dry, this computer-guided machine cuts the sides to that shape.", "The next step will be to veneer the sides with a decorative wood, such as olive, rosewood, redwood, or california burr walnut.", "For aesthetics, workers tape four identical sheets together so that the grain of the wood appears in mirror image.", "The carpenter then applies a coat of glue onto the sides of the box and presses on a piece of veneer.", "They've embellished this one with some inlay work beforehand.", "He presses the veneer flat to force out any trapped air.", "This design calls for a black strip of bolivar wood to ornament each corner.", "To make the box cover, the carpenter uses a machine called a pantograph.", "He moves the head in the middle over a model of the cover.", "This simultaneously moves routers on each side to shape a piece of wood to the same form.", "Meanwhile, the inlayer lays a drawing of the cover's decorative design on a stack of wood boards and cuts out inlay pieces for several covers at once.", "To color the edges of select pieces, the inlayer burns them in hot sand.", "Some types of wood turn brown-- others, green.", "After hand-cutting the design outline in a veneer sheet, the inlayer uses tweezers to position the pieces of inlay one by one.", "A sheet of adhesive paper underneath holds the pieces in place for now.", "Once the design is complete, the carpenter fills the crevices around the pieces with plaster tinted to blend in.", "A final layer of plaster goes over the entire design to hold all the pieces in place permanently.", "Once the plaster hardens, he covers the entire inlaid sheet in glue, further securing the inlaid pieces.", "Now he flips it over, then peels away the adhesive paper...", "And voilà.", "He glues the inlaid sheet to the box cover.", "Pressing it down firmly is a delicate process when the cover's curved like this one.", "One wrong move, and crack.", "After lacquering the edge of the cover, workers apply four coats of high-gloss varnish to protect the wood.", "Finally, they screw on the box bottom, mount the cover to the box with hinges, install any other hardware, such as keyholes, and if it's a music box, install the musical movement.", "Conventional gas water heaters are only about 75% thermally efficient.", "But high-efficiency water heaters are up to 96% thermally efficient, meaning almost all the heat they generate gets transferred to the water.", "It's the unique heat exchanger that makes these water heaters so energy-efficient.", "The heat exchanger resides in the center of the unit.", "It's made of steel pipe that goes through a process called mandrel bending.", "Mandrel bending prevents the 12-yard-long pipe from kinking as it turns into the shape of a coil.", "A welder fuses steel rods to the sides of the coil, making the flexible heat exchanger suitably ridged.", "Next, a machine pumps a ceramic enamel through the pipe, from the bottom up, to ensure full coverage.", "This coating protects the interior of the pipe against corrosion.", "It takes about 6 minutes to fully coat the inside of the pipe and drain the remaining liquid.", "It takes about 15 minutes inside a furnace for the coating to cure and become rock hard.", "Now it's time to seal the heat exchanger inside an inner tank.", "They first set it down on a base, then cover it with a steel enclosure.", "It's this inner tank that holds the hot water.", "The tank then goes into a vertical press that pushes it down onto the base.", "A computerized arc-welding machine welds the tank together.", "A technician then pressurizes the tank with air, and, using water, he checks for leaks until he's satisfied there are none.", "He then pumps ceramic enamel into the tank, and a tumble-coating machine shakes up the corrosion-resistant enamel, fully coating the inside of the tank as well as the outside of the heat exchanger.", "A technician then inserts cold-water inlet tubes into each tank.", "He also inserts aluminum anode rods to help protect the inside of the unit by absorbing corrosive elements in the water before they can attack the steel tank.", "After attaching all the plumber's fittings, he installs a second anode rod that gives the tanks double corrosion protection.", "Now they put on what's called a rolling foam stop that helps them fit a painted jacket over the shell and maintain it in place.", "Here, they attach the gas valve that is used to light the burner.", "A painted cover then goes on the top of the jacket.", "They connect a blower to the tank.", "The blower is what expels the burner's spent gases to the outside air.", "The next step is to hook up a burner to the gas valve.", "This burner is what heats the air that goes through the heat exchanger, which, in turn, transfers its heat to the water.", "A technician now fills the cavity between the inner shell and outer jacket with high-density expanding foam.", "This foam insulation is about 2 inches thick and goes all around the circumference of the tank to prevent heat loss.", "The unit then gets a cosmetic cover that conceals the blower.", "Finally, a technician hooks up and tests each unit.", "He follows strict quality-control standards which guarantee that the burner and all the fittings and connections are working properly.", "Only then is the unit ready for shipping.", "High-efficiency water heaters can deliver all the hot water you need and save you money while they're at it.", "The motor scooter as we know it hit the streets just after world war ii.", "Europe was rebuilding its devastated infrastructure, and the scooter offered affordable transportation at this critical time.", "So in a small way, it helped put the postwar economy on the road to recovery.", "Many decades after it was first introduced, the scooter is still big on the streets, and the uncertain cost of fuel is one reason why.", "Production begins with a step-through chassis.", "It's often built on a tubular frame.", "But at this factory, they have a unique approach.", "Robots join three pieces of molded steel together by executing hundreds of precision welds.", "This transforms the three molded pieces into one solid chassis.", "After rustproofing and priming, the chassis gets a paint job and a clear protective veneer.", "They cure the finish by baking it on.", "Then they polish away any imperfections.", "The chassis moves down the line, where a technician installs its radiator system.", "The next assembler clamps the radiator's wiring and hoses to the vehicle framework.", "Some plastic edging helps define the lines of the scooter.", "This model receives a 4-stroke, 150cc engine, which will make this scooter a bit more peppy than some.", "It also has an automatic transmission.", "Once the rear wheel has been installed, the worker hoists the engine over to the chassis.", "He guides it into place just behind the passenger seat and then bolts it to the steel framework.", "Next up is the steering column with the front brakes and wheel hub already attached.", "The technician assembles it to a front fender...", "Then inserts the steering column in its slot at the front of the scooter body.", "Securing it is a delicate business.", "He tightens this special tool to gently squeeze the assembly together.", "This technique prevents damage to the components.", "The handlebar is loosely screwed into place for now but will be properly tightened down later.", "This scooter's front wheel has a 12-inch rim.", "That's quite a bit bigger than those on early scooters.", "The bigger wheels add stability and allow this scooter to reach a higher speed than its forerunners.", "To illuminate the road ahead, this 2-wheeler will need a headlight.", "It mounts onto the handlebar.", "A technician then puts this scooter to the test.", "She checks the headlight and all the signal lights.", "She engages the motor and throttles up to check both wheels and the speed gauges.", "Once it gets the okay, a worker installs the cover on the horn and then accessorizes the scooter with pieces of trim.", "And now they install the scooter's saddle on a hinge over a storage compartment.", "Another buff and polish makes this machine gleam.", "The worker then installs pop-out footrests for the passenger.", "After one last shine, it's over to the quality inspector.", "That's the lady in yellow.", "She scrutinizes the vehicle from all angles.", "And when she gives it the green light, this scooter is ready to merge with traffic.", "Life on the street can be tough, but this design has had a lot of road testing over the years, and that's what makes the motor scooter a classic." ]

{ "things": [ "Thinning Shears", "Wagon Wheels", "Toaster Pastries", "Violin Bows" ] }

[ "Thinning shears are scissors with at least one comb-like blade.", "When the blades come together, some hair falls between the teeth of the comb, and that hair is cut while other strands are left intact.", "A few quick snips, and this handy tool can do a lot for your style.", "It's often necessary to go many lengths to achieve the right look.", "Stylists use thinning shears to layer a cut from the inside.", "This removes bulk to give hair height.", "When it comes to improving your hairdo, thinning shears definitely have the teeth for the job.", "They start with stainless-steel rods.", "The rods ride a magnetized conveyor up to an induction heater.", "It heats each rod from the ends until it becomes white-hot and soft.", "The rod is now ready for forging.", "A worker moves the hot rod back and forth over a die as a hammer slams into it.", "This flattens and forms it into the shape of two scissor blades.", "The forging leaves a lot of excess steel around the blades.", "They cut away that excess.", "Reheated now, a worker plunges the blades into a lead bath.", "Then he dips them in oil, standing back as they flame up.", "The lead bath and the quick cooldown harden the steel.", "Another worker then clamps a blade into position.", "A cutting wheel rolls into action and carves a comb profile into the blade.", "A constant flow of water-based coolant keeps the temperature of the cutting wheel and the scissor part down, otherwise the cutting process could cause them both to overheat and compromise their strength and integrity.", "This is the thinning scissor blade before cutting, and this is the blade with its new teeth.", "At the next workstation, a robot transfers a blade to an automated grinding machine.", "The machine grinds both the front and sides of the teeth to smooth the rough edges.", "This robotic system processes up to 150 scissor blades an hour.", "Next, it's into a tumbler filled with synthetic pebbles.", "As the thinning blades bounce around, friction happens.", "This smoothes more rough edges, especially the handles and finger rings that didn't undergo grinding at the robot station.", "After about four hours, a magnetic conveyor retrieves them.", "Then the midsection, where the two blades are to be joined, receives hands-on attention as a worker smoothes it using a fine abrasive sanding belt.", "They move on to the straight scissor blade.", "An employee hones it against a horizontal grinding wheel.", "This aligns the cutting edge.", "He inserts the threaded screws in holes in a straight-edged blade and in the corresponding comb-like blade.", "He brings the two together and then tightens the screws to a specific torque.", "Too tight or too loose, and these thinning shears won't operate smoothly.", "With an emery board, he gently files the shears to get ride of lingering dust from the extensive grinding.", "He now tests their function.", "It isn't entirely smooth, so hammers a section of the comb blade to level it.", "It now moves more freely against the straight blade.", "And now the ultimate test-- he tries them out on a lock of artificial hair, and he confirms that these thinning shears are as sharp as they look.", "Next, the blade comes up against a spinning leather belt.", "This takes it from merely sharp to razor-sharp.", "It also polishes the blade to a mirror finish.", "A computerized laser burns the brand name and model information into the shears.", "They screw a brass nub to the finger ring to give the pinkie finger something to rest against.", "These thinning shears are now ready for shipment.", "Soon, they'll be in the thick of things at the beauty salon.", "Wooden wagon wheels roll through the tumbleweeds of another time.", "Fixed to covered wagons, they transported settlers to the american west in the 18th and 19th centuries.", "There are now cities and freeways where wagon wheels once blazed trails, but making them is not a lost art.", "A thriving nostalgia industry keeps these big wooden wheels turning.", "Wagon wheels are in demand for historical re-enactment events, museums, and the movies.", "The wheelwright carves the hub from a chunk of strong, rot-resistant oak.", "As it spins on a lathe, he cuts it to length.", "He stops the lathe and marks measurements for the wagon wheel's profile, sizing it for reinforcing metal hoops.", "He resumes carving, using the penciled lines as a guide.", "He transforms the oak blank into a barrel-shaped design, which is traditional for wagon wheel hubs of the 1870s.", "With the hub now clamped in another machine, he uses a mechanized chisel to punch out regular spoke holes known as mortises.", "He angles the edge of each hole to receive the tenon end of the spoke.", "He slides steel hoops onto the hub at the ends and in the center.", "It's a snug fit, but it's not quite tight enough.", "A hydraulic press squeezes the hoops around the hub to provide just the right tension.", "The hoops will act as a constricting force to keep the wood from splitting.", "From a chunk of wood into a substantial wagon wheel hub.", "Now using tools called spokeshaves, the wheelwright shapes the hickory wood spokes.", "He narrows the throat of the spoke to add flexibility, where it is to be inserted into the hub.", "He coats the mortises of the hub with glue.", "He inserts the spokes into the glued holes.", "He drives them into place with a sledgehammer.", "There are 12 spokes in total for this front wagon wheel.", "The wheelwright then spins the wheel and eyeballs it to confirm that the spokes rotate on an even plane.", "Then like sharpening a pencil, he brings the ends to a point.", "This prepares them for the tenon cutter that now carves them into peg shapes for insertion into the wheel rim.", "He installs the steam-bent wooden rim in two sections.", "It's drilled to match up with the spokes.", "At first, it's easy, but as the tension builds, it becomes tougher to insert the remaining spokes, so he stretches the rim wider with a clamp.", "This gives him more room to maneuver as he fits the others into the rim half.", "In the process, he creates a slight bow in the plane of the wheel.", "It's a truss-like state that adds strength to the wagon wheel.", "Now using an electric roller machine, he bends a strip of steel into a round wagon-wheel tire.", "It takes just one pass through the rollers to achieve the desired bend.", "The length will need to be precisely measured.", "He measures the inner circumference with an old wheelwright tool called a traveler, to determine just how much tweaking it needs.", "Then using a torch, he cuts the tire to the exact length required.", "He makes the tire slightly smaller than the wheel itself because it must serve as a heavy-duty elastic band to hold the assembled wagon wheel together.", "He welds it where the ends meet, and this completes the wagon-wheel tire.", "He now bakes the tire briefly in an open fire.", "The metal expands and at a strategic moment, they pull it out of the flames.", "The tire has stretched to the point where it can be installed on the wheel, but it's not quite hot enough to cause the wooden wheel to catch fire.", "They pour water onto the tire to bring it back to a cooler temperature.", "As it cools, it shrinks to the wagon wheel, creating that elastic band effect.", "Next, they prime and paint a matching set of wheels in the color of the client's choice.", "And with those finishing touches, these wagon wheels are en route to the past.", "For fans of american history, it's sure to be a sentimental journey.", "For people who need to grab a quick bite for breakfast, the invention of the toaster pastry in the 1960s was the greatest thing since sliced bread.", "Finally, the toaster could be used for more than toasting bread, and the toaster pastry was definitely a sweet alternative.", "The toaster pastry retains its sweetness during toasting.", "The syrupy filling and frosting don't melt out and into the toaster.", "It's all because of the ingredients and how they come together.", "At this factory, they start by making an organic pastry.", "The blender operator loads dry ingredients, like rice bran, into the blender, followed by a sugar syrup and molasses.", "It's the molasses that gives the pastry a brownish color.", "He adds organic palm shortening and organic granulated sugar.", "The flour and water are piped into the blender barrel.", "Spiraling mixers blend and knead the dough to the desired consistency.", "Next, it's into a hopper that feeds the dough between two rollers.", "They squeeze and flatten the dough into a sheet that's about 8/10 of an inch thick.", "A conveyor moves the toaster-pastry dough forward to sets of larger rollers.", "They apply serious pressure to roll the dough much thinner.", "Wheels at the sides fold back the dough as the width expands.", "A dusting of flour to the rollers keeps things from getting too sticky.", "Coming off the final rollers, the thickness of the dough has been reduced to 2/10 of a inch.", "At another station, they whipped up a batch of cherry pomegranate jam.", "The jam is hearty and thick, so it won't run as nozzles pump the jam onto the rolled pastry sheet.", "Each toaster pastry receives three strings of jam.", "This depositor system fills 10 tarts at a time.", "It works out to 390 tarts a minute.", "A second sheet of dough heads towards the jam-filled one.", "En route, a spiked roller punches holes for venting steam during baking.", "Without these holes, the pressure would build and the toaster pastries would explode.", "The top sheet of pastry now merges with the bottom one.", "The conveyor belts move it exactly the same speed, so the top pastry lands in perfect alignment on the jam-filled one.", "A cylinder with a brass grid pattern bears down on the pastry to compress it between the jam fillings.", "This forms pockets of jam.", "A cylindrical blade slices the pastry into individual tarts.", "A device pulls off the side trimmings.", "The toaster pastries travel through a 150-foot-long convection oven heated to 300 degrees fahrenheit.", "The operator keeps a close watch for leaking jam.", "That would be a sign of bad seals in the pastry pockets.", "He rejects any with leaks.", "He also keeps an eye on the color as the pastries brown.", "They shouldn't be too dark or too light.", "Fresh out of the mixer, the pink frosting now flows onto a revolving belt that spreads it onto the toaster pastries at just the right thickness.", "They've added a bit of starch to the icing, and it's this starch that allows the icing to harden and set so it won't melt and drip into the toaster during toasting.", "They sprinkle granulated colored sugar onto the toaster pastries.", "They call this topping the crunchlets.", "The crunchlets add both flavor and texture to the pastry.", "Once cooled, the toaster pastries transfer from one conveyor to another.", "A breaker roller snaps them at the crimp line to separate them into groups of two.", "The completed tarts head towards the packaging line.", "An operator does a visual inspection as they pass by.", "Mechanical arms push the tarts into aluminum wrapping.", "Hot rollers seal and cut the wrap at the ends.", "This wrapping preserves the tarts for eight months, no preservatives needed.", "Suctioning arms grab and open cartons to accept the foil-wrapped toaster pastries.", "It takes about an hour to manufacture a box of toaster pastries, and now it's time for a toast.", "The type of bow used today for instruments in the violin family originated in france in the 1800s.", "The master bow makers of the day used pernambuco, a wood being imported from brazil to make textile dye.", "They considered this wood ideal due to its strength, durability, and beauty.", "Today, just like hundreds of years ago, quality bows are made of pernambuco wood from brazil and horse hair.", "To make the wooden part, called the stick, the bow maker lays a template onto a .", "4 to .", "5-inch-thick block of pernambuco and marks where he'll make his cuts.", "He follows his markings with a band saw, cutting out the stick's basic shape.", "Then he planes the stick, thinning it out, tapering it to narrow toward the front, and angling the corners to make the square contour octagonal.", "Next, he repeatedly heats the stick with a gas flame to soften it and gently bends it against his knee.", "Then, afterward, against a wooden form to give the stick a very precise curve.", "This is referred to as the camber of the bow.", "Next, using a handsaw and template, he cuts out a piece of pernambuco for the bow's front tip, called the head.", "He refines the shape, first with a rasp, then with a file, then with sandpaper.", "Then he glues on a bone plate to protect the head from damage.", "He wraps string tightly around it to apply continual pressure while the glue sets overnight.", "The next day, he files down the sides to make the plate flush with the wood.", "Using a traditional drill, he bores a hole about 4/10 of an inch deep into the head and chisels the hole into a trapezoid shape.", "This forms the hair block into which he'll later insert the hair.", "Next, he measures and marks a block of ebony wood to begin making the bow's frog, the piece at the bottom by which the musician holds the bow and adjusts the tension of the hair.", "He shapes the block using first a saw, then a chisel, and rasps, files, and sands all the surfaces smooth.", "The frog has a space on top called the mortis, into which he'll later insert the hair.", "The bow maker glues a decorative mother-of-pearl accent onto the side, then cuts two small plugs out of maple wood.", "These will anchor the hair at each end of the bow.", "He inserts one into the frog's mortis...", "And the other into the hair block in the head.", "A bow this size requires a tenth of an ounce of hair.", "That's approximately 180 horse hairs.", "The bow maker bonds them at one end with some melted rosin, a sticky plant resin, then inserts this end into the frog and anchors it with a plug.", "Then he bends the hairs and slides on a nickel-silver ring called a ferrule to hold them together.", "More expensive bows often have a gold ferrule.", "To mount the frog, he inserts a long metal screw with an adjuster head into a hole drilled into the back of the bow.", "The screw operates an eyelet connected to the frog.", "Now he combs the hair straight.", "The individual hairs must be parallel to each other for the bow to perform properly.", "He ties the loose ends together with thread and bonds them with rosin.", "Then he inserts the sealed end into the tip and anchors it with that second plug.", "Back to the frog now, he moves the ferrule out of position, seals the mortis with a mother-of-pearl slide, then puts the ferrule back.", "He wraps the parts of the stick the musician holds in silver or gold wire and leather to protect the wood from wear and brands the maker's name.", "Turning the adjuster at the back moves the frog forward and backward to alter the tension of the hair.", "The violinist tightens the hair before playing and loosens it when putting the instrument away." ]

{ "things": [ "Architectural Moldings", "Pulleys", "Industrial Rubber Hose", "Sheet Vinyl Flooring" ] }

[ "Today on \"how it's made\"...", "Decorative moldings.", "Commercial pulleys.", "Industrial rubber hose.", "And sheet vinyl flooring.", "When you consider the high cost of renovations, architectural moldings are an easy way to get a lot of decorative bang for your buck.", "By adding a crown molding along the ceiling, baseboard molding, casings, and maybe even a chair-rail molding, you can take a room from drab to dazzling without breaking the bank.", "Decorative moldings can be made of solid wood, medium-density fiberboard, or finger-jointed pine.", "These planks of eastern white pine are on their way to becoming finger-jointed molding.", "They've just come out of the kiln.", "A hygrometer measures the humidity in each plank to ensure the wood is dry enough to cut cleanly.", "A worker directs a laser to read the dimensions of each and every plank.", "The laser transmits that information to a computer, which guides a plane further up the line to shave the plank to the required width and square it.", "This process transforms the plank into a block.", "The blocks now enter a high-tech piece of equipment that identifies defects.", "As each block enters the machine, a scanner records all its features.", "It sends that information to a computer which calculates a cutting plan.", "Guided by the computer, a saw chops out any knots or poor-quality wood.", "The machine's kickers, as they're called, boot the cutoffs from the conveyer.", "The blocks continue on, running against razor-sharp rotating heads that carve finger joints on the ends.", "The next station coats the joints with industrial-strength carpenter's glue.", "The conveyer picks up speed now and butts the blocks together with high pressure.", "The joints lock in a tight fit.", "When the glue dries, the joints strengthen even more.", "The jointed blocks are connected in a continuous unit.", "A saw now cuts it into standard molding lengths.", "These lengths are known as finger-jointed blanks because they haven't been shaped.", "A saw now cuts the blanks lengthwise to the thickness of the specific molding they're producing.", "The final step is to profile the blanks.", "A machine called a molder uses rotating steel knives to carve the wood to the required shape.", "There's a different knife for each style of molding.", "The molder transforms the blanks to moldings at a rate of 100 feet per minute.", "Moldings made of finger-jointed pine or medium-density fiberboard are the least expensive on the market, but you can't stain them like moldings made of solid wood.", "They have to be painted.", "A pulley is a wheel with a grooved or barreled rim in which you can run a rope or belt.", "It's a simple device used to lift a load that's hard to access or too heavy to move by hand.", "Pulleys and multiple-pulley systems are vital components of many types of machines.", "These pulleys are designed for use in small- to large-scale electric motors-- for example, fan belts in the air-circulation systems of office buildings, factories, and mines.", "The factory makes its pulleys from a 50/50 mix of scrap iron and steel.", "The furnace heats the metal to 2,500 degrees fahrenheit, slightly above the metal's melting point.", "Workers adjust the chemical composition by adding carbon and silicon.", "The right recipe is essential for producing quality metal.", "In the furnace, the metal's impurities, called slag, rise to the surface.", "Workers use giant paddles to skim it off.", "Once the lab analyzes and approves the sample, they transfer the molten metal by ladle to a 30-ton holding furnace.", "This furnace maintains the metal at a constant 2,500 degrees fahrenheit, the required temperature for a proper casting.", "You can't pour metal this hot into a metal mold.", "The mold would just melt.", "So instead, the factory uses damp sand.", "Sand withstands intense heat by absorbing it.", "The machine forms the molds much the way you'd use a pail to form a sand castle.", "It first constructs the bottom half of the mold.", "This filter will screen out any slag particles the molten metal may still contain.", "And these cores create empty spaces within a part.", "Now the machine forms the top half of the mold.", "They slip a weighted metal jacket around the finished sand mold.", "This keeps it from collapsing under the weight of the metal.", "Workers fill the molds right to the top.", "It takes from 30 to 45 minutes for the molten metal to solidify.", "They remove the weighted metal jacket...", "Then dump the mold into what's call the shakeout.", "The vibration breaks the sand mold apart, releasing the metal pulleys.", "While the pulleys go off to be cleaned, the sand is recycled into new molds.", "The pulleys are in rough form.", "They still have to be machined to specifications.", "A robot places each one under a computerized camera.", "A visual-recognition program guides the robot to position the pulley properly into various automated-tooling machines.", "This first machine makes the pulley's grooves.", "The next machine will drill holes in the hub for installing the screws.", "At the end of the machining process, a gauging system takes precise measurements and guides the equipment to correct any errors.", "This is a two-part pulley, known as a variable pulley, because it can run a belt at variable speeds.", "This tooling machine performs several operations on the male component.", "It machines the face and outside diameter on one side, then flips the pulley over to make the bore and threads on the other side.", "The last operation drills holes for two screws that will affix the pulley to the shaft of the electric motor.", "A touch of lubricant, and the next machine assembles the male and female parts.", "After setting the proper speed, the user locks the parts in position with a screw.", "Many industries use rubber hose in their day-to-day operations.", "They use it to remove water, clear out waste, or supply certain machines with air, water, or raw materials.", "For instance, food producers might feed ingredients through a rubber hose into a mixer.", "This company makes low-pressure and medium-pressure rubber hoses.", "The intended use is what determines the rubber composition.", "Function also determines the color, because industrial hoses are often color-coded.", "The rubber arrives at the factory from the supplier in rough strips.", "The first step is to run it through a mill.", "The rollers heat the rubber, softening and smoothing it to an even texture.", "The next machine cuts the rubber in strips to the precise width and thickness required for the size of hose they're going to construct.", "Workers lubricate a steel mandrel that's the exact size of the hose's bore.", "As the mandrel spins, they wrap a rubber strip around it, measuring and layering to build the necessary thickness.", "Next, they add one or more reinforcement layers.", "This strip is made of a high-strength synthetic fabric that's been coated in rubber.", "It's designed to withstand the pressure to which the hose will be subjected.", "The last layer of rubber forms the hose's outside covering.", "After verifying the final diameter is correct, they wrap the entire hose construction tightly in wet nylon tape.", "The tape will later shrink and compress all the materials together.", "This factory also makes hoses with a built-in attachment on the end.", "They position it on the mandrel, then glue the first layer of rubber to it.", "This bond is reinforced with special textile strips and tightly wound, high-strength, carbon-steel wire.", "They continue the wire more loosely down the body of the hose at a specific angle designed to withstand vacuum pressure.", "Then they wrap the hose in a soft, stretchy rubber strip that fills the gaps between the wires.", "Next comes a layer of high-strength, rubber-coated fabric, then, finally, the exterior covering-- light blue rubber for this model.", "Again, the hose is pressure-wrapped with wet nylon tape.", "Then, to make the hose more flexible, they create corrugations by wrapping it tightly in rope.", "What's under the rope compacts, creating a dip.", "They add another layer of nylon tape to hold the rope in place.", "When construction is finished, the hoses, on their respective mandrels, go into an autoclave, a cylindrical chamber into which they feed hot steam at high pressure.", "This vulcanization process, as it's called, triggers a chemical reaction that cures the rubber, making it elastic.", "Once the hoses come out and cool, workers remove the tape.", "The layers are solidly compressed.", "They wash the nylon tape, then rewind and reuse it.", "Now workers begin the process of removing the hose from the mandrel.", "They tie one end with the rope to create pressure, then gently pump water between the mandrel and rubber.", "The lubricant they applied earlier has prevented the rubber from sticking to the steel, so the hose separates easily.", "They simply slide it off the mandrel.", "Workers will now trim the ends, cut the hose to the length the customer ordered, then coil and package the hose.", "This factory makes a wide range of industrial rubber hose in different diameters, different bore sizes, and varying degrees of flexibility.", "Some hoses have specialty features, such as heat-resistant fabrics incorporated right into the rubber layers.", "In 1860, an englishman invented linoleum, a revolutionary floor covering made of linseed oil, pigments, pine rosin, and pine flower.", "A century later in the 1960s, vinyl flooring was introduced and eventually rendered linoleum flooring obsolete.", "Vinyl flooring owes its existence to a german chemist who, in 1872, invented polyvinyl chloride, or pvc.", "Pvc was considered a thoroughly useless substance until the 1920s, when an american researcher tried to make it useful by turning it into an adhesive.", "He didn't succeed, but, in the process, he accidently discovered that heating pvc in a solvent transformed it into a flexible plastic, what we know today as vinyl.", "Sheet-vinyl flooring comes in a wide range of designs, some of which simulate ceramic tiles or hardwood flooring.", "As we see here under a microscope, vinyl flooring is comprised of three components-- a felt-paper backing on the bottom, a layer of vinyl foam in the middle, on which they print the design, and a protective layer of transparent vinyl on top.", "To create texture, the factory applies an inhibitor to prevent the foam from expanding in select areas.", "To make that vinyl foam, they first mix the powdered ingredients-- polyvinyl chloride resins, or pvc, white pigment, and calcium carbonate, which acts as a filler, but also helps color the mixture white.", "In a separate mixer, the liquid ingredients-- plasticizer to make the vinyl flexible, fungicide to prevent mold growth, u.v. stabilizers to prevent fading, and a blowing agent, which they later activate to inflate the foam.", "They combine the liquid and powders and mix for another 15 minutes.", "After filtering the mixture to remove any lumps or paper-bag fragments, the liquid foam goes to the production line.", "There, a large coater applies an even layer to a continuous sheet of felt-paper backing.", "The coated backing then passes through an oven for about 15 seconds.", "The heat-- 430 degrees fahrenheit-- solidifies the liquid foam, fusing the pvc to the backing.", "At this point, it's critical not to activate the blowing agent.", "The floor's design will be printed directly on this foam surface.", "A graphic designer creates the artwork by computer.", "Then a colorist experiments with dozens of color combinations before deciding on which ones to use.", "The computer breaks down the final design by color in order to produce an engraved plate for each one.", "They test out the design on a piece of foam, printing one color after another until the design is complete.", "On the production line, printing works the same way.", "But because it's a continuous process, they use rotating cylinders rather than engraved plates.", "The flooring just rolls right through them, receiving up to six ink colors one at a time.", "A drier dries the ink in between applications.", "Now it's time to apply the floor's top layer.", "This coat of vinyl is known as the wear layer because it will be subjected to the wear and tear of walking.", "The wear layer protects the design printed on the vinyl foam underneath.", "Made of pvc resins and plasticizer, it goes on white but turns transparent when fused in the oven at 430 degrees fahrenheit.", "At the same time, the heat of the oven activates the blowing agent in the vinyl foam underneath, expanding it.", "To create a texture, they use a process called chemical embossing, in which select ink colors contain a chemical inhibitor to suppress foam expansion.", "Wherever they print those colors, the foam remains flat.", "These height variations create relief and simulate grout lines in imitation-tile designs.", "To give the surface a sharper, more natural look, the flooring proceeds to a second process called mechanical embossing, in which an engraved roller imprints its pattern onto the surface.", "The gloss level of the flooring varies with the chemical composition of the wear layer.", "Workers inspect the finished flooring as it rolls off the production line.", "It's 12 feet wide, wide enough for seamless installation in most rooms.", "The packaging is entirely automated.", "This equipment winds 100 feet of sheet-vinyl flooring per roll." ]

{ "things": [ "Hand Forged Hammers", "Gummy Vitamins", "Boat Trailers", "Tea Lights & Jar Candles" ] }

[ "A hammer is an all-purpose tool most commonly used to strike nails.", "Some hammers are designed for a specific purpose such as woodworking, metalworking, and masonry.", "Professional craftspeople often forego mass-produced tools and invest in high-quality hand-forged hammers.", "The steel head of this hammer was forged by a blacksmith.", "This is just one out of 40 different styles of hammers made by a blacksmith.", "Using a metal-cutting band saw, a blacksmith cuts a piece of cylindrical steel he makes the cut slightly larger than the final hammerhead size.", "Next, he burns small amount of paper on coals in a cast steel pot.", "A fan, located underneath the coals blows air upward to stoke the fire.", "Once the coals are hot, the craftsman immerses the steel piece in the fire.", "Once the steel is glowing bright red, he removes the piece with from the fire with tongs.", "He begins striking it with a mechanical forging hammer operated by a foot pedal.", "Throughout the forging process the steel is reheated to keep it formable.", "The craftsman lowers the pedal, which activates the machine's hammer.", "As the hammer strikes, the craftsman turns the cylindrical piece of steel to flatten the sides and shape it into a block.", "Using a specialized tool, he makes a punch on the block to form a channel.", "He flips the block and punches out the compressed steel to create a hole.", "This hole is the eye of the hammer.", "Next, the craftsman uses a tool called a spring swage to flatten one end of the block into the wedge-shaped end of the hammer known as the peen.", "Each side of the peen is shaped against the grinding wheel to even out the surface.", "Working on an anvil, the craftsman flattens the block with a handheld hammer.", "Then, with a tool called a flatter.", "He uses an oval eye-contouring tool to hammer a hole to form the eye.", "Now complete, the craftsman polishes the hammerhead on a series of grinding belts.", "Then the hammerhead is placed back into the fire for more reheating.", "Back on the anvil, he uses a wire brush to remove scale caused by oxidation.", "Then brands the steel with his name.", "After heat treating both ends of the hammerhead, to harden the steel at the striking surfaces, he finishes off the metalwork with a die grinder, smoothing the sharp edges around the eye and forming a bevel.", "Once complete, the craftsman moves on to the wooden handle.", "He shapes a block of wood, often using hickory, with an angle grinder.", "Using the grinding wheel, he shaves off the top to fit in the eye of the hammerhead.", "With a band saw, he makes a 2-inch cut into the wood.", "He cuts a wedge out of a softer type of wood, usually pine.", "He marks the diameter of the eye on the wedge then sands off the excess wood so that the wedge will fit in the eye.", "He inserts the split end of the wood handle in the eye, forcing it through.", "Then he hammers the wedge into the split.", "This pushes the two sides of the split in opposite directions, lodging the handle in the eye.", "Next, the craftsman hammers in a hollow round steel wedge until it's flush with the hammerhead.", "This wedge spreads the wood in different directions, locking in the handle.", "He removes excess wood with an angle grinder until the top of the hammer is level and smooth.", "Finally, this handmade tool is ready to make it's contribution to hand craftsmanship.", "Gummy vitamins were invented in the late the 20th century by an couple looking for a way to entice their daughter to take her vitamins.", "Infused into a gummy candy, vitamins are now a sweet and chewy experience for both kids and adults.", "Just like gummy candies, gummy vitamins come in a variety of sweet, fruity flavors, making a vitamin a less bitter pill to swallow.", "Each gummy vitamin starts with a specific formula.", "First raw ingredients are selected and weighed.", "Some are in liquid form and others are solids.", "The nutritional ingredients are blended with water.", "This particular batch is a multivitamin preparation.", "It includes magnesium, calcium, and other minerals.", "In a separate tank, technicians prepare the gelatin base which gives the vitamins a jelly-like consistency.", "Next, sugar and gelatin pre-mix is poured into the tank.", "The technician adds a sugar substitute to the other ingredients.", "Meanwhile, specific amounts of water and glucose are dispensed into the tank.", "It takes about five minutes to blend the ingredients for the gelatin base.", "Then, the gummy vitamin base is transferred to a large holding tank.", "In the lab, the nutritional mixture is tested for contaminants such as heavy metals and bacteria.", "An automated syringe injects the solutions into test tubes rinsing inbetween injections.", "Now the samples in the test tubes are ready to be analyzed.", "For heavy metal testing, the sample is injected into an extremely hot vacuum chamber.", "The plasma flame turns the metal contaminants into atoms, which the machine reads as different colors.", "The machine also identifies and quantifies contaminants.", "With the samples cleared for processing, they're ready for flavoring and colorant.", "More vitamins are added in powder form to boost the formula's potency.", "The liquid vitamin preparation and the gelatin base is piped into the mixing tank then, everything is blended together.", "The batter is now ready to be made into thousands of gummy vitamins.", "A conveyor queues up the vitamin molds.", "Multiple nozzles deposit precise amounts of batter into small molds.", "The conveyor moves the tray forward as the gummy vitamins begin to solidify.", "A robotic arm stacks the mold trays in a holding area.", "The arm gently lowers the trays into place.", "For several hours, the pills continue to harden in the molds.", "Once completely solidified, the gummy vitamins are removed from the molds and transferred into a revolving drum.", "The tumble in the drum separates them.", "They exit onto a perforated conveyor and any small bits fall through the holes.", "The conveyor zigzags back and forth, allowing the gummy vitamins to cool and further solidify.", "The gummy vitamins have now reached their final consistency.", "The gummy vitamins head into a steam chamber.", "The humidity from the steam preps the vitamins for sugarcoating.", "The sugar clings to the gummy vitamins.", "And the revolving action of the drum shakes off any excess, leaving just a dusting on the surface.", "At the packaging station, the vitamins funnel into chutes where sensors count and release the pills into bottles.", "As the bottles move forward, caps land on the rims.", "And spinning rubber mechanisms screw the caps on tightly.", "Down the line, labels with product information are placed onto each bottle.", "Depending on the formulation, it can take up to three weeks to produce gummy vitamin pills and the result?", "Nutritious gumdrops that are a real treat.", "Before you can take a boat out on the water, you have to transport it to the water.", "A boat trailer attaches to the rear of your vehicle with a trailer hitch.", "You back the trailer into the water then release the boat and let it float away freely.", "A boat trailer has either a quick-release latch system or a winch, a wheel you crank to wind or unwind a strap that hooks onto the boat.", "Boat trailers back up into water so using corrosion-resistant materials is vital.", "This trailer is aluminum with torsion axles made of galvanized steel.", "Torsion axles contain shock-absorbing rubber cores.", "On each axle, a machinist greases the spindle, and installs a mounting bracket for the brake caliper.", "All the nuts and bolts holding the trailer's parts together are stainless steel.", "The machinist mounts the wheel hub on the spindle.", "The brake rotor is built right into the hub.", "He secures the hub with a castle nut and adjusts the tension.", "He inserts a cotter pin to lock the castle nut, bending the pin with a few taps of a hammer.", "He pumps grease into the hub for lubrication then taps in a dust cap to seal in the grease.", "He installs the brake caliper on the mounting bracket.", "He hooks up the brake line to the caliper and mounts the tire to the hub.", "On the back of the tire, there's a small brass elbow for connecting the brake line.", "The frame that sits on the axles is made of aluminum.", "Aluminum is strong and corrosion-resistant but also lightweight.", "The frame has two main front-to-back beams.", "Using a template for accurate positioning, another machinist punches boltholes into the beams with a hydraulic tool.", "He uses a bending press to curve the beams to the specified angle.", "This type of aluminum can be bent without compromising its strength.", "Next, an anti-corrosion coating is brushed onto the axle's mounting plates.", "Technicians position the beams on the axle plates, aligning the matching boltholes.", "They bolt the beams to the plates, then bolt a rear crossmember underneath the two main beams.", "This gives the frame side-to-side strength and stability in addition to helping support the load of the boat.", "A pair of mounts are bolted onto the rear crossmember and on each of the two axles.", "The bunk, the part that supports the boat, slots into the gap between each pair of mounts.", "The bunk has a wood cap that's carpeted to protect the boat's hull.", "To reinforce the bunk, punch holes are made in aluminum plates and bent with a press.", "Sway braces are bolted to the mounts for additional support.", "This company makes a patented pivoting bunk that adjusts to boat hulls of varying shapes.", "At the front of the frame, machinists install the tongue.", "The tongue unites the two main beams with the coupler that hooks up to the toe hitch at the rear of the vehicle.", "For trailers with a winch, aluminum parts are cut for the winch stand.", "A technician places the parts in an assembly jig which aligns them correctly.", "Then, the parts are tack welded together.", "Once welding is complete, the technician removes them from the jig, tack welds one additional part, then welds all the parts together.", "He removes any debris from the welded seams with a cleaning solution.", "Next, the winch stand is bolted to the tongue and the winch is installed.", "Then, the brake line and the electrical cable for the trailer's l.e.d. lights are connected.", "Guides are also installed, which center the boat on the trailer.", "An aluminum fender is mounted over each pair of tires and reinforce it with a support bracket which they bolt to the frame.", "Latch system trailers have an aluminum bar which stops the bow, securing the boat at just the right position.", "Finally, this tow trailer is ready for smooth sailing.", "There's a lot more to candles than lights the eye.", "Before they were invented, people relied on candles made with wicks floating in flammable, spillable oil.", "In the past, candles weren't just used for illumination.", "Since they burn at such a steady rate, people have even used them as clocks.", "Thanks to electricity, candles no longer have to illuminate our homes.", "They can simply brighten our evenings with atmospheric lighting.", "This wax has been made into a powder with a rotating bar that sprays drops of hot wax into the air.", "As the drops fall, they cool and become solid wax particles.", "A specialized machine called a core press vacuums the powder and begins a multi-step process.", "A series of small tube-shaped holes with powder then hydraulic pistons compress the powder into short cylinders.", "Transport units move them to the next station.", "The compressed wax cylinder will form the core of the candle and prevent the burning wick from touching the edges of the glass.", "First, it needs a wick and a sustainer.", "The metal sustainer is the wick's base.", "This machine shoots wicks into the sustainers, crimps them, and inserts the components into the candle core.", "A machine places drops of glue in the bottom of a series of small glass containers before placing the candle cores inside.", "The glue holds the sustainers in place to prevent them from sliding around when hot.", "Onto the next phase of production, liquefied wax is poured into a mixing tank.", "A technician pours in a series of additives.", "They include plasticizers to help solidify the wax and prevent crystallization, as well as uv light inhibitors that can protect the wax from color fading.", "He pours a premeasured quantity of dye into the container.", "An agitator begins the mixing process which takes 20 to 30 minutes to ensure that everything is thoroughly combined.", "The wax is maintained at 185 degrees fahrenheit so the liquid is kept in its liquid state.", "Then, the liquid wax travels through tubing to a computerized filling station.", "A set of nozzles fill the jars, surrounding and covering the cores.", "Once filled, the jars move slowly through two separate cooling chambers.", "The candles undergo extensive quality control testing for flame height and the temperature on the exterior of the container.", "This facility also manufactures tea light candles.", "The containers are made of aluminum alloy pressed into a cup shape with small panels at the bottom designed to direct melted wax to the center.", "Moved by air, the containers fall into a sorter which spins them into an upright position and onto a conveyor that offloads them to the next stations.", "Like candles, tea lights require sustainers and glue to hold the wick in place.", "The steel discs drop into a vibrating sorting device.", "A giant spool of waxed thread is fed into the wicking machine the machine cuts, and inserts it into the sustainer clip, and glues the assembly into a tea light container, the containers, with sustainers and wicks in place, move to a circular buffering table which disperses into three channels.", "A multi-prong device advances the containers onto the filling machine's conveyor system.", "The machine fills the containers in a two-step process, filling them halfway, letting them cool, then topping them up and cooling the completed product.", "The two-step filling process ensures a consistent product at a faster manufacturing rate.", "The cooling chamber circulates air through the space at a specific temperature to cool the candles at a calibrated rate.", "From start to finish, it takes just 45 minutes to produce and package a tea light.", "There's a lot more to that cozy candle glow than just wax and wicks." ]

{ "things": [ "Indy Car Seats", "Paper Flowers", "Stand" ] }

[ "Indycars are open-cockpit race cars that compete in the annual indianapolis 500 race in the u.s. the cars are entirely custom-built.", "Even the driver's seat is specially contoured to the driver's body shape and position in which he or she sits most comfortably in the car.", "The custom-made driver's seat in an indycar is made of fire-resistant fabric over impact-absorbing foam.", "It has openings at the shoulder, lap, and legs for the safety harness.", "To make the seat, they first have to produce a template, which is, in itself, a two-day process.", "Technicians prepare, then pour an adhesive into a bag full of foam beads.", "The adhesive contains resin and a hardener.", "Once the adhesive seeps in, they squeeze out the air and tie the bag closed.", "They knead the bag to spread the adhesive over all the foam beads inside.", "Next, laying the bag flat, they spread the adhesive-saturated beads in an even layer.", "Then they install a valve...", "Attach it to a vacuum pump, and suction out most of the remaining air.", "They shape a cavity in the middle to fit the driver's body.", "Once they vacuumed out enough air to make the bag tight enough to hold the shape of this cavity...", "They place it in the race car's cockpit, pressing the foam beads as snugly as possible into all the nooks and crannies.", "This ensures the car seat will fit properly and not shift under the driver.", "The driver now has to sit in the car so they can custom-contour the template to his body in the driving position.", "Once he's settled comfortably with hips and shoulders square and wearing his helmet, they begin taking measurements, starting with the height of his head, critical for aerodynamics, and of his sight line over the hood, critical for safety.", "Both measurements must conform with the racing association's strict regulations.", "They also measure the distance between his chest and the steering wheel and ensure there's adequate leg clearance to enter and exit the cockpit.", "The driver sits down, gets out, gets back in several times as the technicians measure and make adjustments.", "The entire process takes about 40 minutes.", "When it's all done, they run the vacuum for another four hours and let the foam cure overnight.", "The next morning, they use a hot knife to melt a line through the foam and dislodge the template from the cockpit.", "The driver returns for a final two- to three-hour sitting, during which the techs trim the foam as closely as possible to his body contour.", "The shape now finalized, they cover the entire surface with cloth adhesive tape and a matte finish.", "This creates a non-reflective background suitable for laser scanning.", "Onto this dull surface, they adhere positioning targets-- reflective dots spaced four inches apart that create a grid pattern over the entire template.", "The 3-d laser scanner reads these reflective dots...", "That a computer translates into a 3-d image.", "Specialized software then converts this image into a technical drawing, which guides an automated router to cut the seat parts out of polypropylene foam.", "This precision-cutting process takes four to six hours.", "The router cuts out six to eight sections, which technicians then carefully glue together into the full seat.", "They cover the finished seat in fire-retardant material, first applying the fabric with spray adhesive, then trimming it to the shape of the seat.", "This foam is quite elastic, so it absorbs impact and protects the driver.", "At the same time, it has memory, so after a blow, it regains its driver-customized shape.", "People have always been enchanted by the beauty of flowers.", "It's not surprising that these jewels of nature, often in artificial form, are used in decorative objects and arts and crafts projects.", "Paper flowers last forever, and you don't have to remember to water them.", "These flowers are made of saa paper.", "The saa tree is a variety of mulberry that grows abundantly across southeast asia.", "For more than 700 years, villagers in northern thailand have been using saa bark to make paper.", "The paper is used for crafting items such as umbrellas, fans, and flowers.", "They soak the dried bark in water overnight to begin softening it up, boil it over a wood fire for four hours, then soak it again overnight.", "All of this softens the bark into fibrous pulp.", "Next, they soak the pulp overnight in hydrogen peroxide to whiten it, then they rinse off the bleach, which would interfere with the dying process later on.", "Workers discard any discolored pieces.", "The goal is to make each sheet of paper evenly white so that it absorbs colored dye uniformly.", "Now they load the pulp into a mill, which grinds it up and mixes it with water.", "This process, which takes about half an hour, transforms the pieces into soft, fluffy, and very soggy fibers.", "What was once tree bark is now ready to be processed into paper.", "Every single sheet is handcrafted on fine mesh screens.", "They submerge a screen in water, then drop in roughly 15 ounces of fibers.", "They manually stir the water to spread the fibers in a thin layer across the screen.", "They slowly lift the screen out of the water and press the surface by hand to smooth it out.", "The screen then stands in the sun for three to four hours, flipped a few times until the fiber's dry into a solid sheet of paper.", "To color the paper, they fill a basin with hot water and add a chemical dye.", "They test the color, and if it's just right, they submerge the sheet.", "The sheet absorbs the dye instantly in a consistent shade thanks to the uniformly white base color.", "They hang the sheet outside to dry in the sun.", "In three to four hours, the paper is ready to bloom.", "They cut out flower shapes with a hand-operated press that stamps a sharp metal dye through the sheet of paper.", "Each shape will be a layer of petals in a flower.", "There are dyes in various shapes and sizes.", "However, the petals they produce are flat-- not very lifelike-- so workers place one petal at a time on a flower-shaped mold and stamp it with a hot press.", "This permanently shapes the petals to the contour of the mold almost the same way a hot iron presses clothes.", "Then it's assembly time.", "To make a rose, they mount a white ball made of foam, or flower and glue, onto the end of a three-inch-long wire.", "They fold the inner petals over the ball and pinch them together to create the center of the rose.", "Then they thread four to five petal layers of the same size on the wire, bending and pinching those, as well, to form the rose shape.", "Once the petals are complete, they finish off with a green paper leaf at the base.", "To make a daisy, they take a flat flower and glue a brown paper dot in the middle.", "Then they glue another flat flower beneath it and a leaf base beneath that.", "To make another type of rose, they gently twist the tips of the petals.", "Even though they're made from trees, these artificial flowers are environmentally friendly.", "The saa's severed branches and stripped bark grow back quickly, providing a renewable supply of raw material for crafting blooming paper bouquets.", "Weather-wise, these are turbulent times.", "There are more storms and heat waves, and that means an increased likelihood of power outages.", "A standby generator supplies emergency electricity within seconds of an outage so a homeowner can ride out the storm in comfort.", "In today's high-tech world, staying plugged in has never been more important.", "Wired to a home's electrical system, a standby generator automatically powers up in the event of an outage.", "It assumes the electrical load until the public-utilities system comes back online.", "With your own standby generator, a power outage is never a crisis.", "Production starts with a stator.", "It's the stationary core of the alternator-- the part that converts energy from the motor to electricity.", "A press compacts 100 or more laminated steel disks to create the stator core.", "Machinery unwinds steel banding and wraps it around the stack to hold the core layers together.", "Machinery lifts the stator core out of the assembly device and transfers it to the next station.", "Here, an automated system insulates the numerous slots in the core.", "As the core turns, a machine cuts, forms, and inserts synthetic insulating fabric into each slot.", "Meanwhile, at another station, an automated system winds copper wire onto a mandrel.", "The slots in the mandrel are the same size as the insulated slots in the core.", "This configures the copper windings to fit the core slots.", "But first, a technician slides the copper coils onto a threading tool.", "This tool maintains the configuration of the coils to prepare them for installation in the stator core.", "They wind more bundles of copper wire.", "Once all the windings have been correctly arranged on the threading tool, the technician is ready to transfer them to the stator core.", "He places the stator on top of the threading tool and activates a hydraulic device that pushes the wires up through the tool and into the slots of the stator core.", "The device retracts, and he removes the stator.", "The copper wires transform the stator into an electromagnet, which is critical for electrical generation.", "He trims the ends of the wires and sets the leftovers aside for recycling.", "He slides insulating sleeves onto the ends.", "Then it's into the lacing machine.", "This machine crochets a string wrap around the bundles to hold the wires together.", "It also pulls in any loose strands to keep them from snagging on generator components.", "With the wiring precisely wound and wrapped, this important generator component is ready for the finishing touch-- a clear varnish.", "The lid closes on the tank, and a vacuum pulls air out.", "The tank then fills with clear varnish to coat the stators.", "The varnish fills in any gaps in the windings.", "They transfer the stators to an oven and bake on the varnish.", "Once hardened, the varnish insulates the entire assembly.", "The next technician connects the stator lead wires to a testing machine.", "The machine applies high-voltage pulses to the wire windings and monitors the output for anything that could cause generator failure.", "The stator passes the test.", "A technician now positions an outer casing and an end cap on top of the stator, followed by a steel pressing plate.", "A hydraulic arm then provides the muscle power needed to fit the casing and cap snugly to the stator.", "Coming up next, the generator stator joins the rotor and engine, and the result is purely electric.", "The average home may contain over 100 electrical appliances and devices.", "When there's a power blackout, everything shuts down.", "A standby generator restores electricity in seconds to keep the refrigerator running and the heat on.", "In an extended power outage, a generator can be a life saver.", "To produce the alternator's rotating part, the rotor, the technician stacks laminated steel disks to the same height as the stator core.", "He lubricates the opening in the center of the disks.", "He inserts a shaft, and a press pushes it into the stack to complete the installation.", "Powered by the generator engine, the shaft will spin the rotor.", "The technician installs steel rods to maintain the disks' alignment and then removes the rotor from the assembly device.", "He fits more rods to it on a slight angle.", "They'll act as conductors and stabilize the rotor's electrical output.", "He slides aluminum caps onto both ends of the rotor.", "Then it's over to an automated welder.", "The machine grips the rotor at both ends and slowly turns it as a robot welds both caps to the rotor body.", "Welded in place, the caps secure the aluminum rods.", "The aluminum solder used in the weld is conductive and will create an electrical connection.", "The technician unclamps the rotor from the welding machine and then tucks insulation into slots on the sides.", "The rotor then goes for a spin in a machine that winds bands of copper wire around the insulated sections.", "These wires will act as electromagnets and help produce electrical current.", "They tie string around the wire, add bearings and a copper collector ring, and bake an insulating varnish onto the entire rotor.", "They're now ready to assemble the standby generator.", "Using a lift, the technician lowers the engine into position.", "He joins the rotor shaft to the engine crankshaft.", "To secure the assembly, he drives a very long bolt through the rotor to the crankshaft and tightens it to a specific torque.", "Next up is the stator.", "It will provide a magnetic field to advance the flow of electrons in the rotor.", "The technician slides the stator onto the rotor.", "A steel end bracket is next.", "It aligns the rotor and the stator.", "He forces the bracket into place.", "To secure the alignment, he installs four long bolts from the end bracket to the engine-adapter plate.", "He anchors the stator and rotor to the generator base and adds special rubber mounts under the supports to buffer vibrations.", "He attaches a motorized carbon brush to copper rings on the rotor shaft.", "The brush will collect electricity from the shaft and transfer it to the generator controller.", "He secures it to the end bracket with screws.", "He connects the wiring harness that moves electricity from the brush to the controller.", "He links the other end of the harness to the engine.", "He plugs in a sensor to monitor oil pressure and makes all the other electrical connections.", "Next up is a panel through which he runs some of the wiring.", "It acts as a separator to prevent entanglements and also supports the fuel regulator.", "Other parts include a muffler to help dampen engine noise and a controller that converts generated power to the correct voltage.", "The assembly of this standby generator is complete.", "The technician fuels up and runs it first at partial capacity, then to the max.", "The test confirms there's no wavering in electrical output.", "Once encased in a neutral-colored corrosion-resistant shell, the standby generator blends into the background, but in a power outage, its contribution will definitely be noticed." ]

{ "things": [ "Wooden Barrels", "Fire Hydrants", "Automotive Seats", "Cathode Ray Tubes" ] }

[ "Today on \"how it's made\"...", "Wooden barrels...", "Fire hydrants...", "Automotive seats...", "And cathode-ray tubes.", "In the old days, wooden barrels stored all kinds of goods, simply because they were easy to move.", "If you couldn't lift them, you could roll them.", "Today modern machinery has made barrels obsolete, except for storing fine wine and spirits.", "And so the time-honored tradition of barrel making lives on.", "These wooden barrels are for storing whiskey.", "They're made from american white oak cut into pieces called staves.", "The staves go into a planer that shaves them to about an inch thick.", "Next, a machine punches two quarter-inch holes on either side of each stave.", "Dowel pins made of hickory, a very strong wood, go into these holes to hold the staves together.", "Workers take the staves, place them on a guide, and press them together.", "A smaller piece completes the shape.", "Now it's onto the rounder, a machine that cuts it into a circular shape.", "This creates the barrel's lid, or head, as it's called.", "And each barrel requires two, one for the top and one for the bottom.", "The barrel head now goes onto a contraption called the char tunnel.", "Its gas burners scorch the wood.", "This charring not only changes the wood's appearance, it also gives color, flavor, and aroma to the whiskey this barrel will hold.", "The workers coat the head's edge with liquid beeswax, which helps them set it snugly into the barrel body.", "They run the staves against this machine to narrow their ends.", "This gives the barrel its characteristic shape, with a smaller radius at the ends than in the middle.", "At the barrel-raising station, a worker positions an iron hoop and starts to assemble the barrel inside it.", "He selects staves that vary in width in order to use as few as possible.", "This reduces the numbers of joints and potential leak points.", "He has to be gentle as he lassos the barrel together.", "If he pulls that dry wood too tight, it'll break into pieces.", "A loose hoop gives the wood room to expand.", "Next, the barrels pass through a steam tunnel for about 15 minutes.", "This adds moisture to the wood so it can flex without snapping.", "Workers pull out the barrel and remove the top and bottom hoops.", "Sturdier hoops replace them and are hammered into place.", "Without them, the barrel would spring apart.", "Next, two more hoops around the body.", "The wood groans from the intense pressure that forces the staves together, but there can't be any gaps between the staves, or else the barrel will leak.", "The barrels pass over a gas burner that blasts a flame inside each one to char its interior.", "Seconds later, water shoots into the barrel to put out the flames.", "An automated saw cuts a v-shaped notch into the top and bottom of each barrel.", "This is where the barrel head will slide in.", "A fan blows away the sawdust.", "Now a machine removes the iron hoop on each end.", "A worker pours in a gallon of water to cool the barrel, still hot from the charring process.", "Then he puts on a barrel head and stronger, permanent iron hoops on both ends.", "Now machines remove the two iron body hoops and replace them with stronger ones.", "These barrels hold their shape by sheer pressure.", "There's not a drop of glue holding them together.", "That gallon of water is still inside the barrel.", "Workers drill a hole in the side, then plug it by hammering in a rubber stopper with a spout.", "An inspector checks the barrel for leaks, stamps it approved, and labels it with a bar code for inventory.", "Then they remove the stopper and out comes the water, turned to steam because of the heat.", "The barrels are now ready to go on to the distillery, where they'll get their fill of some fine kentucky whiskey.", "When we return, you see them on every street corner, but how are they made?", "Fire hydrants have been in use for more than 200 years.", "In the old days, their main purpose was to supply water to fight fires, but they also provided the public with a handy water supply.", "Today fire crews rely on the nearest hydrant to help them douse flames whenever and wherever they break out.", "Fire hydrants are essential to every community.", "They need to be instantly recognizable, easily accessible, and simple to operate.", "The ones in residential areas are designed to deliver an impressive 1,500 gallons a minute.", "The hydrant-making process starts with recycled scrap iron, along with steel and raw iron.", "Using a magnetic crane, workers load the metals into a furnace and melt them at 2,800 degrees fahrenheit.", "This turns the scrap metal into molten iron.", "This superhot mixture is transferred into a remote-controlled ladle...", "And emptied into an automated pouring system.", "To cast the hydrants, workers first make two-part molds by compressing a mixture of sand and bonding materials.", "One part, called the mold, forms the hydrant's exterior shape, while the other part, called the core, forms the interior shape.", "An automatic core setter positions a core in each mold.", "Then a conveyer advances the mold under the pouring box, which fills the cavity between the mold and core with molten iron.", "After the iron cools and solidifies, the molds enter a tumbling barrel.", "As they revolve, the sand gradually disintegrates, freeing the iron casting inside.", "Workers drill and thread the hydrant castings to prepare them for assembly.", "Then they preassemble and paint them.", "The fire hydrant's internal workings, called the valve assembly, allow water to flow through when the hydrant's open.", "A series of rubber \"o\" rings on the main valve will prevent leaks when the hydrant is closed.", "Now the hydrant is ready for final assembly.", "Workers attach the nozzle section to the top of the hydrant barrel and fasten nozzle cap chains with a crimping tool.", "Using a torque wrench, they attach cast-iron safety rings.", "These rings are designed to disengage the top from the bottom of the hydrant so it doesn't get damaged if a vehicle hits it.", "Workers clamp the water-main connector into place and pressurize the hydrant to normal city pressure to check for leaks.", "Using a hoist, they lower the preassembled nozzle section over the stem...", "And fasten it to the water-main connector with stainless steel bolts.", "They lower the bonnet into place...", "Bolt it to the nozzle section...", "Then open the hydrant for a high-pressure test.", "They turn the operating nut to allow water to flow through.", "But first, they have to force out the air inside the hydrant with water.", "Workers transfer the finished hydrant to a pallet and apply final paint touch-ups.", "Some fire hydrants that were installed more than 100 years ago are still in use today.", "Coming up, it's a cushy job, but somebody's got to do it.", "Most people don't pay too much attention to car seating, but this feature has come a long way since the car was invented in the 19th century.", "Back then, seats had no springs and not much padding.", "So you could feel every bump on the road.", "In today's car seats, we have a much easier ride.", "Padded and belted, modern automotive seats are designed to be safe and comfortable.", "The components are manufactured separately and shipped to this factory for assembly.", "They arrive as needed on the production line so there's not a lot of stockpiling.", "It means the flow of parts into this plant has to be highly organized because they make over 400 seat variations here.", "The parts are carted to the assembly line in the order they're needed.", "On this assembly line, there are 60 workers, each with specific tasks to perform.", "They receive a build ticket for each part and scan it.", "This allows a central computer to track production and verify that the right parts are being used to build the right seat.", "An operator tucks the seat-warmer pad and cables into the cushioning for the bottom half of the seat.", "She loosely places the fabric cover over the assembly and attaches it with wire.", "Then it's over to the next station, where the operator completes the upholstery job.", "Each worker has just 88 seconds to perform his or her tasks, so there's no sitting down on this job.", "They install a seat-warmer system on the backrest section of the seat and cover it.", "Then they slide an air bag into a special sleeve.", "These seats come with springs that clip on to their metal framework to provide lumbar support.", "Workers fit the cushion assembly onto the spring framework and pull it tight.", "They smooth out any wrinkles, a process called finessing.", "Then they install the headrest.", "Next they tackle the lower framework.", "They equip it with a mechanism that adjusts the height of the seat.", "Electrical connectors go in next.", "Then they bolt the lower framework to the cushioned backrest.", "They attach the pretensioner apparatus, which locks the seat belt into position, then wire the connector box.", "They fit the lower cushioning on the framework and add the recliner spring.", "A plastic valance makes it all look neater.", "Now it's time to take this driver's seat for a test run.", "Inspectors hook it up to a power source and make sure the air bag and seat warmer are operational.", "They iron out all the wrinkles because the automaker will reject any seat that's less than perfect.", "Then they slide and tilt the seat to make sure the adjustment mechanisms are working properly.", "Workers assemble the rear seats using the same techniques.", "Again, each operator gets exactly 88 seconds to complete his or her job.", "When you add it all up, an entire seat set takes just 62 minutes to assemble.", "Before they ship the seat set to the car factory, they snap a photo as a production record.", "It proves each set was in perfect condition when it left the factory.", "Now these seats are ready to hit the road.", "Workers strap them onto delivery pallets and load them into a big truck, 60 sets at a time.", "They'll arrive at the car plant just as the vehicles they were made for are rolling off the assembly line.", "Once they're installed, all you need to do is sit back and enjoy the ride.", "Next, making the tubes that bring tvs to life.", "The crt, short for cathode-ray tube, produces the image that we see on our tvs and computer monitors-- the ones that aren't lcd or plasma, that is.", "Believe it or not, the cathode-ray tube was invented back in 1879.", "A crt is made up of two main components, a large glass bulb and an electric gun.", "Crts start with a molded glass bulb.", "Workers remove microscopic debris with a high-pressure water rinse.", "Then they spray hydrofluoric acid to clean the glass at an atomic level.", "Phosphor solution is poured into the bulb.", "Phosphor is an organic compound that emits light when struck by electrons.", "The phosphor particles settle and form a chemical bond with the bulb face.", "Workers pour off the excess solution...", "And clamp the bulb over a nozzle that sprays clear lacquer over the phosphor.", "The centrifugal force guarantees an even coat.", "This worker paints a conductive coating over the anode button which will provide a flow path for the electrons that will light up the phosphor particles.", "Meanwhile, another worker drops an aluminum pellet into a tungsten coil.", "He places the bulb over a vacuum device and draws out the air.", "Then he applies an electrical current to the coil.", "It evaporates the aluminum pellet, which spreads a mirrorlike coating on the inside of the bulb.", "Now they heat the bulb to 425 degrees fahrenheit for one hour.", "This bakes out the lacquer and any trace of moisture.", "Using a high-temperature flame, a worker aligns and fuses a glass neck to the bulb.", "Then he paints it with the same conductive coating.", "This assembly is part of the electron gun that goes inside the bulb.", "It shoots electrons at the bulb's phosphor particles that lights them up, creating the image we see on screen.", "Workers stack the grip cups that focus the electrons on the screen.", "Then, using beading glass, they align and fuse them into position.", "Robots heat and affix the beading glass to assemble the electron-gun components.", "Then the gun is cooled with pressurized air.", "Once cool, a worker builds up the gun and inserts the completed gun assembly into the bulb.", "Next he positions the bulb on a glass-blowing lathe and cuts excess glass from the neck.", "Using a graphite paddle and a high-temperature torch, he mates the glass neck to the electron-gun stem.", "This ceramic heating coil melts that green glass pellet to keep the bulb under vacuum.", "The tube is heated to 750 degrees fahrenheit for two hours, and once again a vacuum is drawn.", "To minimize image flicker over the tube's life-span, workers condition the bulb using a high-voltage coil.", "It smoothes any rough surfaces that might remain on the electron gun.", "Finally, workers apply electrical connections to the electron gun to bring the cathode-ray tube to life." ]

{ "things": [ "Jaws of Life", "Artificial Christmas Trees", "Soda Crackers", "Ratchets" ] }

[ "The jaws of life were first used in 1963 to free racecar drivers from car crashes.", "It was so big, it had to be suspended from the back of a pickup truck.", "Today it weighs as little as 33 pounds and is small enough for one person to operate.", "It can free an accident victim from a car in minutes.", "In an emergency situation, timing is everything.", "A rescue tool has to pry open a vehicle as easily as a tin can or cut through solid steel like butter, because a few seconds can make all the difference.", "What gives the cutting blades and the spreading arms their power is hydraulic fluid.", "The jaws of life begin with a milling machine that shapes the spreader arms from a bar of solid aircraft-grade aluminum.", "The spreader arms then get a protective coating.", "A lathe now makes the cap that fits on the end of the tool.", "A high-speed carbide tip shapes the solid aluminum into a finished endcap that is then drilled and treated to a coat of rust-resistant protection.", "Arms that both cut and spread are made from tool steel.", "A surface grinder ensures that the two arms are perfectly flat.", "A worker installs a seal that prevents the hydraulic fluid from leaking out of the cylinder.", "He lubricates a piston with hydraulic fluid so it slides into the cylinder without damaging the interior.", "Then he taps it in so it will connect with the link assembly.", "He attaches a link assembly to the piston and secures it in place.", "The link assembly relays power to the cutting blades or spreader arms.", "He then attaches an assembled end cap to the cylinder and bolts it in place.", "He connects the two hoses that lead to the tool's hydraulic cylinder.", "He puts on a handgrip that protects the hoses and makes it easier to work the thumbwheel.", "He tightens the bolts and completes the control valve.", "He then attaches the front handle that allows the operator to hold the tool safely.", "This protective guard will keep all the moving components away from a rescuer's hands.", "Then he aligns the holes in the blades to the tool and inserts a steel pivot pin.", "He puts on a locknut, and, as with all fasteners on the rescue tool, he tightens it to a precise engineering specification.", "After mounting the blades, he secures them to the link assembly with a steel-alloy pin and a snap ring.", "Then he folds the protective guard back and finishes assembling the tool.", "A worker then tests the tool, which has been filled with fire-resistant hydraulic fluid.", "The fixture he uses is designed to measure the pressure at the strongest point in the cutting.", "The tool passes the pressure test.", "Whether it's a rescue tool that cuts through metal or pries it open, emergency-response teams arriving on an accident scene will have what it takes to help save lives.", "The quest for the perfect tree is a rite of the holiday season.", "And ever since the late 19th century, people have been trying to come up with an artificial version.", "First, there were feather trees and, later, trees made of animal bristles.", "But by the 1960s, the use of synthetics finally gave us the perfect fake fir.", "Today's faux firs can be several stories tall-- big enough for your town square.", "You can get them with many of the trimmings so decorating isn't such a stretch.", "These big artificial trees start with a steel skeleton.", "Rollers bend steel tubing into arcs.", "They'll be joined to form the base of the framework.", "Workers weld vertical supports to the arcs, building the structure in sections.", "A spray of polyester powder gives the welded metal a smooth finish that's actually tougher than paint.", "They bake the parts to set the coating.", "After a quick cooling, it's time to assemble all the pieces.", "They fasten the structure together with u-bolts and a ratchet.", "Meanwhile, a roll of green pvc plastic winds its way towards a roller equipped with many circular cutters.", "They slice it into 4-inch-wide strips.", "Each of the narrow plastic strips then goes under a roller with even more blades.", "They shred it into a needlelike configuration, leaving a solid spine at the center to hold the simulated needles together.", "An automated spool then winds up the fringed green pvc.", "These artificial needles come in an assortment of colors, so if you want glitz, you can really go out on a limb.", "Here, streams of the fringed green and a strip of brown pvc travel over tension-control guides.", "Steel wire unwinds and merges with the green and brown pvc.", "This machine twists them together.", "The brown strip lands at the core of the twisted fringe, creating the illusion of a stem among the needles.", "This twisting technology churns out a continuous supply of artificial greenery.", "Giant scissors slice it to the correct length.", "To make branches that appear snow-tipped, this machine twists and then frosts the pvc needles with a spray of white latex paint.", "They use this ring fastener to crimp the artificial foliage together, branch by branch.", "This creates a tightly knit mass of greenery that will be used to cover the tree's framework.", "They apply single garlands on key parts of the tree grid first, using a handheld pneumatic fastener.", "They fill in the sections between them with the assembled branches.", "This is easier than attaching them to the framework branch by branch.", "They string the lights and then plug them in to check each bulb.", "After all, it's easier to change one now than after the tree has been erected, especially since this one will be a story and a half tall.", "They also wire the ornaments to the branches.", "It's one less job for the customer to do.", "And now it's time to put up the tree.", "They bolt the cone of wired greenery to the lower framework...", "And then hook the panels of artificial greenery onto the rest of the structure.", "It has taken just one day for this artificial tree to come together, where growing a real one this size would take many years.", "And the convenience is unreal.", "Soda crackers are also called saltines, originally a brand name that over time became a generic term.", "You can eat them plain or spread something on them or crumble them into soup.", "Doctors even recommend eating soda crackers when you're nauseous, because they're dry and easy to digest.", "They're flat and bumpy on the outside, with a tasty texture resulting from some interesting chemical reactions.", "Workers first dump ice into a trough to prevent the dough from overheating during fermentation.", "The first ingredient is a specific amount of finished dough to kick-start the fermentation of this new batch.", "To that, they add water, wheat flour, yeast, and enzymes to help the fermentation.", "A mixer blends the ingredients for about 5 minutes.", "They let the dough sit for 16 hours while the enzymes break down the starch and the wheat into simple sugars.", "The yeast then reacts with those sugars, producing carbon-dioxide gas, which makes the dough rise.", "Then they adjust the fermented dough's ph level with sodium bicarbonate to produce the right flavor, color, and shelf life.", "Then, for additional flavoring, some salt...", "Malted barley flour...", "And vegetable oil.", "Then the mixer remixes the dough for about 5 minutes to blend in these new ingredients.", "Now they let the dough ferment for another 6 hours.", "The sodium bicarbonate counteracts the acidity this produces and relaxes the gluten so that the dough now breaks easily when stretched-- the perfect consistency for soda crackers.", "A machine then extrudes the massive dough into a sheet that's 2 inches thick and folds the sheet over itself 3 times.", "This folding creates the light and flaky layers inside the cracker.", "The dough sheet then goes through a series of rollers that reduce it to its final thickness, about a millimeter.", "A revolving die cuts the cracker shapes, perforations and all.", "The little pins puncture the dough and push it firmly onto the conveyor belt.", "This keeps the dough from deforming when moisture and gases escape during the baking process.", "From there, the sheet passes under a shower of salt.", "The sheet now takes a three-minute trip through a long oven with different temperature zones.", "Gas flames bake the dough from above and below.", "The heat transforms the sodium bicarbonate in the dough into carbon-dioxide gas, which then breaks through and escapes.", "This drives out trapped moisture and forms blisters in the crackers.", "As the sheet of baked crackers exits the oven, a roller breaks it into rows.", "The rows then run from one conveyor belt to the next, stacking like roof shingles.", "Alignment wheels keep them straight until the next set of wheels gently breaks the rows into individual crackers.", "Each row makes its way through a series of gates that guide it onto a track that leads to the packaging equipment.", "The crackers are upright now, and the machine begins dividing them according to the number of crackers per package-- in this case, those little 2-cracker packs you often get with soup.", "The cracker pairs enter the wrapping machine, which sandwiches them between a sheet of printed plastic film.", "A wheel then simultaneously seals and cuts the wrapper between each pair.", "This all happens at an astonishing rate of 525 packages per minute.", "And that's the way the cracker crumbles.", "Ratchets come in many shapes and sizes and can tackle almost any job.", "Ratchets with socket attachments deliver more power and speed without slipping or damaging the bolt or nut.", "Just snap an interchangeable socket onto the ratchet, and you're ready to get the job done quickly and properly.", "Versatile and easy to use, a ratchet tightens or loosens nuts and bolts in a continuous motion.", "It uses removable sockets that fit many different sizes of fittings and fasteners.", "To start, a steel bar travels into a shearing machine that cuts it into specific lengths.", "These pieces, called billets, will be used to make the ratchet.", "A machine feeds the billets into an induction coil, which heats them to about 1,800 degrees fahrenheit.", "A forge press then shapes the soft billets into ratchets.", "The first die creates the ratchet's general form.", "The second die gives it its finished shape.", "And the third die cuts off excess metal.", "The ratchets exit the forge press and fall into a collection box, where they cool.", "Then a vertical milling machine prepares the body cavity to receive the internal working parts of the ratchet, called the gear assembly.", "A worker then places the ratchet on a hydraulic press, which stamps the brand name and the on-and-off indicator on the ratchet's face.", "A lathe cuts away the rough forged metal from the handle and trims off the end, making it ready to receive the handgrip.", "A worker then grinds any rough edges off the machined ratchet.", "Then he crimps each side of the smooth handle so it will hold a rubber handgrip in place.", "The ratchets now undergo a 3-stage tempering process that hardens and strengthens the metal.", "Ceramic stones and a chemical solution prepare the ratchets for nickel and chrome plating.", "A plating machine cleans the ratchets, then treats them to a nickel and a trivalent chrome plating.", "The two platings make the ratchets corrosion-resistant and give them a bright cosmetic finish.", "A worker then lubricates the ratchet cavity, puts in an on-and-off switch and a spacer to support additional components.", "A worker sets a retention ball onto a ratchet gear, then a punch press locks it in place.", "Next they fit a gear mechanism into the cavity, then attach all the internal components that control the movements of the ratchet.", "Once completed, the gear assembly allows or restricts movement.", "So, putting the assembly into either the on or off position is all it takes to tighten or loosen a nut or bolt.", "She then puts a rubber seal onto a cover plate and closes up the ratchet.", "She makes sure the gear assembly works properly.", "Finally, this machine friction-fits a handle on the ratchet's shaft.", "Evolving from a steel bar to a finished product in 10 steps, the ratchets must undergo a final test of strength to prove they meet the highest quality standards.", "Ratchet sets are available in a variety of sizes.", "They're used for big and small jobs by handymen and professional mechanics alike." ]

{ "things": [ "Powder Horns", "Handcrafted Molds", "Pierogi", "Inner Tubes" ] }

[ "On the battlegrounds of american history, powder horns were everywhere.", "These modified cow horns served as carrying cases for gunpowder in 18th century colonial battles and the american revolution.", "For soldiers engaged in heated battle, the containers were a good way to keep their powder dry.", "With the invention of ammunition cartridges in the 19th century, muzzle-loading firearms and powder horns became a thing of the past.", "But today, they're back.", "Powder horns are in demand for historical re-enactments and among some sportsmen and collectors.", "The concept of using a cow horn to make a gunpowder container demonstrates the resourcefulness of people in an earlier time.", "Cow horns were accessible.", "They're naturally hollow, lightweight, and waterproof.", "To start, the craftsman selects the cow horn and evaluates it for structural flaws.", "Finding no cracks or weaknesses in this one, he proceeds.", "He scrapes off the scale to clean it and get a better look at its condition.", "Next, he identifies the depth of the cavity with a thin wire.", "This tells him where the hollow section ends and the horn becomes solid.", "He marks the spot then draws another line 1 1/2 inches down.", "These markings serve as guides as he now turns the tip of the horn into a spout.", "He cuts off the pointed end along the second line.", "He drills into the horn all the way through to the horn cavity.", "He lays out the design of the spout with rubber rings.", "He traces around them and then scores the horn at the pencil marks.", "He files the horn around the score marks to give the spout end the desired contours and builds up a ringed ridge for the powder-horn strap to rest against.", "Next, he gouges the horn to create ornamental notches above the spout.", "This is known an engrailing.", "He pencils lettering onto the side of the powder horn.", "He scratches the horn along the penciled lines to engrave the letters into it.", "Historically, powder horns were a soldier's canvas upon which he etched maps, designs, and personal information.", "He rubs ink onto the lettering, and it seeps into the fine cuts.", "When he wipes off the ink, it remains in the engravings to make them really stand out.", "He slices the other end of the cow horn to create an even edge.", "Then, he boils butternut hulls and wood chips in water to make a dye.", "He immerses the powder horn in the dye for about an hour to give it a look that would take decades to achieve naturally.", "It gives the powder horn a yellowed, more aged patina.", "He now carves a base plug from pinewood.", "He trims the rough shape to the exact curvature of the horn.", "He inserts the plug and ensures it's a snug fit.", "He drills six holes into the horn and through to the plug.", "With a tack hammer, he drives wooden pegs into the holes, securing the plug permanently.", "He slices off the end of the wood to make it flush to the horn.", "He stains the wood plug with shoe dye to make it blend in with the color of the horn.", "Once the stain has dried, he creates a hook for a shoulder strap.", "He drills holes that are a little smaller than the hook so that when he pounds it into the holes, the hook is firmly installed.", "He loops the strap through the hook and stitches it up.", "He inserts a wooden stopper into the spout, and this powder horn is now ready for containment.", "But mostly, it will just hang around as a reminder of another time.", "Mass-produced glass items are typically shaped by automated machines, which insert molten glass into an assembly line of molds.", "Specialty items are usually cast individually with the artist manually planting the molten glass in a mold crafted by skilled mold-makers.", "These molds for making specialty glass items are entirely handcrafted.", "This one, comprised of three sections, produces the ornate shade of a glass candle lamp.", "This one, comprised of two sections, produces the lamp's base.", "The glass manufacturer submits the design sketch of the item to the mold shop.", "The shop, using computer software, converts the sketch into technical drawings.", "Then following the drawings, workers prepare a wooden pattern of the mold.", "They first make a cardboard template for each mold section, then trace the template on a piece of wood, saw along the pencil line, then finalize the shape with a sander.", "They send the patterns for the mold sections to a foundry, which casts copies in iron.", "These iron castings are rough, so when they return from the foundry, the mold-makers refine each section with a series of milling machines.", "This takes a tremendous degree of expertise, as these are not computer-guided automated machines.", "These skilled tradesmen maneuver the mills manually, following the technical drawings.", "Once they finalize the shape, they use a drill press to bore holes for the hefty pins on which the mold sections will pivot open and closed.", "Iron is the ideal material for glass molds because it withstands a temperature of over 2,000 degrees fahrenheit for molten glass.", "Iron does expand with such heat.", "However, once cool, it contracts and resumes its original shape without any distortion.", "They mount the mold section on a lathe to begin forming the cavity.", "Using a tool called a boring bar, a mold-maker shapes the cavity as per the technical drawings.", "Then he takes the mold section off the lathe and paints the cavity yellow to give him a bright background against which to sketch out the fine details of the design.", "This particular pattern features circles, which he sketches with compasses.", "Using an arsenal of chisels with different size and shape tips, he chips the metal to carve out what he sketched.", "Again, he follows the technical drawings meticulously, giving the carved lines the specified depth and profile.", "Once he finishes the pattern, he mounts the mold section on one side of a mechanical copying machine called a pantograph.", "On the other side, he mounts another section of the mold which doesn't yet have the carved pattern.", "The pantograph stylus traces the pattern on the carved section and simultaneously moves an engraving tool through the identical motions on the uncarved section, transferring the pattern.", "Because this is a three-sectioned mold, they make two copies on the pantograph.", "The carving tools leave marks on the surface of the cavity, so the next step is to polish them away with emery paper.", "On the right, you can see the marks.", "And on the left, the smooth, polished surface.", "The sections are now ready to be assembled with pins into a complete mold.", "When it's time to pour in the molten glass, the pins enable the sections to close and interlock.", "Once the glass cools and solidifies, the pins make it easier to open the mold to extract the casing.", "Glass artisans and glass manufacturers alike use handcrafted molds to produce a wide variety of glass items from functional to fancy.", "The perogi is a pillowy pastry stuffed with mashed potato or other fillings.", "Popular for centuries in eastern europe, perogies were initially peasant food.", "But today, their appeal crosses class and cultural boundaries, and worldwide there's a growing appetite for perogies.", "Perogies are comfort food, traditionally made from scratch by generations of polish grandmothers.", "But today, few people have time for all that work, and the job of making perogies has moved from the kitchen to the factory.", "All you have to do is add the sour cream and chives.", "Production starts with the potato and cheese filling.", "They boil potatoes until tender.", "Then, still piping hot, they transfer the potatoes to a mixer grinder.", "They add a generous amount of shredded cheddar cheese along with some salt and spices.", "A spiraling blade mashes and mixes the ingredients.", "The blade misses a few chunks of potato, so the machine forces the ingredients through a perforated metal plate.", "It gets rid of the chunks and leaves the mix smooth and creamy.", "With the filling done, it's over to the dough department.", "They pour measured amounts of flour into a mixer.", "They add oil for texture and flavor and some salt to further enhance the taste.", "They open an overhead tap, and a measured amount of water flows directly into the mixer.", "The mixer's roller bars blend and knead the dough to a fairly thick consistency.", "After leaving the dough to soften a bit, they feed it to a special perogi-making machine.", "The potato and cheese filling flows into the same machine.", "It forces both the filling and the dough into a forming device.", "It's enclosed for safety reasons, so you can't see it here.", "Inside, the machine shapes the filling into a cylindrical form and the dough around it into a sleeve.", "Here, the machine pumps out a roll of potato filling, the dough surrounds it, creating sausage-like form.", "As the filled dough exits, a roller shapes it into individual perogies.", "It also cuts and crimps the edges.", "This produces uniformly plump perogies at an incredible speed.", "This machinery churns out 50,000 perogies an hour.", "The freshly formed perogies ride by a divider mechanism that separates them, preventing clumping as they transfer to another conveyor.", "An inspector rejects any defective dumplings so that only perfect perogies head into a freezer.", "The temperature inside is an icy negative-50 degrees.", "It's a winding journey on spiraling tiers, where they chill for about 14 minutes.", "When they exit, they're frozen solid and ready for packaging.", "The dumplings ride a series of conveyors towards the packaging line.", "It's a quick journey, giving them no time to thaw.", "The perogies funnel into weigh stations.", "Below, mechanical fingers open bags.", "The scale releases 22 ounces of perogies into each bag.", "That's about 23 perogies per bag.", "Hot jaws seal the plastic.", "The bags of perogies travel through an x-ray station on their way to the warehouse freezer.", "It scans them for bits of metal or glass that may have contaminated the perogies during production.", "Today, perogies have many different fillings.", "There are even fruit-filled ones for dessert, the recipe may be centuries old, but there are a few new tricks.", "The earliest tires were bands of steel fitted to wooden wheels, hardly a comfortable ride.", "Air-filled inner tubes were part of the first successful car tire in 1911, and inner tubes are still used today in most bicycle tires and many motorcycle tires.", "These motorcycle inner tubes are made with a combination of synthetic and pure, natural rubber.", "They come in a variety of sizes and offer superior quality because no recycled or reclaimed rubber is used during the manufacturing process.", "A worker selects a slab of synthetic rubber, a package of chemically enhanced rubber, chemicals used as antioxidants, accelerators and curing agents, and finally a package of pure, natural rubber.", "A worker pulls the materials from an internal mixer and guides them into a two-roll mill, where they're squeezed together.", "He trims off the rubber sheet.", "Ideally, the texture of the rubber sheet is smooth.", "Carbon black provides pigmentation to the process and reinforces the rubber.", "The rubber is now sent for cooling.", "It soaks in a mixture of calcium carbonate, which, once dry, will prevent the rubber from sticking to itself.", "Workers carefully fold the continuous sheet of rubber in a stack to dry.", "The next day, the rubber is cool and hard, and the calcium carbonate has dried into a powder.", "A worker places the small strip coming out of the two-roll mill onto an overhead conveyor belt, which takes it to the next phase of production.", "The strip falls into a extruding machine, where a turning screw forces the raw rubber through a strainer.", "A worker uses a wire to cut the rubber strands as they emerge.", "He places the rubber wad in the two-roll mill once again.", "The rubber will gradually be shaped in preparation for the next phase of extrusion.", "Squeezed into a strip, the rubber falls into a tube extruder machine.", "As it passes through the die, it emerges in a cylindrical shape.", "The rubber tube is hot.", "Water cools it down and cleans away any remaining residue.", "The rubber tube now enters a cutting machine.", "Calcium carbonate powder helps prevent sticking.", "After being cut, a hole is punched in the tube and a valve inserted.", "The first cone punches the hole.", "The second inserts the valve.", "A worker replaces each valve after it's been inserted into the rubber tube.", "This machine can process 22 tubes per minute.", "Here is the rubber tube with the hole punched and with the incomplete valve inserted.", "A worker now connects the two ends of the cut tube.", "He places both ends into the machine, which, using different steps, cuts and fuses them together.", "By the time the machine completes the process, the worker has two more loose ends in place.", "First, the knife cuts both ends of the tube.", "By clearing away the calcium carbonate powder, the two heated ends can stick together.", "No glue is needed.", "The cut is clean and straight.", "Heat, combined with the rubber's natural stickiness, firmly holds the seam together.", "A worker now pumps air into the circular tube.", "He hammers wax into the incomplete valve in order to temporarily seal the air inside.", "Another worker places the tube in a mold.", "It will be heated for a few minutes, part of the vulcanization process.", "The wax that held the air inside has melted, but after being vulcanized in the mold, the tube retains its cylindrical shape.", "To flatten the shaped tube, any air remaining inside is removed using a vacuum.", "These workers give the inner tube its finishing touches.", "They complete the valve by adding a core, followed by a ring, a nut, and a valve cap.", "They fold the finished inner tube and circle it with two elastic bands.", "The folded inner tubes are inserted in packaging that is then heat sealed.", "Ready to hit the open road, these motorcycle inner tubes are sure to get riders pumped." ]

{ "things": [ "Conga Drums", "Metal Plating", "Buttons" ] }

[ "Today on \"how it's made\"...", "Conga drums...", ".metal plating...", "And buttons.", "The conga drum may be a staple of latin-american music, but it was developed from an ancient african drum made from an animal skin stretched over a hollow tree trunk.", "Today, they stretch the hide over a wood or fiberglass cylinder.", "As you're about to see, making congas takes plenty of hands-on skill.", "these congas are made of ash, a wood that has good acoustics.", "That means sound resonates off of it rather than being absorbed into it.", "First, the drum maker cuts the curved slats that will form the drum's body, called the shell.", "He traces a slat-shaped template on a rectangular piece of wood.", "Then, using a band saw, he cuts along the trace line, creating a curve on the outside and inside surfaces.", "Then he moves to a bench saw, a saw whose blade can be adjusted to different angles.", "He clamps the piece onto a template and angles the edge.", "He flips the piece over...", "And angles the other edge.", "The drum maker applies carpenter's glue to both edges and clamps the slats together in a circle on a specially designed form.", "The number of slats per drum varies, depending on the diameter of the shell.", "The larger the diameter, the lower the conga's sound.", "The glue dries in 24 hours.", "It comes off the form looking like this bongo shell, but taller.", "The drum maker now mounts the dried shell on a wood lathe.", "Using a tool called a wood gouge, he shears off about .", "2 of an inch, rounding the outside of the shell.", "Then he uses a series of woodworking tools to add decorative detailing.", "Once that's done, he smoothes the shell's surface, using three progressively finer grains of sandpaper.", "Then he either leaves the wood its natural color or stains it.", "A thick coat of oil-based lacquer protects the wood from both dryness and humidity.", "Now for the essential hardware.", "First, side plates made of chrome-plated steel.", "Their job is to anchor the drum's animal-skin head.", "They're bolted to the shell.", "Next, the drum maker feeds a steel strip through a bending machine.", "Its high-pressure rollers curve the strip, forming the drum's rim.", "Then he rivets v-shaped steel pieces onto the rim.", "Elsewhere in the workshop, they prepare the cowhide that will become the drum's head.", "First they soak it in a corrosive bath of cold water and lime.", "This literally burns the hair off the hide.", "After two or three days, they remove the skin and scrape off any stubborn hairs.", "Then they stretch it over a circular frame, leaving it to dry at room temperature for a couple of days.", "After chrome-plating the rim, it's time for the final assembly.", "They stretch the head over the shell and clasp it in place with the rim.", "They hook the v's to the side plates, then adjust the tension to tune the instrument.", "The last step is to trim off the excess skin.", "Now the musical handiwork can begin.", "Plating is a layer of metal coating an object made of a different type of metal.", "The purpose can be decorative, as in silver plating, or practical.", "With industrial parts, for instance, zinc or cadmium plating prevents the underlying metal from rusting, while nickel or chrome plating protects against wear.", "You can plate almost any type of metal.", "Let's follow some steel aerospace parts as they're about to be plated with cadmium to make them corrosion-resistant.", "For the plating metal to bond properly, the steel surface must be free of contaminants such as oil and grease.", "Workers suspend the parts over a vat of boiling chemical solvents.", "As the hot vapor comes in contact with the colder metal, it condenses, dripping down into the vat and taking any contaminants along with it.", "The remaining solvent residues evaporate, leaving the parts squeaky-clean and dry.", "Next, a worker wearing protective clothing sandblasts the parts with aluminum oxide powder, a strong abrasive.", "This roughens up the surface so that the plating metal will adhere better.", "The most common plating metals for industrial purposes are zinc, chrome, and nickel.", "Think motorcycle parts or sink faucets.", "Decorative items, on the other hand, are most likely to be plated in tin, brass, gold, or silver.", "Traditional tea sets, for instance, are often made of silver-plated copper or zinc.", "The plating process is called electroplating because the key is electricity.", "They start by tying strands of copper wire to a copper support frame.", "Copper is the best metal for conducting electricity.", "Then they attach the steel parts they'll be plating.", "When they hook up the support to an electric current, electricity will run from the support through these wires right to the pieces.", "They do the electroplating in a tank.", "After filling it with water, they add a handful of chemicals to help conduct electricity, because water alone won't conduct it sufficiently.", "Along the sides of the tank, in bags, are metal baskets.", "They contain bars or balls of the plating metal-- in this case, cadmium.", "Workers connect the support frame with the steel parts to the negative terminal of an electric source-- the baskets of cadmium to the positive terminal.", "Then, they switch on a steady d.c. current no stronger than six volts.", "The electricity dissolves the cadmium, placing the particles with a positive charge.", "They travel through the water and attach themselves to the negative-charged steel parts.", "This creates a smooth and even layer of cadmium.", "Thin plating requires just a few minutes in the tank.", "Thick plating, several hours.", "Then workers rinse the parts in water for about a minute to remove the chemical residues.", "To make the parts even more rust-resistant, workers immerse them in a series of compounds.", "This triggers a chemical reaction in the plating, enhancing its ability to withstand corrosion.", "This reaction, however, changes the color.", "A final rinse in hot water, and this cadmium-plated steel aerospace part is finally ready.", "From start to finish, the process has taken about 90 minutes.", "To plate with chrome or gold, they have to use a chemical compound containing gold or chromium.", "That's because electricity can't dissolve solid chromium well enough, and it can't dissolve solid gold at all.", "The compound dissolves in the bath like salt, but then solidifies once it reaches the object being plated.", "Metal plating is very durable, but if subjected to a lot of wear and tear, the object will eventually have to be replated.", "Have you ever wondered why men's buttons are traditionally on the right side of a garment and women's on the left?", "Legend has it that this enabled a man to unbutton his coat with his left hand while drawing a sword with his right.", "Wealthy women, meanwhile, had their buttons sewn on the left side to make it easier for their right-handed maids to dress them.", "One way to make plastic buttons uses a multilayer sheet of synthetic resin-- hence the industry term, sheet buttons.", "Workers start by mixing liquid polyester resin with a catalyst to gel it.", "They pour the material into a revolving drum, which disperses it evenly.", "They spray a solution containing an ultraviolet pigment on this first layer only.", "You'll see why later on.", "For this particular model, they make grooves in the resin while it's still malleable.", "This will create a design.", "After about five minutes, the resin gels and they can mix and add a second layer in a different color.", "Besides building up the thickness of the sheet, the resin flows into the first layer's grooves, creating a design of contrasting lines.", "Once this second layer gels, they mix and pour in a third color.", "The drum spins for another 10 to 15 minutes until all layers cure.", "A resin sheet can be comprised of up to 4 different color layers.", "Workers can now remove the sheet.", "It's hardened enough to be cut into buttons, but it's still flexible enough not to crack when cut.", "They feed each sheet into a press that's outfitted with the die for that particular button model.", "The press punches out circles in the diameter of the button.", "These circles are called blanks.", "Here, you can see the different color layers.", "The blanks move on to the machining center, where they'll be transformed into buttons.", "Automated equipment loads them onto carousels with the back of the blank facing outward.", "How does the loader know which side is which?", "Remember that ultraviolet solution the workers sprayed onto the first layer of resin?", "A u.v. detector scans each blank to make sure the first layer is facing upward.", "If it isn't, the machine rejects the blank, then flips and reloads it.", "The carousels first run the back of the blank against a series of cutting heads.", "The heads are changed according to the model being produced.", "For this one, the heads gradually carve a curved back.", "The equipment then transfers the blank onto a second carousel, exposing the front side this time.", "Again, a series of cutting heads gradually carve the front of the button.", "The shape of this model exposes the different color layers underneath, creating a veined effect.", "The last cutting head drills the holes.", "Here, you can see the full progression from blank to button.", "Now they polish the buttons for several hours in drums containing abrasive ceramic stones and pumice.", "Then workers flush the drums with water.", "The heavy polishing stones sink to the bottom while the lightweight buttons float to the surface and spill out.", "The buttons then go into drums that contain silicon wax and thousands of tiny wooden pegs.", "While the drums spin, the pegs act as a carrier, distributing an even coat of wax.", "As the buttons exit the drums, the pegs are screened out.", "From here, plain buttons are often custom-dyed to match fabric swatches provided by clothing manufacturers.", "You've seen how they manufacture some types of plastic buttons, just a few of the many styles on the market.", "There are several different ways to produce these handy little fasteners.", "So, forgive us if we buttonhole you to stay tuned and watch some more.", "Archeologists have unearthed bone buttons dating back to prehistoric times.", "The ancient greeks and romans used buttons to fasten and decorate their clothing.", "Europeans wore buttons strictly for adornment until about the 1200s.", "That's when fitted garments became the trend, fastened by a long row of buttons down the front.", "The rich wore buttons made of silver or gold, sometimes set with precious gemstones.", "Ordinary people wore buttons made of bronze or wood.", "This is another way to make plastic buttons using polyester resin.", "Only instead of turning it into sheets, they pour the resin into long metal tubes.", "Here, they're mixing two different colors to create a design in the plastic.", "The tubes go into an oven, where they bake at 212 degrees fahrenheit for about an hour until the liquid resin hardens.", "Once the tubes cool off, workers remove the contents.", "These long resin rods will become what the industry calls rod buttons.", "The rods go into a machine called the slicer.", "Its sharp carbide blade chops the long rods into button-sized blanks.", "Here's what that looks like in slow motion.", "It's no use showing you this at regular speed.", "It would be but a blur.", "This machine cuts up to 700 blanks per minute.", "Blanks cut from resin rods run through the same machining center as those cut from resin sheets.", "In the last segment, we showed you the machining steps in slow motion.", "Here's what they look like at actual speed.", "Any type of button can be engraved with a company name or logo.", "They do this using a computer-programmed laser machine.", "The laser beam burns the lettering into the plastic.", "Workers visually inspect the finished buttons to make sure that none have defects.", "A third way to make plastic buttons is a method called thermoset compression, a technique that combines both heat and pressure to mold the button's shape.", "As we see here in slow motion, the raw material isn't liquid resin, but rather melamine powder.", "A pill-making machine-- the kind pharmaceutical companies use-- compresses the powder into pill-shaped blanks.", "Here's what that pill-making action looks like at actual speed.", "To transform these pills into buttons, workers load them onto a press.", "The press uses high pressure to force each pill into a button mold for a period of 40 to 60 seconds, depending on the size of the button.", "At the same time, it heats the mold to 325 degrees fahrenheit.", "This bakes the melamine into hard plastic.", "They cool the molded buttons in a basin of cold water.", "Some specialty buttons will be gold-plated, but not before soaking in a chemical bath to clean their surface so that the plating will bond well.", "As a rule, only materials that conduct electricity can be metal-plated.", "Plastic, of course, is nonconductive.", "This company has managed to devise a way to gold-plate plastic buttons.", "Exactly how is a closely guarded secret it's not willing to divulge.", "After plating the buttons in copper, a 12-hour process, they plate them in nickel, which takes just a couple of minutes, and finally, in 24-karat gold, which takes just a few seconds.", "A mere one ounce of gold is enough to plate 180 pounds of buttons.", "Thermoset compression buttons are a lower-end product used primarily for uniforms.", "Sheet buttons and rod buttons are higher quality, the standard choice for everyday and higher-end clothing." ]

{ "things": [ "U" ] }

[ "The best way to protect your bicycle against theft is a heavy-duty lock.", "A u-lock is the most secure option.", "Unlike a cable or chain lock, you can't quickly sever a u-lock with a pair of bolt cutters.", "It takes large conspicuous tools-- not something a thief can likely get away with unobserved.", "U-locks come in various sizes so that you can lock your bike to different structures from thin bike racks to thicker tree trunks.", "The shackle and lock are made of hardened high-alloy steel, which is resistant to cutting, sawing, and twisting.", "To shape the shackle, workers load steel bars into a computer-guided bending machine.", "The machine applies more than 25 tons of force to bend the bar in the shape of a \"u\".", "The machine also notches each end of the shackle.", "These notches are what receive the locking bolts.", "To make the steel hard enough to be tamper-proof, they send the shackle to an outside facility for heat treatment.", "This demonstration re-creates a small part of that complex process, which is to heat the shackle to almost 1,500 degrees fahrenheit to rearrange the molecular structure, cool it in oil to set the hardness of that rearrangement, then reheat at moderate temperature to restore the flexibility the steel lost due to the previous steps.", "When the shackle returns to the factory, a laser machine precision measures and, if necessary, corrects the dimensions as per specifications.", "Then the shackle is dipped in durable anti-corrosion paint.", "Once the paint dries, and automated machine slips a pvc tube over the shackle.", "Next, they screw a plastic bracket to one end of the shackle.", "This connects to a corresponding bracket you screw to your bike frame to mount the lock on the bike when you're cycling.", "The rectangular block that houses the locking system is called the lock body.", "It, too, is made of hardened steel.", "An automated press punches holes on the ends for the shackle and in the middle for the lock cylinder.", "The locking system has a housing in the center for the cylinder.", "Workers mount two metal plates over it.", "When you insert the security-coded key in the cylinder and turn, the cylinder rotates within the housing and the plates move apart, triggering other components to lock the inserted shackle.", "The cylinder is made of brass, a relatively soft metal, so there's an impenetrable steel plate on top to prevent a thief from drilling into it.", "Workers give the cylinder grooves a squirt of grease-- the housing, as well-- then insert pins into the grooves.", "These act as blockers, preventing the wrong key from opening the lock.", "With the correct key, they give way, enabling the cylinder to rotate within the housing.", "This spring applies tension to the cylinder's steel and drilling plate, keeping it in position so that the key inserts easily into the cylinder.", "On each side, workers insert a lever and bolt.", "When you turn the key to the locked position, the lever pushes the bolt into the shackle's notch, immobilizing the shackle.", "This component spring-loads the bolt to prevent the inserted shackle from popping out prior to being locked.", "A pneumatic machine inserts the locking system into the steel lock body.", "A two-tone plastic cover gives the u-lock a snazzy appearance and makes the surface easier for the cyclist to grip.", "Here's how the lock works.", "When you turn the key, the cylinder rotates.", "This moves the two plates over it outward, triggering the levers on each side to hold the bolt in the shackle notch, locking the shackle in place.", "Every lock undergoes an opening and closing check.", "Random samples are subjected to more extensive quality-control testing.", "It takes 13 tons of cutting force to break the steel-- far more than even this larger-than-typical bolt cutter can apply.", "This torsioning machine measures how much twisting the u-lock can withstand.", "A bike-robber would have to apply more than 350 pounds of force with a crowbar.", "The bike owner, on the other hand, needs only the coded key.", "The native north american tepee was designed to be a home where the buffalo roamed.", "Centuries ago, tribes were constantly on the move hunting the buffalo, which was their main source of food.", "Easy to pack up and reassemble, the tepee served as a portable shelter for this nomadic lifestyle.", "Today, people are rediscovering the appeal of a cone-shaped tent with a cook fire inside, and that's put the tepee on the comeback trail.", "No need to hand-stitch tepees anymore.", "Today, they produce them at a factory using industrial sewing machines.", "They start with the front panel.", "It's three layers of canvas and vinyl.", "They sew details like pockets for poles to open smoke flaps and rectangular patterns to prevent stretching and tearing from holes for lacing the front of the tepee together when pitched.", "The sewer now chops through the three layers of fabric with a chisel to make those holes.", "Another sewer stitches strips of buffalo hide to the door opening to make it more rugged.", "Using a pattern as a guide, the next worker cuts another panel on a slight curve.", "He then pieces together panel after panel to construct the rest of the tepee cone.", "He reinforces the hem with heavy nylon webbing.", "He tucks loops between the webbing and the fabric and secures them with more stitching.", "The loops will be used to stake the tepee to the ground.", "The team stretches out the completed tepee cover.", "An artist maps out some lines for painting on the fabric.", "There's 73 yards of it.", "It becomes a huge canvas for traditional artistry.", "The designs are southwest american in style and highly symbolic.", "Circles can represent phases of the moon or the sun.", "A sample of the artwork has been drawn up beforehand for the client, and the artist refers to it as she works.", "She brushes exterior latex paint thinned with water around the perimeter of the designs.", "Then she soaks up paint onto a pad and presses it to the fabric within the painted lines.", "This avoids brushstrokes and produces a flat finish that almost looks like dye.", "With the artwork complete, the tepee cover now makes a colorful statement.", "Outside, an employee shaves the bark off young trees to prepare the poles.", "There are 17 per tepee.", "Each one is 27 feet tall-- the height of a two-story building.", "A two-person team now arranges three of the poles in a specific sequence to build the tripod that is the basic framework of the tepee.", "The assembler lashes the poles near the top with thick rope and a tight knot.", "He leaves a length of rope to dangle as they raise the tripod.", "The rope will come in handy later on.", "The arrangement situates the door pole east towards the rising sun and away from westward winds that could interfere with the cook fire.", "The team props up the remaining poles between the main tripod poles.", "The first two groups of poles form the front of the tepee, and a third group forms the back.", "The assembler grabs the rope that still dangles from the central tripod, and, from the ground, winds it around all the poles where they meet at the top.", "The last pole is called the lifting pole.", "It's used to lift the painted tepee cover to the wood frame.", "They unbundle the cover and wrap it around the poles like a blanket around a person's shoulders.", "Once the fit is nice and snug, he laces the front panels together using willow branches for lacing pins.", "There are 18 pins in total fastened above and below the doorway.", "He pegs the canvas to the ground and then installs two last poles for opening and closing the smoke flaps from the ground.", "Traditional in design with modern-day materials and construction, the tepee is still an idea worth pitching.", "\"croissant\" is the french word for \"crescent\".", "This flaky, curved roll is generally associated with france even though many food historians believe its origins are austrian.", "Regardless of where it came from, the croissant is a popular breakfast pastry in many parts of the world.", "Plain, with jam, or dipped in a cup of coffee, there's nothing like the light, flaky texture and buttery flavor of a croissant.", "This commercial bakery makes its croissants with soft-spread margarine in lieu of butter.", "The other ingredients are yeast, very cold water-- because warm water would trigger the yeast to react prematurely-- sugar, a touch of salt, and white all-purpose flour.", "All the ingredients go inside an industrial mixer for 10 minutes-- first at slow speed to blend everything and form the dough, then faster to knead it.", "Next, the sticky, elastic dough enters the multi-roller machine.", "As an automated dispenser lightly dusts the dough with flour to prevent it from sticking to the equipment, a series of 16 rollers progressively flattens the dough into a thinner and thinner sheet.", "The next process, lamination, is what creates the croissant's flaky layers.", "The first station on this line extrudes 44-pound blocks of margarine into a 2/10-of-an-inch-thin sheet.", "The next station lays the margarine sheet on top of the thin dough sheet then folds the ends of the dough upward, enveloping the margarine.", "Then rollers compress the overlapped dough ends to seal the margarine inside and flatten the whole thing down to about 4/10-of-an-inch thick.", "The next station repeatedly folds the dough over itself, then, with rollers again, presses the layers into a thin sheet.", "This laminating cycle repeats over and over again until each dough block coming off the line comprises 243 layers.", "Plastic wrap keeps the dough moist as it now undergoes eight hours of refrigeration.", "The cold re-hardens the by-now softened margarine and lessens the dough's elasticity.", "The dough is now ready for the automated machine that forms the croissants.", "The first rollers progressively flatten the connected blocks into a thin sheet.", "Then another roller runs over the dough horizontally to expand the sheet to the required width.", "Next, cutters divide the sheet into seven thin bands, each one four inches wide.", "Then a roller surfaced in triangular blades cuts each band of dough into triangles.", "A robot separates the triangles and turns them all in the same direction with the flat side forward.", "A stopper running the width of the conveyor belt aligns the triangles in straight rows for the next station, inside which a device rolls each triangle into the shape of the croissant.", "The bakery's two forming machines output 50,000 raw-dough croissants per hour.", "Next stop-- the proofer, a steam chamber inside which the heat and high humidity activate the yeast.", "The dough rises, and by the time the croissants exit an hour later, they've doubled in size.", "They now bake for 14 minutes in a tunnel oven at a temperature of 350 degrees fahrenheit.", "The moisture in the dough evaporates, the resulting steam, along with the melting margarine, producing air bubbles which separate the layers, creating that signature flakiness.", "The croissants are now fully baked, golden brown, and fragile.", "Soft rubber suction cups delicately transfer them to a conveyor belt.", "The belt leads to a spiral tower.", "By the time the croissants descend to the bottom, they've completely cooled.", "As they travel to packaging, a quality inspector pulls any misshapen croissant.", "A multi-tasking robot slaps an adhesive label on plastic bags, counts out and drops in two dozen croissants, then securely seals the bags to lock in the freshness until the croissants reach your breakfast table.", "Thousands of years ago, someone invented the wheel.", "In 1970, this fundamental invention was applied to luggage thanks to an american luggage executive who came up with the concept while carrying heavy bags on a trip.", "By the 1980s, virtually all luggage had wheels.", "Today, we take rolling luggage with us everywhere we travel.", "They take the heavy lifting out of a trip so it feels more like a vacation.", "These hard-shell rolling bags start with polypropylene pellets.", "It's a synthetic material.", "They add a small amount of colored polypropylene pellets to the uncolored ones.", "They'll act as a dye for the batch.", "They allow the mix to dry for an hour, getting rid of humidity that would freeze in icy temperatures and cause the luggage to fracture.", "They mix and melt the polypropylene pellets into a thick blue liquid.", "Then it's over to the injection molding system.", "The molds close and a nozzle injects the liquid polypropylene.", "The molds are equipped with a cooling system so that the polypropylene hardens almost instantly into a lightweight yet durable material.", "A pile of pellets becomes half of a luggage shell in mere seconds.", "A robot transfers the molded shell to the next station.", "An employee glues the company logo into a slot.", "To ensure it really sticks, it's over to the logo machine.", "It uses hydraulic energy to press the logo firmly into position.", "He now screws a service handle into its molded slot.", "This handle is for those times when the traveler has to lift the bag by hand, up stairs, or onto a baggage belt.", "These triangular molded parts are the side feet.", "They'll keep the luggage upright.", "He fastens them onto the base of the shell.", "It's time to close this bag.", "He adds the other half.", "He threads a steel rod into hinge holes to hold the two shells together.", "Next, they mold wheels from nylon.", "A robot transfers the wheels to another part of the mold.", "The mold closes and a nozzle pipes in hot liquid rubber to apply it to the rolling surface of the wheels.", "The rubber adheres to the nylon and solidifies.", "They attach two wheels to a polypropylene hub for stable swiveling action.", "A factory worker now inserts an extendable handle.", "Then, working from the inside, she screws the handle to the luggage shell.", "She reinforces the connection with a metal bracket, ensuring that the extendable handle will hold fast even when the load is heavy.", "She plugs the wheels into their slots in the base of the luggage.", "She secures them with screws.", "This bag is now mobile with 360-degree swiveling action.", "The next employee installs this water-resistant rubber piping.", "It will seal the bag and keep the rain out.", "She presses it onto the edge of one of the shells.", "She attaches brackets for hanging dividers to the other shell.", "She snaps three side-locks and one central combination lock onto the bag.", "She screws down the hanging divider brackets.", "The fabric liner, with its zippered pockets, goes in next.", "The elastic dividers extend from it to attach to the brackets.", "It's time for the tumble test.", "A technician places the luggage in a rolling steel drum, and it bounces around.", "They conduct this test on a random bag every now and then to confirm that the luggage will bear up to rough handling.", "And with that, these bags are ready for a vacation." ]

{ "things": [ "Mountain Bike Suspensions", "Surgical Sutures", "Grain Dryers", "Frying Pans" ] }

[ "Mountain bike suspension forks were developed in the early 1990s.", "Like shock absorbers on a car, these forks expand and contract, absorbing the impact of rough terrain.", "They also provide traction, which adds both comfort and control to an offroad ride.", "There are plenty of jumps and bumps on an offroad trail.", "A suspension fork ensures a cushioned landing.", "They start by making the adjustment knob for the compression mechanism.", "Computerized tools carve an aluminum bar into a round shape with grooves for better gripping.", "Then, they add a protective black coating.", "A worker inserts a tension bar into a quick-release lever.", "The lever allows the rider to detach the wheel from the suspension fork.", "He presses a fastener into the lever to secure it to the bar.", "He lubricates the tension bar with grease.", "Then, he inserts the bar into the wheel axle, joining it to the lever.", "A steel pin holds them together.", "An employee places the inner fork upside-down in a hydraulic press.", "He inserts the steering tube in the center hole and activates the press.", "Then, he lubricates one of the tubular legs and the upper part of an air spring.", "He pushes the part through the bottom of the leg.", "It slides to the top, where he installs an adjustment knob.", "He inserts the lower part of the air spring into the leg.", "The air spring allows the suspension to move up and down.", "He snaps a collar on the end to lock the air spring in place.", "The damper is next.", "It's a piston and oil-compression mechanism that absorbs energy.", "He pushes it into the second leg of the fork.", "He screws a threaded collar and valve into the top of the damper leg.", "He adjusts the damper's position.", "He adds oil to the damper, using a fill sleeve to prevent spills.", "He pushes a rod through the damper to get rid of any air.", "Once the damper is full of oil and air-free, he installs the top cap and seals it with a gasket.", "He screws a base ring onto the gasket.", "Then, he installs the compression knob we saw machined earlier.", "The knob allows the rider to adjust the compression of the oil.", "With the inner fork complete, they now move on to the outer fork.", "An employee inserts bushings in the tubular legs and activates a two-pronged press.", "The press pushes bushings securely into the cavities.", "He secures the inner fork in a jig upside-down and slides the outer fork onto it.", "He lubricates the spaces between the inner and outer forks.", "After bolting the suspension forks together, he increases the air pressure in the spring and caps the air-fill valve.", "Now, for testing.", "A motor moves the fork up and down, simulating a bumpy ride.", "A computer monitors the suspension fork's performance.", "After passing the test, a worker applies brand decals to the fork.", "Finally, he slides the axle into the lower part of the fork and secures it.", "This mountain bike suspension fork is complete.", "Now, a technician fits it to the front of a bike.", "He attaches the handlebar to the steering tube with a nut and a long screw.", "Next, he attaches the wheel to the fork with the axle.", "It takes just two hours to make a mountain bike suspension fork...", "But they're strong enough to last through many more hours on long, bumpy mountain trails.", "Humans have been performing surgery for over 7,000 years, but the use of surgical sutures is fairly recent.", "Ancient greek surgeons were thought to be the first.", "They used gut strings to mend the wounds of gladiators over 2,000 years ago.", "Today's medical sutures come in different forms, such as synthetic monofilament threads, natural collagen fibers, or braided synthetic threads.", "A technician sets a tension meter to check the quality of the raw materials.", "The machine applies tension on the knot to measure the force needed to break it.", "A worker tests the material's absorption process in a heated bath.", "This simulates the temperature and moisture of the human body.", "A technician enters the product's medical specifications and prints out a batch of labels.", "Then, a supervisor selects needles and places them on a table.", "He retrieves spools of thread from a refrigerated room.", "To preserve the thread, it's been stored in sealed containers.", "The supervisor gathers all the materials and brings them to the material preparation department.", "The supplies are passed through an air lock to maintain the department's positive-pressure environment.", "On the other side, a technician opens the airtight foil and removes the thread spool.", "She threads the spool in a custom-made winding and cutting machine.", "The technician sets the mechanical thread counter back to zero and starts the winder.", "It can wind threads that are up to 100 inches.", "The counter tracks the number of windings as the machine unspools the thread.", "The machine stops automatically once the winding is complete.", "The technician applies medical-grade glue to stiffen the ends of the braided threads before cutting them.", "She places a guide to hold the threads in place while she cuts them along the glue line.", "Sutures use needles of various shapes and sizes, the smallest ones being 10 millimeters in length.", "On the main production floor, dozens of workers attach needles to the threads.", "They make sure the attachment meets the suture's requirements.", "The operator inserts the glue-hardened end of the thread into the back of the needle and crimps it tight with a mechanical swaging machine.", "Then, she hooks the needle into a pull tester to check the strength of each attachment.", "Finally, workers wind the assembled sutures into folded holding cards, tucking the needles in for protection.", "A worker inserts the holding card in a labeled foil pouch.", "Then, he slips it in a second package made of medical paper and polypropylene film and feeds it into a continuous rotary sealer.", "The sealed packages drop into a production holding basket.", "The finished product is sent for terminal sterilizing.", "A worker places the basket into an ethylene oxide, or eo, gas sterilization bag.", "She attaches a biological indicator vial and a control strip on a sterilization control card and puts the card inside the bag.", "She adds an eo gas delayed- release canister in the bag and places the sealed bag into the sterilizer.", "Sutures can be used for a variety of procedures, but each product has a very precise application.", "Harvested grains must be dried before they can be stored.", "Otherwise, they'll spoil.", "Farmers can outsource this work to someone else for a hefty fee, or they can choose to keep everything on the farm by investing in a grain dryer.", "To use a grain dryer, the farmer simply dumps their harvest into a fold-down loading hopper.", "Once the bin is full, he or she starts the dryer's power unit.", "A central auger circulates the grain inside the bin as a fan blows in hot air, drying the grain.", "Most of the grain dryer's components are made out of steel tubing.", "Workers cut the tubes to the various required lengths.", "Once all the pieces are cut, workers position them on an assembly jig.", "Here, they're assembling the dryer's mainframe.", "Once all the parts are laid out, workers lock the pieces in place and weld them together.", "They assemble what's called the spider on a different assembly jig.", "The spider supports the dryer's plenum chamber, the component at the center of the bin that distributes the hot air.", "Workers bolt the spider to the mainframe and move the unit to the paint area.", "They clean and prime the steel, then, coat it with corrosion-resistant paint.", "It takes 24 to 32 hours for the paint to dry.", "At that point, workers mount the agitator to the spider.", "The agitator prevents wet grain from sticking to the bin wall.", "They mount the agitator's main drive chain to the main gear and gearbox drive.", "Meanwhile, a plasma torch cuts sheets of perforated galvanized steel for the bin.", "These pieces will form the circular bottom.", "A press punches holes along the edges of each sheet.", "Workers connect the sheets together and bolt them onto a ring called the transition band at the top of the mainframe.", "Then, they lower the spider and bolt it to the transition band.", "They bolt the plenum chamber to the spider.", "The chamber is made of perforated galvanized steel sheets.", "Hot air blown into the chamber by the power unit exits through the perforations, drying the circulating grain.", "Next, they assemble the bin's outside wall.", "They bolt perforated galvanized steel sheets together, as well as to the transition band on the mainframe.", "The sheets enclose the plenum chamber at the center and vent the dry air through the perforations.", "Workers mount the power unit to the mainframe.", "The unit, consisting of a burner and fan, blows hot air into the plenum chamber.", "In another part of the factory, they build the loading hopper on an assembly jig.", "After welding the parts together, they clean, prime, and paint the steel; install the auger that moves the grain; then, a cover the farmer can adjust to regulate the flow.", "He also adds a protective screen, for safety.", "Then, they attach the finished loading hopper to the dryer's mainframe.", "It connects via a pivoting hinge on the front of the loading tube.", "The hinge lets the farmer fold the hopper up and out of the way when it's not in use.", "Workers install springs to make it easier to lower and raise the 60-pound hopper.", "They also install a latch, which secures the hopper against the bin during storage or transport.", "The grain dryer rolls on wheels attached to axles bolted to the mainframe.", "The last step is installing a ladder on the outside of the bin.", "This provides access to the top of the grain dryer for monitoring operation and maintenance.", "Frying pans were first used by the ancient greeks and romans over 2,000 years ago.", "These wide and shallow pans can be used to sauté, sear, or fry food.", "Water released from the food during cooking creates that sizzling sound.", "The shape of the pan allows steam to dissipate, giving food a crispy finish.", "A good nonstick frying pan is a must in the kitchen.", "A frying pan can be made of any heat-conductive metal.", "In this case, aluminum alloy ingots.", "They melt the ingots.", "A robotic ladle scoops up molten aluminum to be used for casting.", "They use this two-part die to transform liquid aluminum into a frying pan.", "The robotic ladle pours the aluminum into the die through a cylindrical port.", "This high-pressure casting produces a very precise shape.", "After about a minute, an operator takes it out.", "They cut off the excess using a computerized tool.", "The table moves as the tool cuts the edge of the pan to specifications.", "A worker sands the edges and rounds the rim of the pan a little more.", "They cast pans in several sizes and thicknesses.", "An employee keeps a detailed inventory of the pans.", "Next, they put the pans in a sand-blasting chamber.", "The sand blaster cleans off oil and residue.", "It also roughens up the surface of the pans to prepare them for coating.", "An employee scrubs off the sand using an abrasive pad.", "Next, the pans receive their ceramic coating.", "Each pan spins on a pod as a plasma flame melts three different powders onto it.", "The coating protects the pan from corrosion.", "An employee scrubs each pan with an abrasive pad to remove the residue.", "This time, the frying pan spins slowly as torches heat them to approximately 175°.", "This preheat preps the pans for the final coatings.", "They prepare up to five proprietary coating formulations for each frying pan model.", "Each one contains dozens of chemicals and thousands of tiny diamond particles.", "The diamonds increase durability and heat conductivity.", "They also make food less likely to stick to the surface of the pan.", "The final coating contains a nonstick chemical known as ptfe.", "They spray the different coatings onto the surface.", "The spinning ensures even coverage as the coatings adhere to the hot pans.", "Now, a primer is applied.", "It allows the final nonstick coating to bond to the frying pan.", "At the end of the line, an employee inspects the finish and sprays a little more of the nonstick formula onto the handle fitting.", "Then, the frying pans go through a furnace to bake the coatings onto the pans.", "An employee checks the finish for bubbles, scratches, or color inconsistencies.", "Once the pans have cooled, a robot transfers them to a lathe.", "The lathe spins the pan as a tool shaves off a thin layer of aluminum.", "This leaves a clean, level surface on the bottom of the pan.", "A suctioning robot moves the frying pan to the next station, where a worker attaches a handle to the pan.", "An automatic screwdriver secures it.", "A technician heats one of the frying pans on a cooktop as a mechanical arm rubs the pan thousands of times with a coarse piece of sandpaper.", "There are no scratches, so the entire batch of pans is approved.", "Thousands of nonstick frying pans are ready to leave the factory and cook up a tasty meal." ]

{ "things": [ "Crayons", "Wooden Kayaks", "Lawnmowers", "Gold Chains" ] }

[ "Today on \"how it's made\"...", "Crayons...", "Wooden kayaks...", "Lawn mowers...", "And gold chains.", "Crayons are a popular drawing tool for today's young artists.", "The average north american kid uses 730 of them by the age of 10.", "An american chemical company invented crayons in 1903.", "It took the basic wax crayon it already made for marking crates and barrels and came up with a nontoxic version in different colors.", "These crayons are made from a combination of waxes-- primarily paraffin, which is ideal for making crayons because it's inexpensive and easy to melt.", "It also has what's called a nice rub-off, meaning it leaves enough wax on the paper.", "They melt the wax at 143 degrees fahrenheit.", "Then add a secret powder to strengthen the crayon and act as a filler, boosting the number of crayons the wax will produce.", "They also add various synthetic chemicals-- there's one to keep the wax from sticking to the mold...", "And a fatty acid, called stearic acid, to improve the rub-off.", "Now they tint the wax-- in this case, yellow and red to produce orange crayons.", "This factory can produce 127 different colors.", "Every ingredient in the crayons is nontoxic.", "After adding more wax, they blend the mixture for about 45 minutes.", "Now they pump the wax into this device called a rotary machine.", "It first injects the wax into crayon-shaped molds.", "Then it envelops the molds in cool water, hardening the wax within roughly a minute.", "As the molds continue along the circuit, a blade scrapes off the excess, which gets recycled.", "Just one rotary machine molds more than 2,700 crayons per cycle.", "With several machines operating simultaneously, this factory churns out 30,000 crayons per hour.", "The machine ejects the crayons, and a conveyor transports them to the labeling machine.", "One by one, they drop into the grooves of a revolving drum.", "At the bottom left, a gluer coats the surface in between the grooves just before the crayons go in.", "The machine then slaps a label onto each crayon.", "A roller presses the label against the adhesive, then a little arm wraps it around the crayon.", "This machine labels 8,500 crayons per hour.", "The crayons exit the labeling machine and land in a bulk box.", "Workers sort the crayons by color into the appropriate hoppers of the packing machine.", "The packaging line is entirely automated.", "The factory programs the machine to collect a certain number of crayons in specific colors according to the type of pack in production.", "Their best sellers are packs of 16 and 24.", "The packing machine is designed to handle the crayons gently.", "Occasionally, though, a crayon does crack or a label comes loose.", "When that happens, a sensor automatically stops the machine and a light goes on above the problem hopper.", "Workers clear the jam, then production resumes.", "Once the count is complete, the crayon line and the box line meet.", "A pushing device slides each set of crayons into a box.", "A built-in scale weighs every box.", "Should one be underweight, the machine automatically blows it off the conveyor belt.", "A worker then manually adds the missing crayon, ensuring a full complement of colors for every budding artist.", "For thousands of years, aboriginal people in the arctic have used kayaks to hunt and for good reason.", "These slender vessels glide swiftly in the water and are light enough to carry.", "High-tech materials make today's wooden kayaks more durable than ever, but its shape and performance in the water are basically the same.", "It starts with plywood made from okoume-- a rugged type of mahogany.", "A computer-guided routing machine cuts out the boat's various parts.", "One has finger joints that interlock with another piece to make one long strip.", "These panels will cover the sides of the vessel and most of the top.", "The planks are so thin-- just a little over an eighth of an inch-- that the entire kayak will weigh only 37 1/2 pounds.", "Then there are bulkheads, end panels, footrests, and curved pieces to support the deck and sides.", "After applying two coats of epoxy resin, a craftsman assembles the parts and secures them in a jig for six hours until the glue sets.", "The side panels will span the entire length of the boat, at just over 16 1/2 feet.", "Assembling the kayak is pretty straightforward, so if you want to save money and do it yourself, you can buy this kayak cheaper as a kit.", "He planes and sands the end panels to create a curved tip.", "He drills small holes spaced 4 3/4 inches apart along the edges of the bottom panels.", "Then he threads copper wire through the holes.", "This stitches the panels together temporarily, keeping them flexible and thereby easy to assemble for gluing.", "He places wooden pegs between the side panels to pry them open...", "Then joins those panels with two screws in the front and two in the back.", "At this stage, the kayak is upside down, so they add the bottom panels.", "He attaches them with copper wire because it won't stick to the resin he'll use to glue these parts together.", "After flipping the boat, he attaches a bulkhead with more wire.", "It's one of two separators that create stowage compartments.", "Using a putty knife as a gauge, he ensures the gaps at the seams are even, then he flips the boat and coats the seams in resin.", "He lets it dry for 6 hours, just part of the 40 hours it takes to build the kayak.", "Before the glue hardens, he makes sure the top of the boat is level.", "This way, he can adjust the pieces if he needs to.", "After removing the wire from the seams, he applies more resin to these areas.", "Over this, strips of fiberglass cloth to form a watertight seal.", "He'll also apply three more coats of resin throughout the inside of the kayak.", "Once it dries, and he sands and varnishes the entire surface, the craftsman adds the footrest assembly.", "This one's got pivot pads with cables that control a rudder to help steer the boat.", "This is an optional feature.", "Otherwise, there's a simple foot brace, and you just use your paddle.", "Next, craftsmen apply resin along the kayak's upper rim.", "They add the top panel to form the deck, then they wrap the entire boat in packing tape, which compresses the panels as the resin sets for 12 hours.", "These pieces form a raised rim around where the kayaker sits.", "A waterproof skirt fits under this rim, keeping the area dry in the water.", "The deck gets two coats of resin.", "An hour later, they spread fiberglass over the bottom to seal and protect the wood.", "The bottom then gets three coats of resin.", "Next, they spray on up to six coats of varnish, depending on the type of finish the boat will have.", "This protects the wood from sun damage.", "They add a foam backrest and a seat for your comfort on the trek.", "And finally, flexible rubber straps-- they're for securing your paddle to the kayak.", "Now it's off to the water.", "Gardeners' jobs got much easier in 1830 with the invention of the first mechanical lawn mower.", "Nowadays, most lawn mowers have electric motors or gas engines.", "They turn blades that are either on a reel and cut like scissors or rotate like a propeller to chop the grass.", "These gas mowers have rotary blades that spin horizontally on a vertical crankshaft.", "To make the blade housing, which is called the deck, a machine first applies a lubricating chemical to sheet steel, which was coiled when it came to the factory.", "The chemical helps flatten it so it's easier to cut.", "A press then perforates the sheet every 2 feet.", "After the press separates the segments and rounds off the corners, a robotic arm moves each segment onto a die.", "A 500-ton press bends the steel like tinfoil between two molds to give the deck its basic shape.", "A robot lifts the oily decks with suction cups and moves them to another press.", "This machine trims away the excess around the deck's edges.", "Another machine bends the sharp bottom lip inward to make the deck safer to handle.", "The factory uses robots because they work faster than humans, processing 500 decks an hour.", "After a thorough cleaning, the decks move into an electrostatic-paint booth.", "They lace the powder paint with a negative electric charge, the decks with a positive one.", "This draws the paint particles onto the decks, creating a thorough and even coat.", "The factory's six paint booths are on tracks so when it's time to change color, workers can easily switch the entire chamber for a clean one.", "The paint cures at 374 degrees fahrenheit for 15 minutes.", "This press bends 8-foot-long tubing to form the mower's upper handle.", "Another press bends 6-foot-long tubes to make a shorter, lower handle.", "Workers will later attach the two handles to form one folding handle.", "By folding, it takes up less space in the shipping box and, later, in your garage.", "Here's the mower's 5-horsepower engine.", "A worker attaches it to the deck with three bolts.", "He uses a powerful torque gun so the bolts won't loosen because of vibrations.", "Later, workers will mount the blades to the engine's crankshaft that protrudes through an opening in the deck.", "Next, workers install a plastic rear door, through which the grass clippings eject.", "This door attaches to brackets, which have levers that adjust the mower to nine different height positions.", "It's time to mount the plastic rear wheels.", "Next an adaptor to stabilize the blade on the crankshaft, then the blade.", "It's wider at each end to create the proper airflow inside the deck.", "They secure the blade tightly with a powerful wrench because it's going to spin at 3,300 rpm.", "The front wheels are 1/3 smaller than the back ones.", "This makes the mower easier to maneuver over uneven terrain.", "They put rubber covers on the height-adjustment levers so they're softer on the fingers.", "The mower adjusts from 1 inch to nearly 3 1/2 inches off the ground.", "They secure the lower handle, then loosely attach the upper handle to the lower one.", "The consumer can tighten this after shipping.", "They add a safety handle that turns the engine off if you're not squeezing it against the upper handle.", "It attaches to a caliper system, much like what you'd find on a bicycle.", "Finally, workers apply labels to indicate the mower's horsepower and width.", "Fill it up with gas, and it's ready to give your lawn a trim.", "Some of the first gold chains date back to the ancient cultures of iraq and greece.", "They were symbols of wealth, royalty, and the divine.", "Lucky for us, jewelers now make these personal treasures more affordable and more durable than ever.", "But you may be surprised to learn what they put in the gold to make it better.", "Pure gold is fairly soft and bright yellow, so it's common to create an alloy to strengthen it and alter its color.", "Copper lends a reddish hue.", "And brass helps the alloy melt more quickly than gold and copper would alone.", "Depending on the ratio, adding these metals produces 14- or 18-karat gold.", "They melt the mix in a crucible at 1,850 degrees fahrenheit.", "Just three of these scoops are enough to make about 5,000 14-karat-gold chains.", "A worker pours the molten alloy into a casting machine.", "Water cools the metal to around 700 degrees fahrenheit, solidifying it.", "The metal passes through a round die which shapes it into a golden rod that's nearly 6 1/2 feet long.", "After cutting the rod in half, workers pass it through what's called a breakdown mill.", "The machine reshapes the rod from round to square so it will be easier to stretch.", "Next stop-- a tandem mill.", "It's got 12 rollers that stretch the rod until it's about as thin as a piece of spaghetti.", "As it emerges, rollers shape the rod into a coil that's nearly 78 feet long.", "Workers soften the coiled metal in an oven.", "Then they uncoil and continue stretching what's now a wire by passing it through a die lined with industrial diamonds.", "To prevent overheating, the machine sprays lubricant to cool the wire while reducing it to the width of a human hair-- its final size.", "The wire then winds into a spool that's over 1 1/2 miles long.", "Next, they unwind 32 of the spools and run the wires through another oven to soften them even more.", "Just in case you're thinking about walking off with some of them, you should know that security is very tight.", "Employees must pass through metal detectors before going home, and wearing jewelry to work is strictly forbidden.", "This machine makes what's called cable chain.", "It passes wire through a link and closes it to make another link.", "The machine makes 600 links per minute.", "Here, a worker does a random quality check.", "This machine makes a chain in what's called a venetian style.", "The wire passes through a channel where mechanical jaws bend it over a die to make a link with the preceding segment.", "To make what's called a spider style, this machine passes a wire through up to five loops before closing the link.", "For a figaro-style chain, this machine makes three short links before a mechanical arm moves the chain to another area to add one longer link.", "The arm then moves it back to add three more short links.", "The simplest style is what's called a rope chain.", "To make it, this machine threads a wire through as many as two loops then closes it to make another loop.", "They coat the finished chains with a lubricating powder that prevents the links from sticking to each other during the next step, when they heat the chains to 1,500 degrees fahrenheit.", "This activates a soldering agent added to the metals earlier.", "It fuses the ends of the links to each other.", "This machine welds a link to a clasp on the chain.", "A tag indicating the gold quality goes onto the clasp.", "Finally, the chains go through four chemical baths, which thoroughly clean them, then workers plate them with a layer of 14- or 18-karat gold.", "Plating gold with gold creates a more vibrant finish.", "After one last quality check, these chains are ready to dazzle their way to a neckline near you." ]

{ "things": [ "Wood Burning Stoves", "Orthoses", "Ballet Slippers", "Buses" ] }

[ "Today on \"how it's made\"...", "Wood-burning stoves...", "Orthoses...", "Ballet slippers...", "And buses.", "Wood-burning stoves do more than create a cozy ambience.", "They're also powerful enough to heat an entire house.", "More and more people are installing a woodstove as an additional heat source in their home.", "It's economical, and the new low-emission models are more environmentally friendly.", "Every woodstove has a fire baffle-- a stainless-steel barrier above the burning wood that shields the top from the intense heat.", "The baffle also slows down the smoke exiting by the chimney, which reduces the upward draft that the rising heat creates.", "Production begins with large steel sheets that are 1/4 of an inch thick.", "A computer-guided laser cuts out pieces that workers will shape into the various parts of the stove.", "The laser slices through the metal quickly and with extreme precision.", "And because it cuts with intense light rather than punching force, the pieces have neat, smooth edges.", "Workers use a strong magnet to lift and transfer the pieces to the next production area.", "The largest piece becomes the surround-- the part that forms the sides and back of the woodstove.", "Workers use a machine called a press brake to shape it.", "A computer guides this large hydraulic press to bend the flat steel in exactly the right spots.", "Now they position the surround in an assembly jig to keep it steady during welding.", "After welding the front of the stove to the surround, they weld the air intake, which allows oxygen to enter the stove to feed the fire.", "Next they weld the top-- the fire baffle-- and air channels near the top, which are also designed to feed the fire with oxygen.", "The quality of welding in a woodstove is critical because the joints have to be able to withstand extreme heat.", "Now they weld the bottom of the stove.", "It has a hole in the middle through which you sweep the embers to an ash pan below.", "Now they weld the flue collar, the steel ring that attaches the stove to the flue pipe that leads to the chimney.", "Workers now bolt the stove to a pedestal.", "The pedestal is also made of welded steel.", "Meanwhile, the door takes shape.", "They glue a fiberglass rope to the perimeter of the doorframe using a silicone-based glue that's resistant to extreme temperatures.", "This cord prevents air from seeping in through the door and fueling the fire out of control.", "After installing the locking door handle, they weld the door hinges.", "The stove's interior, where the wood burns, is known as the combustion chamber.", "They line it with bricks to protect the walls from warping in the intense heat.", "Bricks do deteriorate over time, but it's easy to replace them.", "The last steel part they install is the cap for the ash pan.", "Now an automated conveyer transfers the stove to the paint station, where a robotic arm sprays on a coat of heat-resistant paint.", "Once the paint air-dries, a worker removes the door to install its glass panel.", "This isn't your run-of-the-mill window glass.", "It contains ceramic, which enables it to withstand temperatures up to almost 2,000 degrees fahrenheit.", "With the glass panel in place, workers can apply decorative features and information stickers.", "Then they put the door back on and lock it shut.", "They rivet on the company logo...", "Then install a fan in the back.", "The fan blows out the heat that the stove generates.", "When the wood-burning stove leaves the factory, its coat of paint is dry, but not yet cured.", "The heat cures it when you fire up your stove for the first time.", "Orthoses are devices such as arch supports and braces that address a joint or muscle problem in the back or extremities.", "An orthosis can provide artificial support, prevent or correct a deformity, or improve how a weak or painful area functions.", "You can buy an orthosis off the shelf or have one custom-made.", "Producing a custom-made orthosis starts with a thorough examination.", "A certified professional, called an orthotist, analyzes the problem area-- in the case of this patient, the feet.", "After a few manual manipulations to test the range of motion and pinpoint weakness or pain, the orthotist uses various instruments to measure the angles of the different parts of the feet.", "Then it's on to specialized devices that analyze foot position and movement during standing and walking and how body weight is distributed onto the feet.", "In this scan, the red areas show that more weight is landing on the left foot than on the right.", "Next, a 3-d impression in foam.", "It goes to the production department, where technicians fill it with plaster.", "Once it dries, they extract an exact model of both feet.", "Now they can construct the orthosis piece by piece.", "Most of the components are made of different types of polyurethane, a lightweight thermoplastic.", "Each type is designed to produce a specific effect at a different phase of the patient's footstep.", "For example, the blue base is made of rigid polyurethane that holds the foot in the correct position.", "At the front, dense, black polyurethane helps propulsion and reduces stress on that side of the foot.", "They cover the assembled orthosis with a sheet of glue and put it in a vacuum press.", "The press applies heat to activate the adhesive.", "It sucks out the air between the components and compresses them tightly together.", "When the orthosis comes out, they place it on the model of the corresponding foot.", "Then it goes into a different vacuum press to mold it to the shape.", "They add made-to-measure corrective parts with latex foam.", "Then, using hypoallergenic glue, line the orthosis with a soft polyurethane.", "All that's left to do now is buff the orthosis.", "This smoothes all the surfaces.", "To ensure the orthosis fits correctly, the patient redoes the key tests while wearing it.", "Remember that scan showing red areas?", "They're gone now because the patient's feet now bear his body weight equally.", "This patient has arrived with a doctor's prescription for a knee brace.", "The orthotist analyzes his mobility, flection, and balance, then sends the technical specifications to the production department.", "There, technicians make a model of the leg.", "They begin by positioning the leg at a 12-degree angle and wrapping it in plaster bandages.", "While waiting for the fast-set plaster to harden, the patient chooses a decorative pattern for the outside of the brace.", "The hardened cast serves as a mold.", "Technicians pour in plaster, let it harden, then remove the cast.", "After smoothing the surface, they draw technical markings, then install the lightweight aluminum joints that will enable the orthosis to bend.", "Now they run a sheet of plastic through an oven.", "This is high-memory plastic, meaning that when you form it, it remembers the shape and maintains it.", "The design the patient chose comes printed on transfer paper.", "They use a laser thermometer to ensure the plastic is at the perfect temperature for the pigments to penetrate properly.", "They carefully position the hot decorative plastic on the model.", "Using a vacuum bag, they remove the air and press the plastic on tightly.", "The plastic sets in about two minutes, maintaining the form.", "They cut the required shape, line the inside, and sand the edges smooth.", "Finally, they attach straps to fasten the orthosis to the leg.", "The orthotist checks the fit on the patient, then runs various tests to make sure the orthosis is doing exactly what it's designed to do.", "Ever wonder how ballerinas manage to dance on the tips of their toes?", "It takes years of training, remarkable skill, and special ballet slippers.", "These toe shoes are handmade in what's truly a manufacturing pas de deux-- a graceful pairing of traditional methods and modern materials.", "They sew the toe shoe's exterior with three pieces of satin.", "They cut those pieces using a press equipped with a metal die.", "It slices through enough fabric at a time to make four pairs of shoes.", "They also cut a pure cotton lining for each piece to protect the dancer's feet from irritation.", "This v-shaped piece is called the vamp.", "It'll become the front half of the shoe.", "The seamstress extends the \"v\" by attaching the two other satin pieces, called the quarter panels.", "They'll form the back half of the shoe.", "She sews the ends of the \"v\" together, making a heel seam, which she reinforces with a rayon ribbon.", "Then she feeds the same type of ribbon through a special machine that folds it in half over a drawstring.", "She stitches it to the top perimeter of the shoe.", "This encased drawstring will enable the dancer to pull the shoe tightly around her foot.", "Now they put the satin upper onto a wooden form to check the sizing.", "It's absolutely critical that the height of the vamp be correct to within 1/8 of an inch.", "If it's even slightly off, the top of the shoe will cut into the dancer's foot.", "The shoemaker nails the cotton lining to an insole on the bottom of the form.", "The insole is made of rigid cardboard for support, imbued with plastic for flexibility.", "After trimming off the excess, he glues the lining onto the insole, making neat little pleats.", "Once the glue dries, he removes the nail and trims the excess pleating to eliminate any bumps that would irritate the foot.", "Now they sculpt the toe box, the hard encasing inside the tip of the shoe.", "It's made of papier-mâché, only instead of paper and paste, they use fabric and paste.", "Then they soften up a piece of resin-coated cotton in water and apply it on top.", "Next they saturate two pieces of burlap with paste and apply them, one after the other, over the cotton.", "The paste is made of flour, water, starches, and a rubber-and-plastic-based resin that hardens to a semi-flexible state.", "That's key, because the toe box has to be stiff enough to bear the dancer's full weight, yet flexible enough so that the ballerina can move fluidly.", "Now the final layer of fabric-- a piece of pure cotton.", "They wrap the toe box in plastic to keep the hammer clean as they square off the front, creating what's known as the platform.", "Then they press the toe box onto a piece of marble to make it completely flat.", "They verify that the platform is perfectly square.", "If not, the ballerina will topple over.", "After letting the toe box dry for 24 hours, they glue the lining over it with contact cement.", "They trim off the excess, then glue the satin over the lining, forming delicate pleats.", "They use lighter glue this time, because contact cement would stain the fabric.", "They apply a foam filler to even out the shoe's underside, then coat it with high-strength vinyl glue.", "They apply the same glue to a sole, then leave both to air dry.", "24 hours later, they put them on a heater set to 200 degrees fahrenheit.", "This reactivates the dried glue in about half a minute.", "They apply the sole then put the shoe in a press for 15 seconds to solidify the bond.", "Now they can remove the shoe from the form.", "The sole is made of suede, a material that has just the right amount of grip.", "It's nonslip, yet still enables the dancer to glide smoothly across the floor.", "The last step is to glue in a white suede sockliner.", "It cushions the ballerina's foot and keeps it from slipping forward when she's dancing on her toes.", "A city's fleet of public transit vehicles might include standard buses, low-floor buses, or both.", "Low-floor buses have a special kneeling feature.", "When they pull up to the bus stop, they can mechanically lower themselves to curb height to make boarding easier for children, senior citizens, and handicapped people.", "This low-floor bus is 40 feet long and can carry more than 80 passengers.", "To build the bus's internal structure, workers put stainless-steel bars into a press.", "It applies between 90 and 110 tons of pressure, bending them to the required shape.", "Workers assemble the structural pieces on a support frame called an assembly jig.", "They use an electronic inspection arm to verify their work.", "Once they've assembled the roof structure and the side structures, they bring them together for welding.", "Everything goes on a rotating jig.", "It turns like a giant rotisserie, giving workers easy access to whatever part of the bus they need to weld.", "When the welding is finished, they turn the bus right side up.", "They put the structure on a dolly and release it from the jig so that they can move it down the production line.", "Meanwhile, the stainless-steel structure for the floor of the bus takes shape.", "Once that's complete, it's back onto the rotating assembly jig to weld it to the rest of the structure.", "This bus factory uses stainless steel because it stands up well to corrosion.", "Transit systems need to keep these buses running full-time for up to 20 years.", "Less rusting means fewer expensive and time-consuming repairs.", "Workers now move the completed structure to another part of the factory where they spray the underframe and lower section with a black, anti-abrasion coating.", "This protects against the noise and damage that stones and other road debris cause when they hit the bottom of the bus.", "Next, workers apply high-strength glue to the floor structure and lay down a subfloor.", "Then they drive in screws for reinforcement.", "Now they turn the bus upside down to install four tanks of compressed air under the roof.", "Three are for the brake systems, the fourth for the doors and other mechanisms.", "Melamine ceiling panels hide everything that's under the roof.", "Next, the engine's radiator goes in at the rear of the bus.", "Then workers turn the bus right side up again and lay down a waterproof vinyl floor covering that's specially designed to withstand heavy-duty transit use.", "They cover the sides and roof with fiberglass panels.", "To prevent corrosion, workers use glue rather than screws or rivets.", "Then they attach the fiberglass front of the bus to the rest.", "The bus's low-emission diesel engine arrives at the factory already assembled.", "Workers attach it to the transmission and drive shaft in the engine compartment.", "Buses without air-conditioning have sliding windows that open widely.", "On air-conditioned buses, just a small top section opens.", "The upholstery on the molded fiberglass seats is a velour-like fabric woven onto a strong canvas, then glued onto a fiberglass insert.", "This construction makes it impossible for vandals to slash the seat with a knife.", "Workers install the driver's seat, the steering wheel, and all the controls, including the toggle switch that activates the kneeling feature.", "This bus also has a ramp for wheelchairs.", "A safety system locks the accelerator pedal and applies the brakes to prevent the bus from moving when the ramp or kneeling feature are in operation.", "The finished bus undergoes a half-hour water-infiltration test with all of the systems running.", "This ensures there are no leaks.", "At every phase of production, the factory does a quality-control inspection, checking everything from mechanical safety to finishings, right down to the tiniest of details." ]

{ "things": [ "Basque Pelota Balls", "Pallet Trucks", "Dumplings", "Brass Faucets" ] }

[ "Today on \"how it's made\"...", "Pelota is a ball game that originated in the basque region of france and spain.", "Most versions are played against a wall, in which the player throws the ball either by hand, racket, bat, or basket.", "Occasionally the game is played in teams, where players are separated by a net or a line on the ground.", "Basque pelota balls come in different diameters and weights, according to the type of play for which they're designed.", "But all of them have had the same basic construction for hundreds of years-- a core wrapped in rubber, wool, and leather.", "To make the rubber wrapping, this machine deposits a line of natural rubber onto a paper strip.", "Next a heating lamp softens the rubber to a formable consistency, while the machine applies a second paper strip on top.", "This process sandwiches the rubber together.", "Then two rollers compress the encased rubber into a flat strip.", "Today, a pelota ball's core is typically made of plastic.", "The size of the core varies according to the final diameter and weight of the ball.", "The second machine removes the paper and wraps the rubber strip around the core, maintaining its perfectly round shape.", "The machine stops wrapping when the ball reaches a specific diameter and weight.", "Manufacturers place the rubber-wrapped core on a third machine, which wraps it in wool yarn, carefully maintaining a perfectly round shape.", "The ball continues wrapping until the ball reaches a specific diameter and weight.", "Now they prepare the ball's outer layer.", "They take a piece of goatskin and trace a figure-8 pattern around it repeatedly.", "Then the shapes are cut out with a utility knife.", "The goatskins are soaked in water for a few minutes to make them supple.", "Then they coat the yarn with liquid synthetic rubber...", "Take two goatskins per ball...", "And wrap them in opposite directions.", "The skins are held in place temporarily with about a dozen tiny nails.", "With strong synthetic thread, they sew the hides to each other.", "The key is to pull the stitches tightly so that the ball inside is immobilized.", "Once the sewing is complete, they remove the nails.", "They apply their maker's mark with a felt pen.", "Next the ball undergoes a size test, using the gauge that corresponds to the ball's intended diameter.", "If the ball does not pass through the first hole but passes through the second, the diameter is correct.", "The final step is to grease the leather with tallow-- purified fat from cows' kidneys.", "One small glob evenly coats 20 or so balls after about 10 minutes in this specially designed machine.", "The tallow nourishes and protects the leather.", "No finished ball leaves the manufacturer without undergoing a bounce test.", "Pelota balls used in regulation play must have a plastic core, whereas balls used strictly for recreation may have a core made of boxwood.", "White pelota balls are designed for playing against a colored wall.", "Balls designed for play against a white wall are dyed black prior to applying tallow.", "Pelota is also played across a net or a line on the ground, the size of the ball varying with the version of the sport.", "A pallet truck is a workhorse in the warehouse.", "This electrically powered vehicle loads and unloads products from tractor-trailers and travels up and down aisles to deliver and retrieve products on low racks.", "The driver stands on the truck's platform to steer and operate the forks.", "Need a lift?", "A pallet truck is small but mighty.", "It can lift loads that weigh up to 8,000 pounds.", "This computerized laser cuts out many of the pallet-truck parts from a sheet of steel, and the software ensures that there's minimal waste.", "A technician inserts one of the parts in a brake press.", "It folds the edges, creating flaps to form it into part of the vehicle battery box.", "This is the part before and after bending.", "At the next station, an operator clamps fork frames in a welding fixture.", "He adds multiple steel supports at the base of the fork frames and along the sides.", "They'll strengthen the structure and add balance to allow the forks to carry heavy loads.", "As the fixture rotates, the robotic welder moves in and fuses the supports to the frames.", "At the next station, the fully assembled battery box is lowered into place and positioned upside down.", "Operators place the fork frames on top and lock them into place.", "The fixture slants the parts towards the robot so that it can get into tight spots and weld them together.", "They also weld together the structure that will house the transmission.", "The parts plunge into a series of solutions.", "The first baths remove grease and residue.", "The final one preps the metal for a powder-coat finish.", "Then a worker applies an electrostatic charge to powder particles.", "The particles gravitate to the parts and form a powder coat on the surface.", "The powder coat gives the parts a protective skin and a uniform sheen.", "Next, technicians install a metal rack on the fork frames to help contain the truck cargo.", "They clamp the assembly in a fixture that holds it sideways so that technicians can install pull rods in the base of the forks.", "Powered by hydraulics, the rods will move the forks up and down when needed.", "Powder-coated bright red, the truck structure is ready for the components.", "A worker bolts swiveling caster wheels to the base.", "Another worker then installs the steel arms that will link hydraulics to the pull rods.", "Moving around to the back of the structure, she connects the arms to the hydraulic pistons.", "She runs hoses from the hydraulic fluid reservoir to the pistons and torques the fittings.", "Each structure is marked to indicate it's been torqued correctly.", "A probe gauges the measurements of parts like this transmission bracket.", "If the measurements are off, the part can't be properly assembled.", "At another station, a technician bolts the drive tire to the transmission and motor assembly.", "A crane lowers the drive assembly into the center hole of the pallet truck structure.", "The worker secures the parts together with bolts.", "Another worker then wires the motor to a controller.", "He makes other connections to prepare the motor to be coupled to the battery.", "Now it's time to marry the truck structure to the battery and fork assembly.", "The worker links the pull rods to the hydraulic lift system using two bell cranks with thick pins.", "Next a technician attaches metal blocks, leveling the forks to a specific height.", "Thick cushioning at the back will give the future operator a comfortable surface to stand on.", "A cover protects the transmission, motor, and the hydraulics.", "This pallet truck is ready to get to work.", "An l.e.d. light system guides the operator to place items on the pallet.", "It both carries the load and tells you how to load.", "Dumplings are a popular cuisine made by a variety of flavors from around the world.", "They can be sweet or savory, steamed, boiled, baked, or fried.", "In chinese cuisine, dumplings have been refined to an art form and are often eaten on special occasions like chinese new year.", "To make a dumpling, you first wrap a thin layer of dough around a filling.", "Dumplings can come in many different shapes.", "These are filled with shrimp and pork.", "Food-prep technicians at this facility peel, devein, and sort shrimp for different kinds of dumplings.", "As they work, they double-check each shrimp for freshness and quality.", "The 30 people working at this station can peel 10,000 shrimp per hour.", "To make the dumpling dough, technicians begin the process by pouring all-purpose flour into this large mixing bowl.", "They add water at a ratio of two parts flour to one part water.", "A large dough hook mixes the two ingredients together.", "Periodically, the technicians stop the machine to manually test the dough for consistency.", "It's not ready yet.", "After more mixing, they test it again.", "This time, it's just right-- soft and still elastic.", "To strengthen the dough structure, a worker begins folding and rolling it into lengths.", "At the next station, food-prep technicians rip small chunks off the rolls.", "Then they weigh the chunks to ensure they meet the parameter of just 0.28 ounces apiece.", "Two additional technicians collect the chunks and follow a two-step process in which they stand each piece on its round end before flattening it.", "They sprinkle the round disks with flour to keep them from sticking to each other when moved to the next station.", "The next step uses traditional cooking tools to transform each disk into a wrapper for a dumpling known as shao mai.", "The food-prep technicians wear protective clothing to prevent contamination.", "In-house quality control inspectors test the airborne bacteria levels in the facility every month to ensure that it meets the necessary standards.", "Creating the shao mai wrapper requires high levels of skill.", "This worker's right hand rolls the dough while his left hand rotates the wrapper in perfectly coordinated movements, turning out wafer-thin rounds at high speed.", "A second worker uses a different style of rolling pin to crimp the edges of the wrapping.", "The technicians on the left use a wooden spatula to scoop a portion of filling into each wrapper before placing them on a scale to ensure the weight is correct.", "Technicians on the right top off each dumpling with a shrimp.", "Inserting the shrimp is another step that requires carefully orchestrated hand movements to accomplish the task with speed and elegance.", "The worker is able to carefully tuck the shrimp into place with effortless movements of one hand.", "Dumplings come in all shapes and sizes.", "At another table, workers assemble a delicacy in the shape of a half-moon.", "These dumplings start out with the same disk-shaped wrapper and the same shao mai filling.", "Next, a worker uses a special crimping technique, pinching a series of small creases in the dough to seal them in a completely different way.", "By carefully arranging each dumpling, technicians can fit nearly 88 of them in one pan.", "Thanks to an amazing artisanal assembly line of skilled workers, the final product is almost too beautiful to eat.", "Water faucets date back to at least 1700 bc.", "Archaeologists discovered that the minoan palace at knossos, on the greek island of crete, had a plumbing system consisting of terra-cotta pipes, providing water to faucets made of gold and silver.", "Today's water faucets are typically made of cast brass plated with another type of metal.", "This single-handle faucet is most commonly seen in a bathroom and is chrome-plated.", "This factory uses steel molds to produce sand molds for casting the brass components.", "The sand mold is actually a sand model of the brass part, only slightly smaller.", "Workers file off the excess sand, which hardened inside the channels consuming the entirety of the steel mold cavity.", "In the casting area, technicians load brass ingots into the furnace, which stands next to an automated casting machine.", "The furnace heats the solid metal at a temperature of nearly 2,000 degrees fahrenheit, causing the metal to melt.", "Technicians place the sand mold inside a two-part steel mold.", "The inner cavity is in the shape of the faucet part, only slightly larger.", "The molten brass will flow into the gap between the sand mold and the steel mold cavity.", "The casting machine positions the mold over the furnace and lowers the mold into a tube, which injects molten brass into the cavity.", "20 seconds later, the steel mold opens, and technicians extract the castings and set them aside to cool.", "Then the parts are placed into a shotblasting machine, which removes all the sand.", "Next, a worker saws off the excess brass that solidified in the channels of the steel mold.", "This separates two faucet bodies that were cast together.", "At the next station, a press forces the part into another machine, trimming off seams and jagged edges.", "Each faucet body is placed on three consecutive computer-guided machines.", "One machine cuts threads in the spout hole for the screw-in aerator.", "The other cuts threads in the hole on top for the screw-in cap that retains the cartridge.", "The third cuts threads in the installation hole on the bottom.", "A robotic machine polishes the entire surface of the part against three separate sanding belts.", "The first belt is a course grit-- the second, a medium grit-- the third, a fine grit.", "This preps the brass for plating.", "These large automated electroplating tanks coat the parts with two layers of nickel, then a layer of chrome.", "In the assembly area, engineers press a nylon-and-ceramic disk through the top hole of the faucet body.", "The disk has brass threads for the screw-in hot and cold water hoses.", "They attach an anti-leak seal on the bottom and screw the aerator into the threaded spout hold.", "The aerator separates the water flow into tiny streams mixed with air, reducing the flow, which prevents splashing.", "They insert a nylon-ceramic cartridge in the top hole, securing it with a retaining cap hidden by a chrome ring.", "The cartridge is the valve which opens and closes the faucet and mixes the hot and cold water.", "They thread the screw for installing the faucet on the sink.", "Then they screw the rubber-and-steel water hoses into the brass threads of the disk.", "The factory runs every single faucet it produces through a water test.", "Engineers manipulate the still-exposed cartridge to check all functions-- turn on, hot/cold water mixing, and shut off.", "If the faucet passes inspection, they attach the handle with a small screw.", "They hide the screw with a cover, then apply a sticker reminding the consumer to periodically clean the aerator.", "They package the faucet with a pop-up drain stopper and a p-trap set.", "The pvc piping retains a small amount of water as a barrier to prevent sewer gases from backing up into the bathroom." ]

{ "things": [ "Surgical Instruments", "Ketchup", "Double" ] }

[ "Surgical instruments have evolved with the science of medicine.", "They actually date back thousands of years, when primitive man used crude implements to cut holes in skulls to release evil spirits.", "Medical science has come a long way since then, and today's surgical tools are among its advancements.", "In the hands of a skilled surgeon, the right tool can be a lifesaver.", "There are now hundreds to choose from, each designed for a specific task or operation.", "Made of surgical-grade steel-- which is extremely corrosion-resistant-- they can withstand frequent cleaning and sterilizing.", "One of the more useful tools is a self-retaining retractor, which is used to pull back tissues or organs during surgery.", "Using a circular cutter, they round the profile of the tool's joint.", "This round joint allows the tool to open when the shanks are shut, the opposite of a pair of scissors.", "Next, cutters carve slots in two parts to create the retractor's intermeshing jaws.", "These jaws will be used to grasp and retract body tissue so the surgeon can operate.", "A technician sands the teeth down to a precise size.", "He must be accurate within a quarter of a millimeter.", "He then smoothes the jaw's teeth against a fine-grit wheel so they'll easily intermesh when needed.", "He rounds the tips of the teeth to make them blunt so they won't damage human tissue.", "He hammers back the tips of the teeth, giving them a claw-like profile.", "With the teeth now complete, attention returns to the round joint of the instrument.", "The carved slots and counter-sync allow the two sides to fit together perfectly.", "They install a part called the rack, below the joint, and file teeth into it.", "It will be used to lock the tool in an open position.", "After heat treatment, a worker sands all the tool components to smooth sharp edges.", "Vibrating porcelain chips and polishing compound scrub them clean and remove burrs caused by machining.", "Next, they install the pivot screw and trigger for the rack.", "By pressing it, the surgeon can open the prongs to the desired width and lock the tool in position.", "Production now moves to the surgical clamp.", "It's used to block the flow of blood during operations and has a more scissors-like joint-- rectangular instead of round.", "Mechanized cutters carve the joint and catches.", "A worker forces the finger bows against a spinning grinding wheel to remove surface imperfections.", "Precision is again critical, as the worker grinds each of the tool's shanks to the correct thickness.", "He measures to confirm that the size is consistent along the length of the part.", "He then files the joints so they mate perfectly.", "He places the joint part of one of the shanks over hot coals to soften the metal and make it malleable.", "Then he forces a spike through a slit in the joint, and the now-compliant steel stretches to open the slit.", "The other shank now slides easily into the opening.", "He hammers the joint to close the opening, and the two arms of this surgical clamp are now hinged together.", "Next he files the teeth of the clamp so they'll interlock when the tool is closed.", "He bends the two ends around a tool to form the jaws of the clamp.", "These curved jaws will come in handy when the surgeon needs to reach around organs or bone.", "Next, using a variety of tools, he adjusts the shanks and the finger bows to give them a more ergonomic feel.", "This is called soft-setting because at this point, the metal is still soft enough to be manipulated.", "He tweaks the bend of the jaws until he's satisfied with the curvature.", "He smoothes the inside of the finger bows with a fine abrasive belt.", "After heat treatment to strengthen the metal, they blast it with fine glass particles to give it a satin finish.", "They laser-etch the company name and identifying numbers onto the surgical clamp.", "The numbers will allow the tool to be traced back to a particular production run.", "And now it's ready to take its place on the front lines of healthcare.", "Ketchup has a questionable past.", "According to one theory, it comes from the chinese \"kê-chiap,\" a type of sauce.", "Another theory traces it to european pickling sauces, and yet another claims arabic origins.", "But there's widespread agreement on where it ends up-- on hot dogs, hamburgers, and french fries.", "Tomato ketchup recipes vary only slightly, as consumers expect a certain familiar tomatoey taste.", "This u.s. company produces all-natural ketchup made entirely of certified organic ingredients-- tomato paste, agave nectar-- a natural sweetener-- onion powder, spices, salt, and white vinegar.", "The tomato paste, not surprisingly, is the base ingredient.", "It arrives at the plant in huge bins, which have been vacuum-packed to preserve freshness.", "After unsealing each bin, the factory's quality-control technician scoops a sample for testing.", "This is to make sure that the thickness is just right.", "If the sample gets the okay, workers slide the bin under a powerful air-driven pump.", "Then they flip a switch, and the pump begins moving the tomato paste to a large holding tank, transferring nearly 310 pounds of this ketchup base in less than 10 minutes.", "At production time, an intricate system of piping transfers a specific amount of tomato paste from the holding tank into a cooking kettle.", "As the paste cooks, a mixer continuously revolves to keep it from sticking to the sides and to blend in the onion powder workers add next.", "This and the upcoming ingredients have been pre-measured to be in correct proportion to the batch size.", "The next ingredients are salt, then, as a sugar replacement, nectar from the agave plant.", "They pour in an initial amount, mix a bit, then pump in the remainder.", "The last ingredient is white vinegar.", "For competitive reasons, the company won't divulge the mixing time, cooking time, or cooking temperature, all of which are key elements of this top-secret recipe.", "On the packaging line, an alignment machine stands the plastic bottles upright as they make their way to the filling machine.", "The finished ketchup, meanwhile, is passing through an elaborate system of cooling pipes en route to the filler.", "And let the bottling begin.", "The machine fills eight bottles at a time...", "150 bottles per minute.", "The factory tests every batch of ketchup it produces to ensure the correct consistency in every bottle.", "The next machine, appropriately called the capper, places a plastic flip-cap on each bottle, then, with spinning circular belts, twists it on securely.", "The next machine cuts a decorative neck band made of plastic film and slips it over the cap.", "Each bottle then passes under an air jet.", "The air blows the neck band downward until it's positioned under the cap.", "Then a quick blast of hot steam shrinks the band to a tight fit.", "The next machine presses on two adhesive labels-- one on the front of the bottle, the other on the back.", "Then it's off to the packing-and-shipping area.", "A sealed bottle of ketchup stays fresh for at least a year because the vinegar in it acts as a natural preservative.", "Ketchup also has health benefits because it's chock full of tomatoes, which are high in lycopene-- a powerful antioxidant believed to protect against many types of cancer.", "Double-decker buses have long been a fixture on the streets of london, england.", "A typical double-decker carries 60% more riders than a regular bus.", "And though quintessentially british, nowadays you'll find london style double-deckers on the streets of several major cities throughout the world.", "Every bus design undergoes rigorous stability testing.", "They fill the prototype with lead weights to simulate a full passenger load, then tips the bus to a 28-degree angle, the side wheels lifting about shoulder height off the ground.", "If the vehicle doesn't keel over, the design passes the test.", "The bus's underframe-- the chassis-- is made of welded steel.", "They construct it in three separate modules-- front, center, and rear-- then set the three modules in an alignment jig to be welded together.", "Once that's done, welders add a steel structure that'll support the floors, seats, and body panels.", "Then they clean the chassis and paint it with anti-rust epoxy.", "After baking on the paint, they seal the gaps between the welded parts with polyurethane.", "This prevents water penetration, which would cause internal corrosion.", "Meanwhile, technicians bolt the 6-cylinder, 250-horsepower engine to the automatic transmission and connect the hydraulic lines and other piping.", "Then they wheel this engine pack over to the assembly line and bolt it to a bar at the rear of the chassis.", "By suspending the engine, they shield it from impact damage in the event of a rear-end collision.", "They also install the radiator, battery, and other components.", "At the front of the chassis, they install the driver's binnacle-- on which all the controls are located.", "Unlike a stationary car dashboard, for driver comfort, the binnacle tilts with the steering column.", "After installing the front and rear axles, technicians mount the wheels.", "Each one is more than a yard in diameter and weighs 100 pounds.", "The engineering specs require the wheel nuts to be turned to a specific tightness.", "Workers also install the driver's seat and the vehicle's 73-gallon gas tank.", "The complete chassis goes onto a test-drive machine which simulates varying passenger loads and road conditions.", "A camera pointed at the binnacle records the accuracy of the speedometer and whether any warning lights illuminate.", "Then it's in to the body shop, where workers mount fiberglass boxes over the wheels.", "Another team builds the inter-deck floor, the aluminum-frame structure that separates the bus's two levels.", "They affix the lower level's melamine ceiling to one side and the upper deck's plywood floor to the other.", "To make the roof, they construct an aluminum frame then glue an aluminum sheet onto it.", "Most of the bus's body is made of aluminum because, compared to other metals, it's lightweight, durable, and easy to repair.", "Next, they paint the roof and install components integrated within it, such as the aerial antenna and wires for lighting.", "As this computer animation illustrates, step by step, the bus is slowly taking shape.", "Workers insert the pegs underneath the roof into aluminum pillars running the perimeter of the upper deck.", "Along the sides, workers sandwich the structural frame between inner and outer aluminum body panels.", "First, they affix the inner ones, then they fill the spaces in between with blocks of foam insulation.", "Finally, they glue on the outer side panels, pressing out the excess adhesive with a roller so that the panel lays flat.", "The front and back of the bus are made of molded fiberglass.", "They have openings for windows, and in the back, a cut-out beneath the top window for the upper-deck air-conditioner.", "As one crew glues all the window glass into place, others install the doors and, inside, the upholstered seats and a durable non-slip floor covering.", "Once the bus comes back from the paint shop, the factory's quality-control department inspects the interior.", "The seat fabric is dark and patterned to discourage graffiti.", "The bus also has 12 cameras hidden in various locations to deter vandalism.", "The typical double-decker is 11 yards long and nearly 15 feet high.", "It carries up to 92 passengers.", "When you need something to lean on, a walking stick can provide the necessary support.", "Wooden walking sticks have been coming in handy since primitive times.", "The first versions were likely crude branches, but they've evolved into something much finer.", "Today's wooden walking sticks are designed to support the user in style.", "There are rustic versions for the outdoor adventurer and distinguished-looking ones for getting around town.", "But, whatever the style, a walking stick adds stability to the human journey.", "It all begins with these 3-year-old saplings.", "These are chestnut-- a lightweight and durable wood.", "Once the sticks have been peeled and dried, it's into the washing machine to scrub off any dirt or mold that may have accumulated.", "And it's not your usual washing machine-- this one is a long tank sized specifically for these sticks.", "A worker closes the lid tightly so no sticks will spill out as the tank rotates in a trough of soapy water.", "After a few minutes of tossing about, these sticks come out squeaky-clean, and they're ready for the steamer.", "The sticks are steamed for 20 minutes, and this makes them soft enough to bend.", "So next, he secures the stick and activates a spring-loaded arm.", "It wraps one end around a form to curl it into a crook.", "He ties it so it holds the crook shape and retracts the bending arm.", "This crook will serve as the walking stick's handle.", "A century ago, crooks were formed entirely by hand, which took brute strength.", "But with the invention of this nifty machine, the job became a whole lot easier.", "Next, it's over to a device called the straightening horse, because it's used to straighten the stick's shaft.", "This job does take a bit of muscle, as the worker wrenches the shaft between posts to set it straight.", "With the shaft now quite linear and the end curled into a crook and still tied, it's time to set the shape of this walking stick.", "And so it's in to the drying room for a couple of days.", "The temperature in here is around 175 degrees fahrenheit.", "And as the sticks dry, the shape solidifies.", "A worker then cuts the stick to the correct length, and he also pares down the end to prepare it for capping later.", "He also sands down the knots in the wood, creating a smoother surface.", "From a simple sapling to a cane shape, it's quite a transformation.", "And it's not over.", "The next worker exposes the wood to a flame, just long enough to blacken it.", "This is staining without the chemicals, and the finish is distinctive.", "He now turns the walking stick against a very sharp circular blade to carve spirals on the crook and down the shaft.", "It's a candy-cane look, and achieving it is a bit tricky.", "This is where on-the-job experience counts.", "Another worker then trims the end of the handle crook.", "The cutoffs won't go to waste-- they'll help fire the factory furnace.", "Next, a worker inserts the crook in a machine that works like a pencil sharpener, except the blade inside rounds the end.", "This process is called \"nosing the stick\".", "The stick that started out as a peeled sapling now looks dramatically different.", "Next, a dip in water-based lacquer gives this walking stick a high gloss.", "They hang it to drip-dry for an hour, after which the walking stick is ready for the end cap, or ferrule.", "Ferrules come in a variety of styles.", "There are blunt ones, for a good grip on indoor surfaces, and there are pointed ferrules, for navigating rougher, outdoor terrain.", "After hammering the ferrule onto the stick, he drives a nail through it to secure it.", "And these walking sticks are now complete.", "All that's left is to hang around until the orders come in.", "And those orders are usually very specific.", "Customers get to choose the length of stick that's appropriate for their height, as well as the style and finish they prefer.", "From a simple stick to a dignified-looking cane, it's been quite a journey.", "The path ahead may be uncertain, but with one of these walking sticks in hand, a person is well-equipped to make his or her way in the world." ]

{ "things": [ "Skeletal Replicas", "Ice Buckets & Servers", "Dining Chairs", "Inground Pools" ] }

[ "Skeletal replicas are excellent educational tools.", "While real bones are fragile, these reproductions are made of a synthetic resin, which is very tough.", "These models are scientifically accurate and can withstand repeated handling in classrooms or museums.", "This facility is dedicated to producing skeletal replicas...", "Everything from ancient humans to prehistoric animals.", "Cast from real skeletons, these models are virtually indistinguishable from the original.", "The process starts with a real skull.", "This one is of a prehistoric sabertooth cat.", "Using a wire cutter, a worker slices up blocks of clay, placing the pieces on the skull.", "He presses the clay evenly around the skull.", "He soaks a sponge and uses it to moisten and smooth the clay.", "He inserts a plastic tube that will come in handy later.", "Now, he saturates strips of fiberglass with a polyester resin and drapes them around the clay.", "Left overnight, the fiberglass and resin cure into a rigid shell around the clay.", "He repeats this process to create a second, identical fiberglass shell.", "With the skull and clay in the bottom half, he bolts the second shell on top.", "He pours silicone into the plastic tube, filling the space between the skull and the top fiberglass shell.", "After repeating this process on the other side, he opens the shell.", "He removes the skull and examines the two-part silicone mold.", "He places the two-part mold back into the fiberglass shell and straps it to a spinner.", "He pours polyurethane resin into the mold.", "At just over a pound, the weight matches the original skull.", "The spinner spirals at a controlled speed, evenly distributing the resin throughout the mold.", "After the resin has solidified, he removes a replica skull from the mold.", "The specially formulated resin has the look and texture of bone.", "The craftsman scrapes away the ragged bits.", "This part is the jaw.", "Using a special grinding tool, he cleans up the surface and does a bit of contour work.", "With a sharper tool, he better defines the area around the teeth.", "Then he grinds the rough bits away from the cheekbone.", "This is the jaw before and after the improvements.", "Now it's over to the paint department, where a worker airbrushes the skull using acrylic paint.", "He layers shades of brown, black, and red to make this replica look more authentic.", "He inserts the saber teeth in the upper part of the skull and drills little holes in both of them.", "He pushes nails into the holes to secure the teeth in the sockets.", "An inspector now scrutinizes the skull and compares it to the original one on the left.", "Just like the real sabertooth cat skull, it looks ancient.", "It's difficult to tell the difference between the 12,000-year-old skull and the new one.", "The skull is now ready for the rest of the skeleton body.", "It takes five people three weeks to build a skeletal replica like this one.", "The roman emperor nero is believed to have been the first to chill wine in containers of ice.", "Despite the convenience of modern refrigerators, ice buckets and servers are still used today.", "They add presentation value to any occasion, whether the host is on a champagne or a beer budget.", "This ice server's simple design drains melted ice, so food stays cold without getting wet.", "An automatic guillotine blade chops large sheets of high-grade stainless steel into rectangles.", "A worker takes each rectangle to a punch press.", "The press cuts a pattern of holes into the steel.", "The pattern is geometric and will drain melting ice efficiently.", "Next, it's over to a deep-drawing press.", "It uses 110 tons of force to transform the rectangle into a pie-style plate.", "A punch cutter removes the excess steel from the rim.", "The worker now has a perforated ice tray.", "He transfers it to another punch press, which cuts finger holes for lifting it from the base.", "The next worker places a larger steel rectangle into a different press.", "This will shape the bowl the ice tray rests in.", "He returns to the tray and buffs the rim to a mirror finish.", "After polishing the outside of the bowl to a high gloss, he welds two screws to the bottom.", "With the screws firmly in place, he connects the two steel legs to the bowl.", "He attaches a steel platform to the other end of the legs.", "This ice server is complete and ready to chill.", "But before they uncork the champagne, they need an ice bucket.", "The bucket starts with a pre-cut steel disk.", "An employee places the disk in a more powerful press.", "It uses 165 tons of force to transform the disk into a basic bucket shape.", "Next, another press applies over 175 tons of force to deepen the bucket and reduce the diameter.", "Stretching the flat disk twice has made the metal fragile, so it's exposed to induction coils that are heated to over 1,800 degrees.", "After cooling, the steel's strength is restored, and it's ready to be shaped again.", "The final press gives the ice bucket a cone-like shape.", "The ice bucket spins on a table that moves through six different polishing stations.", "The brushes at each stop are progressively thinner, and this gradual polishing gives the stainless steel bucket a high sheen.", "With the help of a template, the worker welds handles to the steel bucket.", "Then the bucket is set upside-down on a revolving table.", "A pressurized sprayer shoots fine mineral particles to give the interior a smooth finish.", "This is the result.", "A filler head now dispenses acid and then plunges into it and applies an electrical current.", "This removes the surface metal, resulting in a brilliant finish.", "After the acid has washed off, a worker inserts a perforated plate for drainage.", "This ice bucket is now ready for a party.", "It's not enough for a dining chair to look inviting.", "It also has to be comfortable and sturdy.", "The secret to manufacturing a quality dining chair is to use hardwood and traditional furniture construction techniques.", "This company makes dining chairs out of hardwoods, such as birch, walnut, oak, and ash.", "They dry the wood until its moisture content is 7%, so the chair size stays consistent after construction.", "First, workers stand planks of wood on a conveyor belt to apply glue.", "Then they align the planks' glued edges...", "And clamp them tightly together in a heated press.", "After a few hours of heat and pressure, the glue is dry, and they release the press.", "The planks now form a large panel from which to cut the chair parts.", "A computer-guided band saw cuts the preliminary shape.", "These are chair legs.", "The next machine, the profiler, finalizes the shape and sands the wood surface on all sides.", "Workers now mount the parts on another computer-guided machine.", "This one drills slots called mortises.", "These mortises will receive pins called tenons protruding from adjoining parts.", "Before assembly, workers sand all the parts so they can be stained later.", "To make a curved chair back, they have to bend the wood.", "They need the wood to have a 15% to 22% moisture content.", "Any drier, and the fibers would snap when bent.", "They steam the wood for an hour to soften it and make it more flexible.", "They place the steamed wood in a curved mold on a press.", "Then they dry it with a device that generates heat using radio frequencies.", "After about an hour, they release the press and remove the wood.", "The moisture content is now 7%, which maintains the curve shape.", "Parts that need tenons go into this automated machine.", "Its rotary knife shapes the tenon in about one second.", "Workers glue the mortises in the two vertical sides of the chair back, then brush glue onto the tenons of the chair back's horizontal pieces.", "They align the tenons and the mortises and secure them in place with a mallet.", "They put the chair back into a press to force the tenons in place.", "They reinforce each mortise-and-tenon joint with staples designed for wood.", "They continue to assemble the chair parts with mortise and tenon joints.", "This method is key to the chair's strength and stability.", "Now for the final stage of construction.", "They attach the front-leg assembly to the chair back.", "The chair is placed in a press to completely secure the tenons.", "Then they attach a support piece in each corner.", "In the finishing department, they spray a light coat of stain, wipe off the excess so that the color is even, spray on a sealant, lightly re-sand the wood, and apply a coat of protective finish.", "Finally, they add a seat cushion, which screws into the chair from underneath.", "Now you're sitting pretty.", "The first pools were built by the ancient greeks and romans in the 19th century.", "Large cities like london started building indoor pools for sports and recreation.", "Backyard residential pools became popular in the 1950s.", "Today, residential in-ground pools are available in a variety of shapes and sizes.", "Their parts are made to order in the factory.", "The first step is to design the pool according to the client's specifications.", "Computer software then determines exactly which components must be built.", "The side panels of the pool are made with galvanized steel plated with zinc to prevent rusting.", "They die-cut \"v\"-shaped notches on the top and will cut similar ones on the bottom later.", "These little dimples in the metal will hide the heads of bolts.", "They punch out holes on the remaining ends of the panel.", "These will serve to join multiple panels to create the perimeter of the pool.", "They insert each panel in a powerful metal folder.", "It firmly clamps the sheet of metal and pushes up the edge to create a 90-degree angle.", "Taking a flat, metal sheet and turning it into a three-dimensional object makes it stronger.", "They fold the notches at the top and bottom ends of the panel.", "They also die-cut a large hole for the clean-water inlet.", "To make a curved panel, they place it on a fixed-radius jig.", "They insert a metal profile called a stiffener and bolt it in place.", "They use a custom flat head bolt and nut that will lodge themselves in the metal dimples.", "Next, an automated clamp bends the panel to fit the jig's curve.", "The \"v\"-shaped notches allow the panel to bend easily, but workers must install radius belts to maintain this shape.", "They fasten the radius belts permanently using hydraulic rivet guns.", "All in-ground pool panels are made to order and shipped as soon as they are ready.", "In the thermoforming department, they use a fixed sheet of a.b.s. plastic to make the in-ground pool steps.", "The sheet is firmly clamped in a frame and goes into an oven.", "The oven heats the plastic to around 350 degrees for five minutes until it gets soft and pliable.", "As the plastic comes out of the oven, a fiberglass mold is pushed up, forming the main shape of the steps.", "A rigid cage seals the sides, and a powerful vacuum sucks out the air, forcing the plastic against the mold.", "A series of fans cool down the plastic.", "When it has hardened enough, it's removed from the mold.", "They prepare the vinyl liner for the inside of the pool.", "There are about 30 designs to choose from.", "Workers unroll the vinyl on a cutting table, where a conveyor will keep pulling on it.", "A computer-controlled rotary knife zips over the moving vinyl...", "Cutting effortlessly to create all the required sections.", "The cutting process generates little waste, and the materials are fully recyclable.", "Workers carefully fold each section of the liner.", "All sections will be assembled in another department, according to the assembly plan.", "On-site, they assemble the steps, the side panels, and the piping for the filter and heater.", "They pour concrete around the pool to form a foundation.", "Then they pour some inside the pool to create the bottom.", "They smooth the surface and let the concrete set for two days.", "A worker unfolds the vinyl liner.", "It has a semi-rigid pvc edge that hooks into the top of the pool.", "They fill the space around the pool with gravel and pour a concrete sidewalk on top.", "All that's left to do is add paving stones or a deck, some plants and furniture, and you'll have your own, personal paradise." ]

{ "things": [ "Plant Oil Extractors", "Custom" ] }

[ "In glass extractors, solvents capture liquids from solid or semisolid materials.", "For example, oils can be extracted from plants to obtain the essence of their fragrance and flavor.", "The plant oil can then be bottled for use or incorporated into products.", "Inside this glass apparatus, extraction happens.", "Solvent continuously treats a solid material to extract an oil or other component of interest.", "Making an extractor starts with glass tubing of various lengths and diameters.", "A glass worker uses this one to form a standard taper joint in one end of the extractor tube.", "He heats the end to soften it and places a forming tool over it.", "In its softened state, the glass conforms to the profile.", "After controlled heating removes internal stresses, he grinds the joint to the final dimension.", "The grinding gives the joint a frosted appearance.", "Another worker widens one end of the main extractor body and forms it into an outer joint.", "This end will connect to the condenser.", "The other end connects to the lower extractor body.", "A worker joins them together.", "Then, using a glass support tool, he inserts an inner siphon tube.", "He melts a hole in the lower extractor body and attaches the inner siphon tube to it.", "He makes another hole in the extractor's main chamber.", "He then fuses another siphoning tube to the outside of the main extractor body and bends it into a \"u\" shape.", "He connects the other end of the \"u\" to the inner siphon tube and melts the connecting point all the way around to seal the glass.", "He burns another hole in the lower end of the extractor and installs a tube for solvent overflow.", "He bends it into a vertical position.", "He forms another hole near the top of the main extractor body and connects the overflow tube to it.", "Moving on to the condenser now, a worker shapes the end into a joint that will fit into the top of the extractor.", "He pumps air into the condenser tube to expand the heated glass within a forming tool.", "Another member of the team applies an aggregate compound.", "He inserts in it a spinner that grinds the compound against the glass to refine the profile.", "He tests the fit of this inner joint against a standard outer one.", "Blowing air into one end, he heats the condenser tube in three locations.", "The air gravitates to the heat and forms bulbs in the part, increasing the surface area inside to improve efficiency.", "He opens up one end of the condenser tube.", "Continuing to heat the end, he inserts a reamer tool to widen the opening.", "He carefully slides the condenser into the outer body using a piece of cardboard.", "The worker burns a hole in the bottom of the outer body and fuses the end of the condenser to it.", "He then connects the stem that will eventually carry the condensed solvent to the extraction chamber.", "Next, he makes a hole in the top of the condenser and seals a stem to it.", "This top stem opens the system to the atmosphere to prevent pressure buildup.", "He also equips the condenser with connectors for cooling fluid hoses.", "A worker moistens a decal of the company logo and places it on the condenser unit.", "Then he places the unit into an annealing oven to gradually ramp up the temperature to 1,040 degrees fahrenheit, and then slowly brings it down.", "The process both strengthens the glass and bakes the decal into it.", "Heated, evaporated and then condensed, the solvent in the extractor will separate liquids from solids.", "After more than a century of use, it's still a neat trick.", "The perfect chandelier can be the cherry on the decor sundae.", "There's no shortage of fabulous fixtures in lighting stores and online, but when customers have a unique design in mind, or want someone to design something special, they have to go to a lighting manufacturer that does custom work.", "This striking chandelier is a unique custom design.", "A rustic faux-wood-finish exterior contrasts against a shimmering gold-leaf interior and has handblown, ribbed glass globes suspended like colored jewels.", "A worker constructs the frame for the chandelier's drum shade out of flat bars of cold-rolled steel, steel whose composition makes it flexible enough to be bent without heating.", "After bending two bars into rings, the welder connects them with four vertical ribs made of the same type of steel bars.", "He tack welds the pieces at first, then verifies with a level to make sure the ribs are straight.", "Then, he fully welds the frame and grinds every weld flat to make the joints invisible.", "The manufacturers laser cut and weld sheets of cold-rolled steel to make the light kit that contains the lights and wiring and supports the shade with four crossbars.", "Turning the kit upside-down, the bottom is spray painted gold.", "The workshop's custom painter applies adhesive and begins gently laying down delicate sheets of gold leaf.", "He flattens the leaf with a soft-bristled brush, working the entire surface.", "Once he's sure the gold leaf has adhered everywhere, he brushes away the excess.", "Once the gold-leaf adhesive is dry, he sprays on a coat of clear, high-gloss lacquer, then removes the masking tape covering the side and top.", "The painter also gold leafs the inside and rim of the light housings.", "An assembler now installs them in the light kit, then installs an led bulb in each housing.", "To make the shade, manufacturers mold two half drums of acrylic and paint them black on one side and gold on the other.", "Another painter brushes white lacquer-based paint on the black side.", "Once the paint dries, he applies a coat of diluted brown paint in uneven striations to create the look of wood grain.", "He doesn't let this coat dry because he wants overlapping colors to bleed into each other, so he quickly applies the third coat.", "He immediately applies the fourth and final coat, diluted gray.", "He spreads it with a cloth using small gentle strokes.", "He compares his work to the design sample to make sure it matches.", "Then, he lets the paint dry thoroughly overnight.", "The next day, the first painter applies gold leaf to the reverse side of the painted drum halves.", "Again, he coats the gold leaf in clear lacquer and lets it dry overnight.", "The next day, an assembler takes the drum-shade frame, which has since been painted black, and installs the two half shades, locking them into a lip on the top and bottom rings.", "A worker completes the light kit by splicing the nine wires coming from the led lights to a central wire coming out from the center of the kit's top cover.", "Then, workers line up the kit's four crossbars with the shade's four ribs and insert each crossbar through a notch at the top of the shade.", "They screw the top ring to the crossbar.", "Globes are crafted by a local glassblower.", "The assembler strings each one on a stainless-steel braided cable with a brass check ring on top.", "He sets spring-loaded ball grippers above and below the globe to lock it on the cable.", "The grippers make the globe vertically adjustable.", "This chandelier has seven cables, each one suspending one to three globes.", "A brass connecter at the top of the cable screws securely into a small threaded hole in the light kit.", "With its creative trio of faux-wood, gold and glass, this custom-designed chandelier makes an illuminating statement.", "Strength training is an important component of a fitness regimen.", "One way to build strength is to lift weights or exercise on machines that provide resistance when users pull, push or lift.", "Typically, weights produce that resistance, but some machines use a completely different system.", "This exercise machine doesn't have the typical stack of weights.", "Instead, the handles are connected by a rope-and-pulley system to a pneumatic cylinder which creates resistance.", "This computer-guided laser cuts many of the parts out of sheet steel.", "It can make complex cuts, which are accurate within 100 microns, the width of two human hairs.", "The parts go into a vibrating tumbler filled with ceramic stones and water.", "The stones rub against the parts, removing what's called scale, a flaky substance produced on the surface of the steel by the heat of the laser and oxygen in the air.", "A worker clamps the parts for the trainer's power module onto a welding fixture.", "The fixture is on a robotic cell.", "The cell rotates, delivering the parts to the robot, which proceeds to weld them together.", "Welding the power module takes 14 minutes.", "When the robot completes the welding, the cell returns the fixture to the worker, who inspects the module thoroughly, then transfers it to the finishing area.", "A worker grinds the welds flat, then, with a finer grinding disc, smoothes them out so that they won't show once the steel is painted.", "After washing the module in iron phosphate, a worker applies a positive electrical charge to the module and a negative one to the powder paint.", "Opposite charges attract, drawing the paint particles onto the surface in an even coat.", "Then the worker bakes the paint onto the steel in an oven.", "Elsewhere in the factory, another worker drills a 12-inch-deep hole into a cylinder rod.", "The rod is steel, the piston on its end, aluminum.", "He inserts the cylinder rod into the cylinder, also made of aluminum, then carefully inserts a sensor rod into the cylinder rod's hole.", "The sensor relays the cylinder's position to the machine's computer.", "Snap rings hold the parts together.", "After a paint-job inspection, the trainer is ready for assembly.", "First comes the decals.", "The assembler wets the surface with soapy water, then applies them.", "Once the decals are partially dry, he gingerly removes the transfer tape and inspects for bubbles or gaps.", "Next, he installs the machine's computer.", "It calculates the power produced with each pull on the handles.", "Then, he installs what's called the accumulator tank, which stores the air for the return stroke of the handles.", "He installs the cylinder.", "The bottom is assembled to a central pulley that connects to both handles.", "The top connects to the accumulator tank with an air hose.", "The amount of force is determined by how much air pressure the user lets in when pushing the yellow resistance-control buttons.", "The buttons are attached to air hoses and wired to the computer.", "The assembler routes a 26-foot-long rope through the central pulley and through the machine's 12 additional pulleys.", "The configuration is designed to enable a wide range of exercises.", "After closing up the power module with a cover panel and installing the two height-adjustable arms, the assembler installs a swiveling pulley on each arm and ties what's called a clevis to the end of each rope.", "The clevis holds a wide range of other attachments.", "Once assembly is complete, an inspector checks for any aesthetic or functional defects.", "He sets a resistance level, then pulls on the handles to make sure the cylinder sensor is reading correctly.", "Pulling a handle pushes the rod into the cylinder, forcing the piston against the incoming air pressure supplied by a compressor.", "Because this power trainer uses air, rather than weights, to produce resistance, users can work out at faster speeds, which producers higher power.", "Single-serving coffee pods provide almost instant gratification.", "The concept has changed the way coffee is prepared, no need to wait around for a whole pot of coffee to brew.", "By simply inserting the pod in a compatible machine, it brews the coffee in seconds.", "These coffee pods are designed to be composted after use.", "They offer the convenience of a quick coffee without long-term landfill consequences.", "The process of making coffee pods starts with bags of unroasted beans from different parts of the world.", "These beans will be combined to create specific blends, but first, they must be thoroughly tested and graded.", "A technician inhales the aroma to sniff out defects.", "He examines the physical condition of the beans.", "He's looking for insect damage or fragmentation.", "If he finds too many defects, the lot will be rejected.", "Too much moisture would be another indication that the coffee beans are substandard, so he measures the water content using an electronic analyzer.", "He roasts samples of the beans in these mini roasters.", "This unlocks the flavors and aromas in the green coffee beans.", "The color deepens.", "The beans harden and double in size due to the release of gases and water vaporization.", "For lighter, milder beans, he does a shorter roast.", "For darker, more intensely flavored beans, he roasts them a little longer.", "He inspects the color frequently, and when satisfied, he empties the beans into receiving trays.", "Fans underneath cool the beans and stop the cooking.", "Roasting has transformed the bitter green beans into something entirely more flavorful.", "The technician grinds small amounts into different glasses in order to prepare for a flavor analysis known as cupping.", "The q grader takes over.", "He's a certified coffee taster.", "He inhales the bouquet of the coffee and assesses it.", "He then pours hot water onto the coffee and lets it steep.", "The grounds float to the surface and form a thick crust.", "He breaks the crust with a spoon and inhales again.", "Then, after skimming off the grounds, he slurps the coffee and ponders its flavor, body and acidity.", "He grades the samples accordingly.", "The highest-grade beans will now be made into coffee pods.", "Big batches tumble in a computer-controlled roaster.", "The computer slowly increases, and then drops, the temperature for the desired result.", "The roaster ejects the beans onto a perforated pan, and rotating paddles mix them to dissipate the heat.", "In this industrial grinder, rollers pulverize the coffee beans to a specific granulation.", "Too fine, and the coffee will taste bitter.", "Too coarse, and the full flavor won't be extracted.", "To test the granulation and density, a technician dispenses some of the coffee into a 1-pint container and then weighs it.", "If the coffee is too heavy and compressed, water won't flow easily through the coffee pod.", "Once it passes the density test, the coffee is packed into pods.", "The filter material unwinds through tensioning rollers towards the assembly machine.", "The pod rings, made from plant-based plastic, head in the same direction.", "A pusher moves the rings into slots on a revolving drum.", "The system pulls the mesh filler material over the pod rings.", "Heated devices descend as the drum turns and seal the mesh to the rings.", "Formers stretch the mesh to shape it into filter cups.", "As the drum continues to turn, depositors fill rows of the mesh filter cups with coffee.", "Paper lid material unwinds from the other side, and heat sealers fuse it to the pods.", "At the same time, the ceiling heads punch out the pods, separating them from the mesh and the excess lid paper.", "The coffee is now encased in pods.", "Exiting the drum, an overhead system moves the pods forward to be weighed.", "This mechanized system produces 220 coffee pods a minute.", "Each will provide a quick, caffeinated pick-me-up." ]

{ "things": [ "Technological Corks", "Zinc Gutters", "Traditional Basque Ham", "Chisteras" ] }

[ "Many wine makers these days are opting to seal their bottles with technological corks.", "These are stoppers made of molded particles of natural cork which have undergone a purification treatment to remove the t.c.a. molecule and other contaminants, which can give wine a musty odor.", "Technological corks look very much like the traditional stoppers that are cut and shaped from a solid piece of cork.", "These two are made of natural cork, only very differently.", "Cork is the bark of the cork oak tree.", "Once the tree reaches the age of 25, it can be harvested for its bark once every decade or so.", "A specialized worker makes cuts in the bark with an ax using a very specific technique that doesn't harm the tree.", "Using the handle of the ax, he gently pries off the bark.", "A cork oak typically lives for 300 years and can be harvested up to 15 times.", "Upon receiving planks of cork from the supplier, the technological cork factory breaks them into small pieces...", "Then grinds those pieces into granules, and then stores them in huge bags.", "The first step is to empty the bags into silos that feed the purification equipment.", "The machines, which purify the cork granules, are giant autoclaves.", "Workers fill each one with a ton of granules.", "Then they start up a compressor, which simultaneously heats and pressurizes carbon dioxide that then transforms into a semiliquid gas called supercritical co2, which is an environmentally friendly solvent.", "They inject the supercritical co2 into the autoclave and wash the granules in it for 3 hours.", "The factory's in-house laboratory then analyzes and compares pre- and postpurification samples drawn from each batch to ensure there are no offending molecules remaining after treatment.", "A technician uses the technique of gas chromatography to separate molecules by their size and structure, then the technique of mass spectrometry to measure the electrical signal that each molecule emits.", "The type of signal identifies the type of molecule.", "The signal strength indicates its quantity.", "Once the batch gets the green light from the lab, the manufacturer mixes it with a food-safe binding agent and transfers the batch to the molding line.", "The molding machine is computer-controlled to automatically adjust the molds to the dimensions of the stopper being produced.", "The machine pours the cork mix into the molds, which then go into an oven for a few minutes.", "The ingredients bake into a solid stopper with just the right degree of elasticity.", "Every stopper made in the same mold shape is identical, but no two stoppers cut from the whole pieces of cork are ever the same because cork has natural variations.", "This is merely the cork's preliminary shape.", "A computer-guided machining center refines them to exactly the shape ordered.", "After finalizing the dimensions, the machine chamfers one or both ends.", "A chamfer is a beveled edge that makes it easier to insert the cork into the bottle.", "Every cork then passes in front of a camera, which detects any defects.", "This machine conducts a permeability test on a few samples from each batch to measure how much oxygen flows past the cork when it's in position in the bottle.", "The corks are usually custom-marked for a specific winery.", "Some wineries order a model that looks more like a traditional stopper cut from a solid piece of cork.", "That type requires a couple of extra production steps.", "A branding stamp burns lines on the top.", "Then a computer-guided laser burns a pattern around the side of the stopper to mimic the texture of natural cork.", "The last step is to brand the winery-specific words and images.", "The cork goes from ground cork bark to a finished stopper and then to a final visual inspection before being shipped out to the winery.", "The cork granules are stabilized by a binding agent and molded to a custom shape to block more or less oxygen according to the winemaker's specifications.", "Some wines require a completely airtight seal while others require a certain degree of air penetration to mature further after bottling.", "Zinc gutters drain rainwater and, in the process, develop a natural resistance to corrosion.", "When zinc is exposed to wet and dry cycles, a chemical reaction occurs, forming a protective patina on its surface, no paint or special treatment needed.", "You can't stop the rain, but you can stop it from damaging buildings and their foundations.", "These u-shaped zinc gutters funnel water away from the structures to keep them dry.", "The process starts with the production of these 46-ton coils of zinc.", "The zinc arrives at the factory in the form of thick plates.", "These plates are almost 100% zinc.", "The plates drop into a furnace.", "Inside, the temperature reaches 750 degrees fahrenheit.", "Workers add a bit of copper and titanium to reinforce the zinc, and it melts into a homogeneous liquid.", "The molten zinc then flows into a trough-style conveyor system.", "Residues, like ashes, float to the top of the metal soup, and a worker skims them off.", "A floating puck monitors the speed and depth of the zinc blend to prevent overflow.", "The molten zinc now arrives at the casting machine.", "Here, 3-foot-wide steel unwinds, and once linear, the zinc flows onto it.", "The steel acts as a mold to form the zinc into a long rigid sheet.", "Water flows onto the zinc to accelerate cooling and solidification.", "Since water and liquid zinc don't mix, the water simply runs off the surface.", "Now solid, the zinc plate is almost 1/3 of an inch thick, far too thick for making lightweight rain gutters.", "The next operation will thin the plate down dramatically.", "This is a powerful rolling mill.", "The pressure on its rollers is so great that they often must be replaced.", "Once the new rollers have been loaded, the mill heats them up.", "The operator activates the rollers.", "As they revolve, the hot rollers exert 770 tons of pressure to iron the zinc much thinner.", "Meanwhile, just ahead, a steel belt tensioning system swings into action.", "This system prevents slackening in the zinc sheet as it exits the rolling mill and moves forward.", "You can see the difference the rolling has made.", "It has reduced the thickness of the zinc sheet to about 3/4 of a millimeter.", "The steel-belt system maintains the tension in the zinc sheet as it's wound around a core.", "This produces the 46-ton coil of zinc.", "It's known as the mother coil.", "Approximately 25 miles of rain gutters can be made from this coil.", "Workers slit the mother coil into three.", "Each coil is a foot wide.", "It is now the correct width to be formed into rain gutters.", "A crane lifts one of the narrower coils over the factory floor.", "Its journey is guided by the operator below.", "This puts it in position to be mounted to the next machine, one that will cut it into uniform 13-foot-long strips.", "That's the standard length for the rain gutters.", "As the zinc uncoils, an overhead mirror provides a top view for the operator.", "In quick swoops, the blade slices the zinc sheeting to the correct length.", "The zinc strips then travel through a progressively narrow channel and over a cylinder.", "This rounds the profile.", "More rollers improve on the u-shape and also curl the edges of the gutters to reinforce them.", "This gives the zinc rain gutters their final shape.", "The automated profiler ejects the 13-foot-long gutters onto a rounded rack.", "Then it tips to stack the gutters neatly on top of each other.", "These zinc rain gutters are ready to hang.", "On site, they'll be welded together and attached to the roof with special hooks.", "They should come in handy on a rainy day.", "The french basque country is, culturally, quite distinct from the rest of france.", "Located in the southwest, bordering spain, the region is known, among other things, for its ham, which is salted and air-cured in an old tradition, passed down through generations of basque farmers.", "There are several types of traditional basque ham.", "This one, called kintoa, is marbled with fat and has a deep, strong, fruity flavor.", "Its distinct taste and composition begin with a specific breed of pig, the basque country piebald, referring to the animal's skin.", "This pig breed is native to the basque region where livestock are raised on small farms in the valleys of the pyrenees mountains.", "Unlike commercially farmed animals, the female pigs have small litters of six to nine piglets, which grow up roaming and grazing along the vast mountainsides on an average of 2 acres of land per 30 piglets.", "As a result of this free-range rearing, the pigs grow more slowly and become heavier than commercially farmed pigs.", "Once the animals reach a weight of about 330 pounds, which usually takes a year to 15 months, they go to the slaughterhouse.", "Each carcass is stamped with an identification number.", "Traditional ham is made from the hind legs.", "After tagging the leg, a worker places it in a machine, which brands the kintoa symbol into the flesh.", "Then another worker spreads dry salt on the exposed portion.", "The salt comes from salies-de-béarn, a saltwater spring in a basin bordered by the pyrenees mountains, the adour river, and the atlantic ocean.", "Workers leave the salted ham in a cold, damp room for 1 day per every 2 pounds, typically about 15 days per ham.", "The salt preserves the meat.", "Next, the ham undergoes a first dry curing.", "It hangs on a stainless-steel rack in a temperature and humidity controlled room for 7 months.", "When the ham comes out of the room, it has lost about 20% of its original weight because most of the moisture has evaporated.", "A worker brushes off the surface...", "And coats the exposed part of the ham with a special grease that's made out of pig's kidneys, rice flour, and water.", "This grease prevents the surface from drying out and crusting during the second dry curing.", "The ham now goes into a second drying room, which dries the ham in the open air, taking advantage of this particular geographic location.", "A warm southern wind from spain and humid air from the atlantic ocean to the west blow into the room through windows.", "Nature does all the work.", "Humans merely regulate the airflow and humidity by lifting or lowering the blinds.", "In this room, the ham hangs from a wooden rather than stainless-steel rack.", "That's because the wood absorbs excess humidity and transfers moisture to the meat if the air gets too dry.", "As the ham dries, its flavor concentrates.", "The charcutier, an artisanal pork butcher, inspects every ham carefully.", "The wind that dries the ham carries pollen and other natural particles, which give this ham a distinct flavor and fragrance.", "The secret is slow curing until the ham reaches optimal maturity.", "That takes approximately 1 month per 2 pounds, so the ham remains in the second drying room for more than a year.", "When the cured ham is ready, workers sprinkle it with espelette pepper, a mildly hot pepper from the northern basque country.", "This gives the ham a fragrance that's as appetizing as its taste.", "The ancient basque sport of pelota, or jai alai, can be played with a paddle, a racket, just your hands, or with a specially made wicker scoop called a chistera, which helps propel a ball at lightning speeds, making the sport one of the fastest ball games in the world.", "The chistera was an innovation of the mid-19th century.", "Ever since then, making chisteras has been the domain of a few specialized artisans.", "The family-owned workshop and all the tools it contains for making chisteras has been passed on from father to son since 1887.", "In use for more than 100 years, these tools still work.", "The great grandson of the workshop's founder uses an old plane and clamping bench to shape a curved piece of chestnut.", "He clamps one end in a vice and uses a modern drill to round the tip before rubbing on a little wax to help fit a crosspiece.", "To prepare for the next phase, he smoothes the surfaces with some fine-grit sandpaper.", "It's now time for him to create the substructure of the chistera.", "He starts by clamping the frame onto a mold.", "He gauges the curve of the side ribs and uses steam to adjust them.", "He's used plaster to patch the mold where it's been worn down by more than 100 years of constant use.", "Then he moves on to the bottom ribs, which he carefully shapes and trims to length.", "Each chistera is completely bespoke-- that is, made to order for the individual pelota players.", "This means each chistera will differ slightly to meet the needs of its owner.", "That's why the artisan must take care to ensure all the dimensions are correct.", "He attaches lengths of elastic strapping to the mold to hold the ribs in place as he works.", "Ribs give a chistera its shape, but they're not strong enough by themselves.", "They need to be woven with wicker made from willow heartwood.", "The artisan prepares the wicker with tools designed to shave it down to the required dimensions.", "He then turns the chistera over to his uncle, a specialist in wicker wood.", "There are two different sizes of chistera.", "For a small one, it takes a specialist roughly 9 hours to weave.", "For a big one like this, it takes about 14 hours.", "In the game of pelota, the small hard ball travels at incredible speeds.", "In fact, the guinness book of world records reports a pelota ball clocked at 188 miles per hour.", "Speeds like that could cause some serious damage.", "Here, the artisan rolls and sews leather padding designed to protect the player's hands from injury.", "Once he's made the padding components, he sews them onto the chistera, positioning them where needed.", "This leatherwork phase alone takes about 2 hours to complete.", "He now cuts out the shape required for the glove portion of the chistera, then slices the outlines for the individual fingers.", "True to form, even the sewing machine is an antique original.", "It may be old, but this well-built machine can still do the job of sewing the leather to a layer of cloth, which is specially formulated to wick away sweat.", "To attach the glove to the wicker scoop, the artisan must set aside the sewing machine and complete this step the old-fashioned way by carefully sewing the components together by hand.", "He then trims off any excess material with a pair of scissors and inserts his hand into the glove.", "This makes it easier for him to complete the final step of attaching a handy loop.", "Preserving a tradition of handcrafted excellence, the finished chistera is a work of artisanal art.", "That helps make pelota one of the fastest games in the world." ]

{ "things": [ "Diamond Cuttings", "Wood Doors", "Paintballs", "Newspapers" ] }

[ "Today on \"how it's made\"...", "Diamond cutting...", "Wood doors...", "Paintballs...", "And newspapers.", "Diamonds are rare crystals composed mostly of carbon.", "They're the hardest natural substance on earth.", "A superb cut manipulates light to maximize a stone's brilliance.", "That enhances the diamond's beauty and increases its value.", "Diamonds come in a variety of colors, the most common of which for jewelry is white.", "They begin as a larger, rough stone.", "The goal is to cut as big a diamond as possible from it while cutting away any imperfections that lessen the value.", "To do this precision work, master diamond cutters use a magnifying glass that enlarges the stone 10 times.", "They carefully examine and re-examine the rough diamond, trying to determine the best way to divide the stone.", "They must saw the diamond in the direction of its grain, then, using hot glue, secure the rough diamond into a holder positioned over the saw.", "The saw has a very fine bronze blade, but it can't cut through the diamond on its own.", "Only diamond can cut diamond, so they coat the blade in a mixture of diamond dust and oil.", "Sawing an average-size rough diamond in two can take up to four hours.", "The second stage of diamond cutting is called polishing.", "It's the process of forming the diamond.", "A special machine first tailors the basic shape.", "Then the diamond cutter puts glue in a mounting tool called a dop.", "This will hold the diamond firmly in place.", "He presses the diamond against a spinning cast-iron wheel coated with a mixture of diamond dust and oil.", "First, he removes any marks that were left by the saw.", "Then, to give the stone its brilliance, he forms facets-- a particular pattern of tiny, flat sides of various shapes.", "The facets are designed to reflect light off each other.", "Each one must be exactly the right size and shape and cut at precisely the right angle in relation to the other facets to create maximum brilliance.", "Here he starts with the table facet, which is the flat top of the diamond.", "How he proceeds depends on the size and condition of the stone.", "Then come the pavilions-- the angled facets that end in a point at the bottom of the diamond.", "If they're cut too deep or too shallow, light will leak out the bottom, making the diamond dark in the center and dull overall.", "The ideal slope is approximately 42 degrees.", "The diamond cutter uses specialized tools to measure the angle.", "Next, the diamond cutter fashions crown facets-- the ones circling the diamond directly under the table.", "Using another type of dop, the diamond cutter fashions what's called the girdle-- the faceted rim that separates the crown facets around the top half of the diamond and the pavilion facets below.", "Diamonds are weighed using a measurement called karats.", "One karat weighs 0.007 ounces.", "Polishing a one-karat diamond can take three or four hours.", "When it's done, they boil it in acid to remove any debris.", "This finished diamond has 58 facets.", "It's called a brilliant cut.", "It's by far the most common style of cut, dating back to the 1600s.", "The quality of the cut is a key factor in grading diamonds.", "Experts also rate what's called the clarity-- the degree of imperfections in the stone.", "Then there's color.", "The finest white diamonds are completely colorless, and the rarest colors are the most valuable.", "Coming soon to a supermarket near you-- food that tells you when it's gone bad.", "Researchers are developing electronic devices that monitor food freshness and detect potentially fatal bacteria like e. coli.", "These devices on the packaging would give off a signal when the food inside spoils.", "We open and close them several times a day, day in and day out and seldom give them a second thought, but imagine your home without doors.", "For one thing, you'd have absolutely no privacy.", "And what would you slam when you get angry?", "The first factory makes the door's plywood facing.", "They start by loading logs into steaming basins for three days.", "This deices them in the winter and softens the wood fiber.", "Inside the factory, the steamed logs line up for the debarker-- a machine that removes the bark.", "The operator projects concentric circles and uses a laser to carefully center the log on the debarker.", "Positioning is crucial for two reasons-- so that as little wood as possible comes off with the bark and to ensure the debarked log ends up perfectly cylindrical.", "That maximizes the amount of wood veneer a log will yield.", "The next step is called rotary cutting.", "As the log spins, a lathe skims off a sheet of wood veneer just 2/100 of an inch thick.", "The average log yields 440 linear feet of veneer.", "Next, they unroll the veneer and cut it into sheets.", "Then they stack the sheets by identical grain patterns.", "Using a laser to position the blade, they cut through the stack to take out visual defects.", "Then they glue the pieces together.", "To make veneer sheets for the front of the plywood facing, the side that will show, they line up the wood's grain and other features in mirror image.", "For the back, the side that won't show, they assemble the defective parts they cut out earlier.", "They use three veneer sheets to make up the plywood door facing.", "They apply glue to both sides of one sheet, then sandwich it between two other sheets.", "They feed the three sheets through a hot press at more than 212 degrees fahrenheit.", "In a minute and a half, the glue cures, and those three sheets of veneer become a 3-ply panel of plywood.", "Then they sand the panel.", "Plywood door facings can be made from more than 15 different species of wood from birch and oak to maple and mahogany.", "At the second factory, they make the core of the door.", "They glue together strips of wood to form the middle, then frame them with pieces of white pine.", "A press pushes the core pieces together, then activates the glue, not by heat as most presses do, but by microwaves.", "Next, they sand and calibrate the core.", "After the glue machine coats the core, they stick a plywood door facing on each side.", "They stack a few doors at a time into a cold press for a half-hour.", "Until the glue dries, then set them aside while the glue cures for another eight hours.", "Next, they size the width and length to the final dimension, bevel the edges, and cut the exact height of the door.", "Then they inspect the door on both sides.", "A machine prepares the door for hinges.", "Then another machine cuts the hole for the knob.", "The finishing process takes just 70 seconds per door.", "One side is sanded, stained, and sealed, then sanded again and varnished.", "The machine then flips the door over and does the same thing to the other side.", "The game of paintball is a cross between tag, hide-and-seek, and capture the flag.", "You try to steal the other team's flag and eliminate your opponents with an air gun that shoots an exploding paint capsule called a paintball.", "Paintballs are made entirely of nontoxic food-grade ingredients.", "To make the hollow shell, they first pour water into a giant, heated mixing bowl.", "They add a sweetener and a secret combination of food ingredients the company won't divulge.", "Then, finally, the key ingredient that gives the shell its shape-- gelatin-- the kind used to make gummy bears.", "They melt and mix everything for a half an hour...", "Then line it up for what they call the drop-- transferring the gel from the mixer into a heated vat called the gel tote.", "They filter out any globs that didn't melt.", "Once the gel is securely in the tote, they lower in a giant blender.", "They pour in food dye and blend for about 20 minutes.", "Elsewhere in the factory, they use the same method to dye what's called the fill-- the paint that goes inside the shell of the paintball.", "It's made of polyethylene glycol-- the inert liquid in cough syrup.", "They thicken it with crayon wax.", "The gel and fill meet their maker in what's known as the feed room.", "Here, the vats of gel and fill feed a capsulation machine one floor below.", "This machine is the same kind used to make bath beads and gelcap medicine.", "First, the machine spreads out the gel onto a cool drum.", "This creates a continuous thin sheet of gel called a gel ribbon.", "This cooling cures the gelatin to the point where it can now be molded into the hollow shell of the ball.", "The machine presses the gel ribbon into a dye with half-circle pockets, each forming one half of a ball shell.", "The machine does the next three steps in one shot.", "It aligns the two half shells together to form a hollow ball, injects the fill, then seals the two half shells together.", "These newly minted paintballs are still quite soft, though.", "If they're not dried out, they'll lose their shape, so they fall down onto a conveyor...", "Then roll into a tumble dryer.", "From here, they'll go onto a bakery-style rack until they dry out completely.", "To make dual-colored paintballs, they use the exact same process but feed two colors of gel ribbon into the capsulation machine-- one color for each half of the shell.", "The finished paintballs go through an automatic counting machine.", "This one is set to count out and package 200 balls at a time.", "Manufacturing this messy ammunition is a painstaking process, but well worth the effort to the millions who love the game of paintball.", "Invented just 15 years ago, it's caught on in more than 40 countries worldwide, and it's not just for kids.", "More and more companies are booking paintball outings for their employees to help build teamwork.", "There was a time when our only source of news was the newspaper.", "Today, though, newspapers have to compete with radio, television, and the internet.", "Still, to get context and analysis of news events, most still turn to the newspaper.", "In medieval times, people got the news of the kingdom from the town crier and from official notices posted in public places.", "By the late 1400s, the first printed news pamphlets appeared in germany.", "The first english-language newspaper hit the stands in london in 1622.", "By the 1800s, new printing technology brought the price of newspapers down.", "This finally made them affordable to the masses, who were becoming more literate.", "The news editor selects the stories and photographs.", "They come from the newspaper's own reporters and photographers and from wire services.", "The news editor accesses the wire services via the internet.", "Local reporters file their stories to the newsroom computer system.", "The photo lab scans the photographers' pictures into the system as well.", "That puts everything at the news editor's fingertips.", "It's just a matter of moving the various items into the page layout.", "Once the layout's complete, they group the pages in sets of four called flats.", "The manager checks each flat for errors, paying special attention to the advertisements, the newspaper's main source of revenue.", "Next, they prepare the printing plates for each page.", "A plate is a plastic-coated sheet of aluminum, just 1/100 of an inch thick.", "It goes into the cylinder of a machine called the imager.", "The imager's laser beam scans the plate, hardening the plastic coating wherever the computer tells it there will be text or pictures.", "The coating in the blank areas that don't harden then washes away in a series of chemical baths.", "It takes about a minute for a plate to pass through those processing basins.", "Next, a machine punches registration marks on each side of the plate.", "The press operators will use those marks as a guide to correctly position the plate on the printing press.", "After they oil the press cylinder, they attach the plates.", "There's one plate per page per color to a maximum of four colors.", "The newsprint comes in jumbo rolls weighing about 1,900 pounds apiece.", "Workers feed several rolls into the reeling machine under the printing press.", "2-sided tape connects one roll to the next, ensuring a continuous, uninterrupted run.", "This is a 4-color printing process.", "There's a station for each color of ink.", "The paper passes through each color one at a time like a car going through an automatic car wash.", "The printing starts out slowly, but within a few seconds revs up to 25 miles per hour.", "Press operators adjust the colors as needed.", "Each line of the press prints a 4-page flat.", "Then it cuts the sheet in half lengthwise, separating two and two.", "Then it cuts the continuous lengths widthwise into a 2-page spread.", "Machines automatically assemble the pages in order, then send them off to the shipping department.", "The stacker makes piles of 50 copies for delivery.", "Then workers hand-stuff the inserts one by one." ]

{ "things": [ "Angle Grinders", "Berry Baskets", "Omnidirectional Speakers" ] }

[ "The angle grinder created a major buzz in the workplace when it was developed in the middle of the 20th century.", "This power tool could do it all-- cut, grind, and polish metal or stone.", "Just change the disk or brush attachment to match the job, and work gets done automatically.", "With numerous attachments available, the angle grinder could be equipped for many different jobs.", "That makes it one of the most useful things on any job site.", "Making angle grinders starts with these blocks of pure aluminum.", "Fired in a furnace, the aluminum melts into a liquid form.", "The factory casts the molten aluminum to create gear housings.", "A robot transfers one of the gear housings to a milling station and then retrieves a finished part.", "The door of the machine closes, and a computerized cutter carves threads into the center bearing seat and generally improves the profile of the part.", "Next up is the rotor for the electric motor.", "An automated system pushes special cardboard end disks onto the rotor shaft.", "The part on the right is equipped with end disks.", "The system now installs a part called the collector on one end.", "Made of copper and plastic, the collector will transmit power to the rotor and ensure that the grinding or polishing attachment can turn.", "The part on the right has had the collector installed.", "Spinning arms wind copper wire into grooves in the rotor at both ends.", "The wire will serve as an electromagnet and maximize power output.", "Moving forward, the system inserts covers into slots in the rotor wall.", "They both insulate the rotor and stabilize the copper coil.", "Spinning devices wrap copper wire around each half of the stater.", "This stater creates the electromagnetic field around the rotor.", "A robot puts the two halves of the stater together in a fixture, and welds make the assembly permanent.", "Over to an injection molding machine now, it forms plastic into outer casings for the grinder.", "A robot transfers the casing to a platform for printing.", "This stamp adds silver ink to the embossed company logo, giving it greater visual appeal.", "A worker then slides the plastic housing over the stater, and a pneumatic machine press-fits the two together.", "The worker then wires the on/off switch for the angle grinder.", "The gear housing has, by now, been equipped with a drive gear and brake.", "He installs the gear system on one end of the rotor.", "He then inserts the rotor assembly in the stater.", "An automated system screws everything together to complete the angle grinder motor.", "Next, a nozzle fills the gear head with grease.", "A worker places the spindle and safety clutch over the gear head, and a mechanized system screws it in place.", "She then wires the electrical plug to the angle grinder motor.", "She encloses the electrical wiring with a plastic cover.", "She locks the cover in places with screws, using a metal template to aid in their placement.", "This angle grinder is now ready to undergo quality control tests.", "This one depresses the angle grinder switch, while a computerized system analyzes the motor's performance.", "If it passes all the tests, the angle grinder is ready to take a chunk out of someone's workload.", "Long before the development of pottery, people looked to the forest for containment materials.", "They made berry baskets from the bark of birch trees.", "The baskets were lightweight and waterproof, due to natural resins in the bark.", "The making of these baskets is a tradition that carries on.", "For containing nature's bounty, birch bark is a natural choice.", "This berry basket is made entirely from materials found in nature.", "Making one starts with birch bark that's been carefully pried off the tree to avoid damage to the inner layer of bark.", "This cardboard pattern will be used as a template.", "The basket maker examines the bark for any holes or serious flaws.", "He flips the bark over.", "He'll use the inner side for the outside of the basket.", "He traces around the pattern, using a scribe that lightly scores the bark.", "This light scoring creates a visible outline on the bark.", "Using scissors for cutting leather, he follows the pattern lines to cut the bark to the pattern shape.", "The contours are harder to follow, so he switches to scissors with curved blades to cut them out.", "He punches holes in the basket corners.", "This will stop the bark from splitting in these spots when it's folded.", "Using a pointed instrument known as a divider, he now etches stitch lines around the perimeter.", "He maps out the location for the stitch holes by lightly piercing the bark along the etched lines.", "Using a ruler for support, he bends the flaps of the pattern up, creating creases that will become permanent folds later.", "He punches out stitch holes where he had lightly pierced the bark.", "He drapes a damp towel over the birch bark and irons it.", "This softens the bark so that it doesn't split as he now forms the final bends along the crease lines.", "He overlaps the ends of the basket.", "He clips the structure to hold it together while he inserts wooden dowels in some of the stitch holes.", "Once the dowels are in, he removes the clips.", "The dowels will keep the basket together for stitching.", "But first, he tapers the stem from a willow shrub using a wood plane.", "He inserts the stem in a cylindrical container and fills the cylinder with hot water.", "The tapered stem soaks overnight.", "It softens and becomes extremely flexible.", "Using a wooden form, he shapes the stem into a ring.", "The tapered ends overlap for a consistent thickness all the way around.", "He clips the ring to the inner rim of the basket and also tacks it in place with a few stitches.", "This willow ring will add support to the lip of the berry basket.", "Next, he stitches the seams together using the root of a spruce tree for thread.", "Its tapered tip serves as a needle.", "He does precise backstitches and ensures all the seams are tight.", "Moving back to the rim of the basket, he punctures the bark just below the willow ring, creating a row of holes to loop the root around the rim.", "This spruce root wrap protects the rim ring, and gives the basket a more finished look at the top.", "He slices a piece of cedar bark into long, narrow strips.", "He'll use these strips to make a handle for the basket.", "He weaves the cedar into a five-strand braid.", "He loops the cedar braid at the ends and uses the loops to stitch the handle to the berry basket.", "It takes this artisan about a day to craft a birch bark berry basket.", "His efforts will no doubt bear fruit for many years to come.", "Choosing the right speakers for your sound system depends on how you prefer to hear music.", "Unidirectional speakers radiate sound in a single direction.", "Omnidirectional speakers radiate in all directions, so the sound bounces off the ceiling and walls.", "This omnidirectional speaker system has four towers-- two main system towers and two subwoofer towers.", "The towers contain the drivers that radiate sound frequencies out of the speaker.", "This computer-guided mill shapes brass sheets into mounting plates for the main system towers.", "Each of the main system towers contains six drivers-- two tweeters, two mid-ranges, and two woofers.", "Each subwoofer tower contains six drivers for the lowest human audible frequencies.", "After the brass mounting plate comes off the mill, workers grind the top surface smooth to prepare it for polishing and chrome plating.", "The mill then shapes brass rings.", "These are bases for the woofers, which fit an opening in the mounting plate.", "Brass is the metal of choice for these parts, due to its acoustical properties.", "For aesthetics, the rings are painted black, and the mounting plates are electro-plated with galvanized chrome.", "In this part of the plant, they build tweeters for the main system towers.", "The first step is to lay strips of resin-impregnated carbon fiber in semi-circular molds.", "After removing the protective film that covers the carbon fiber, they lay foil strips at each end.", "These will direct heat from the oven to the carbon fiber strips and prevent the resin from flowing out.", "They assemble the molds and clamp them shut.", "They place the molds in an oven for 45 minutes at a programmed series of temperatures.", "This heats the resin in the carbon fiber, stiffening and forming the strips to the mold shape.", "Using a punch press, workers slice each carbon fiber strip into several thinner strips.", "They construct each tweeter by gluing 24 of those thin strips to the tweeter's voice coil, a ring made of wound copper wire.", "They brush silicone in between the strips, coat the entire surface with more silicone, then place an aluminum cover plate on top.", "They construct each mid-range driver the same way, but with carbon fiber strips that are thicker and stiffer and therefore radiate lower frequencies better than the thinner, more flexible tweeter strips.", "Placing the strips with tweezers and aligning them properly with a toothpick requires a good eye, excellent dexterity, and a lot of experience.", "Like the tweeter, the mid-range driver goes into an oven for 45 minutes through a specific cycle of temperatures.", "Once the driver comes out of the oven and cools, they glue strips of sound-dampening foam to the inside, sealing the gaps between the carbon fiber strips.", "This prevents sound from radiating inward rather than out the speaker.", "They solder the cables that bring the incoming electrical signal that carries the sound frequencies.", "That signal moves the voice coil up while the driver's magnet moves it back down.", "The repeated up and down motion flexes the carbon fiber strips, radiating the sound frequencies.", "After installing a center rod made of carbon, workers stuff the hollow space inside the driver with sound-dampening wool.", "They pour lubricating oil into a narrow gap in the driver's magnet, then insert the voice coil into the gap.", "The oil contains iron, so it conducts the electrical signal to the coil.", "They screw an aluminum mounting plate to the magnet's posts...", "Then apply a disk of a stiff sound-dampening material.", "They install the tweeter's magnet on the mounting plate, feeding the tweeter's electrical cables, not yet soldered to the tweeter, through the center rod.", "Next they'll make the woofers.", "The sound system's amplifier delivers the electrical signal that carries all the sound frequencies.", "Inside each main system speaker, an electronic component called the crossover separates the frequency ranges and sends them, via designated cables, to the appropriate driver.", "They make each melon-shaped woofer out of 12 aluminum segments.", "They glue acoustic foam to each segment, then trim the foam to the shape of the aluminum.", "Workers assemble the woofer upside-down in an assembly fixture.", "They glue the segments vertically between this woofer's voice coil, which has two cables attached to it and a mounting plate.", "The structural rod through which they'll feed the other driver's cables is in the center.", "Once all the segments are aligned and fixed in place, they coat the edges with glue.", "Then they adhere rubber gaskets in between the segments to block the gaps and prevent air from exiting.", "They seat copper strips in the segment's grooves, hooking the ends into holes at the top and bottom.", "Brass, aluminum, copper-- every type of material used in these speakers has specific acoustical properties.", "The combination produces a natural sound balance.", "They fill the hollow interior space around the center rod with sound-dampening material.", "First, synthetic insulating wool with long, coarse fibers.", "Then, on top of that, a barrier of cotton-insulating wool to prevent those coarse fibers from touching the voice coil.", "Next, they install the painted brass ring they milled earlier, which now has the woofer's magnet fixed to it.", "They place a spacer, thread a screw, pull the voice coil's two cables through the center, then solder those cables, together with the cables from the other drivers, to a main cable that will plug into the crossover.", "They flip the woofer right side up and pour a liquid sound-dampening compound into the center rod.", "The cables inside are too delicate to be shoving in insulating wool.", "Workers now begin assembling the speaker, first soldering the two remaining crossover cables, mid-range and high frequency, to the respective driver cables.", "The tweeter connection cables are attached to the tweeter magnet, installed earlier on top of the mid-range driver.", "They now mount this unit on top of the woofer.", "They install the connectors in the crossover.", "Its electrical components separate the frequency ranges and send each one to a designated connector, which sends it to the cable leading to the appropriate driver.", "After sliding the crossover onto the speaker's base, made of milled brass, they close up the top with the mounting plates, between which they've since sandwiched a thick piece of wood.", "Screw-in stainless steel support posts hold everything together and direct all the weight down to the floor, rather than into the speaker structure.", "They install an aluminum crossbar for structural support, then a second set of posts.", "They fit the ring at the base of the woofer into the mounting plate hole, securing it with screws.", "They insert the tweeter's voice coil into the tweeter magnet that's mounted on top of the mid-range driver that's mounted on top of the woofer.", "They solder the tweeter cables to the two connectors on the tweeter cover plate.", "This completes the lower trio of drivers.", "Now they install an identical upper trio, but upside-down so that the two tweeters face each other in the middle of the tower.", "They mount the crossover for the upper trio and plug in the connector that joins the three cables.", "That brings the correct frequencies to the three drivers.", "They run test tones through every completed speaker.", "A microphone positioned just over three feet away picks up the emitted frequencies, which a computer analyzes for accuracy.", "Once the speaker passes inspection, they install a decorative grill over each woofer voice coil.", "The subwoofer tower radiates the lowest frequencies, with six huge drivers and a built-in amplifier." ]

{ "things": [ "Microphones", "Hot Tubs", "Artificial Turf", "Beer Steins" ] }

[ "People have been doing mike checks since 1876, when the microphone was invented as part of the telephone.", "Microphones convert sound to a signal that can be transmitted through televisions, radios, and many other things.", "If you have something to say, you'll need a microphone to broadcast it.", "From the glory days of radio to stage and screen and the digital age, the microphone has been at the center of it all.", "To make a broadcast-quality microphone, they start with the support piece for it.", "Automated tools carve a brass cylinder to the desired dimensions.", "They also make a retainer ring for the microphone grille that will anchor the grille's metal mesh.", "They layer three sheets of mesh and align them.", "Then they solder the three sheets together.", "A punch press forms the soldered mesh into a concave shape.", "They lower a blade to slice the shaped mesh in half.", "The two pieces will be used to make one microphone grille.", "An assembler squeezes solder paste into a groove in the brass ring.", "Then he presses the grille halves, which have been joined by a bracket into the solder-coated ring.", "On a carousel, a torch heats the rings, and the solder paste melts to bond the grilles to the rings.", "A drill punctures a brass disk up to 90 times to make ventilation holes.", "Another tool levels the surface and shaves off unwanted bits.", "This disk will be the backplate for one of the microphone's capsules.", "An assembler brushes away any remaining shavings and then fixes the backplate in a holding device.", "This plastic membrane has been coated with real gold to conduct electricity.", "She places the membrane and a plastic ring on the backplate and then attaches an electrical lead.", "She screws the plastic ring down to secure the assembly...", "And then trims away the excess plastic membrane.", "This microphone capsule is now complete.", "Next, she'll join two capsules to create the unit that's the heart of the microphone.", "It converts sound into an electrical signal.", "An aluminum spacer goes between the capsules, which face back-to-back.", "Two capsules instead of one means this microphone can be switched to pick up audio from various directions.", "A plastic bracket reinforces assembly.", "A technician then wires the brass support piece that we saw being made earlier to the electronic system, and then he secures it with screws.", "After installing switches, he inserts the microphone capsules in the grille.", "He screws the capsule assembly to the grille and joins it to the electronics.", "He slides the metal casing over the electronics and secures the microphone with a big screw cap.", "He checks the switch that changes the directionality of the mike.", "And now it's ready for a sound check.", "The mike goes into a special anechoic chamber.", "A computer measures its response to various audio frequencies and directions.", "Once a microphone has passed this test and some other checks, it's time to pack it up with great care, because this mike is delicate and worth several thousand dollars.", "Treated properly, this microphone should last several decades.", "In showbiz, that's longevity.", "Like natural hot springs that are heated by the earth's crust, a hot tub can give your aching muscles that healing feeling.", "In fact, the hot tub is a high-tech version of the hot-springs phenomenon, and its invention in the middle of the 20th century made the backyard steam part of the suburban dream.", "There are up to a hundred jets in a modern hot tub.", "Each churns up the water, making waves that have a calming effect on tense and tired muscles.", "To make a hot tub, they start with a sheet of rigid acrylic.", "They rest it briefly over a mold of a hot tub.", "Then a framelike clamp grips it along the edges and transfers it to an oven.", "The oven has heating elements on the top and bottom.", "They bake the acrylic sheet until it's so soft, it sags.", "They transfer the sagging sheet back to the mold.", "And now they turn on a vacuum system underneath.", "It sucks the acrylic sheet into the crevices of the mold so that it takes its shape.", "Then fans cool the molded acrylic, and it hardens in just a couple of minutes.", "Operators then stack the tub shell.", "They mold swim spa shelves using the same technique.", "Swim spas are longer and deeper than hot tubs.", "They're for working out, not unwinding, so there aren't many ledges for sitting around.", "Back in the hot-tub department, it's time for a base coat.", "They spray resin on the shell and then unwind fiberglass twine into a special spray gun.", "It chops up the twine and mixes it with more resin to give the shelf a fiberglass coating that reinforces the acrylic.", "They press out any air pockets in the fiberglass.", "Now they aim another spray gun at the underside of the tub.", "This one contains insulating foam.", "Then they trim the lip of the tub with a circular saw, so it will sit properly in the frame later.", "They sand the edges and then drill holes for the numerous jets.", "Working from inside of the tub, an assembler tucks plastic jets into the holes, while a worker on the other side pulls the jets through.", "They apply silicone sealant around each jet, then equip it with a plastic ring for aligning the jet to the hot-tub frame.", "Using a special tool, the assembler drives a nut into the assembly to secure it.", "Next, they dip pvc tubing in adhesive and attach it to the jets, weaving an elaborate web of hoses.", "The narrower tubing will pipe air to the jets, while the wider hoses will supply water.", "To prevent leaks, they equip them with self-tensioning clamps.", "They connect the intake pipe to the pump, which will force water into the tubing.", "A suction system will return the water to this pump.", "They wire the tub to provide mood lighting, then test all the wiring and plumbing.", "They spray more insulating foam on the outside of the tub.", "It expands drastically in closing the labyrinth of pipes and hoses.", "And for some extra insulation, they wrap foil-backed plastic around the tub.", "The foil will reflect any escaping heat back onto the tub.", "They mount the exterior paneling and drill through the insulation to vent the pumps.", "Corner molding gives the paneling a nice finish.", "This hot tub is now ready to make waves in the neighborhood.", "Some versions even come with tvs, so you can watch \"how it's made\" without leaving the hot tub.", "It takes about 20 person-hours to make a hot tub or one of these swim spas.", "And after that, it's time to take a break and relax.", "The invention of artificial turf in the 1960s led to a whole new field-- one that never needs mowing, watering, or weeding.", "Faux grass was developed by the carpet industry and made possible by technological advances, and the concept has really taken root.", "Synthetic turf has changed the landscape of professional sports.", "You see it in stadiums, arenas, and training fields around the world.", "It all starts with bags of white plastic pellets.", "This is the base material for the turf.", "They add green pellets for color, along with chemical stabilizers and additives.", "Equipment melts and extrudes the plastic through a steel plate with holes in it.", "This creates strands of green.", "The strands exit through a trough of water, which cools and solidifies them.", "Machinery pulls the strands through an enormous comb to keep them separated as they head to the next station.", "Here, rollers stretch the strands until they become as thin as real grass.", "The stretching also strengthens them.", "Spools now roll up the synthetic strands.", "Once a spool is full, they remove it.", "Next, they unwind several spools at a time.", "The strands come together to form a multi-ply synthetic yarn.", "The yarn travels over guides.", "This keeps it from slackening as a big spool winds it up.", "Further down the production line, mesh fabric merges with synthetic sheeting, while the multi-ply synthetic yarn travels through tubing to a tufting machine.", "The tufting machine is a giant sewing machine.", "It has up to 250 needles.", "These needles hook the yarn through the mesh synthetic sheeting.", "They make hundreds of rows of stitches per minute.", "Underneath, small knives cut the looped yarn, so it looks like spikes of grass.", "As you can see, this process is a whole lot faster than waiting for grass to grow.", "An inspector examines the turf to make sure the yarns are even.", "Then machinery moves it forward to a coating roller.", "The roller picks up adhesive from a trough below and applies it to the backing of the turf as it moves across.", "This binds the looped web of artificial grass to the backing.", "The adhesive is a bit gooey at this point and needs to be dried.", "The dryer is partly open-air and partly enclosed.", "The enclosed section is about 55 yards low.", "The temperature is carefully controlled.", "Too hot, and the synthetic grass might melt.", "As it exits, hot pins burn holes into the turf to make it water-permeable.", "Now they check to make sure this grass looks good on the surface.", "They pull out loose bits and measure the fibers.", "Then it's over to a device that simulates the effect of football cleats to confirm this turf is tough.", "To install artificial turf, they lay a rubber base and add the turf.", "They distribute sand throughout spikes of grass to give the turf weight.", "Then they spread rubber granules for a softening effect.", "But some turf is more carpetlike-- no fillers needed.", "You're more likely to see that in floor-hockey arenas.", "It's time to wrap up this turf job and toss a few balls around.", "And when it comes to looking like the real thing, artificial turf is definitely in the ballpark.", "A stein is a beer mug with a hinged lid you open and close.", "According to some historians, it's a product of the bubonic plague.", "After the plague swept europe in the 1300s, municipalities enacted sanitation laws.", "In germany, one law required food and beverage containers to have covers in order to keep out insects.", "These traditional german beer steins, with their ornate ceramic bodies and pewter lids are functional works of art.", "The word \"stein\" is short for a german word meaning \"stoneware jug\".", "Production begins in the casting department with a plaster mold-- its cavity the shape and design of the stein's body.", "They pour in liquid clay, wait about two hours until it thickens, then pour out whatever liquid remains.", "After testing the consistency of what's still inside, they gingerly disassemble the mold, revealing the stein's body.", "The mold has transferred all the intricate detail to the clay's surface.", "For certain stein shapes, they get better results using solid clay.", "They cut off the amount they need, then drop it inside a plaster mold.", "A machine pushes the clay into every crevice of the mold cavity.", "A worker trims away any excess that oozes out.", "Then the mold goes into a drying machine for 20 minutes.", "When it comes out, they disassemble the sections to extract the casting.", "Whether made from liquid or solid clay, each stein body goes on a potter's wheel for some refining.", "The potter removes seams that formed where the mold sections met.", "He also trims and smoothes out the rim.", "Then, using some wet clay as an adhesive, he attaches an ornate handle.", "It, too, is made entirely of clay.", "The factory shapes it either in a mold or with a dye in a press.", "Finally, they stamp the bottom with two marks-- \"made in germany\" and the company brand.", "Now the coloring process begins.", "They coat the stein body with special paint for ceramics-- first, a watery coat of the background color all over, then a thicker coat around the reliefs to highlight them.", "They rub most of the paint off the reliefs to accentuate the contrast.", "Next, workers spray a milky glaze over the stein body inside and out.", "This glaze is made mainly of sodium and silicon, minerals that turn into transparent glass under high heat.", "This will strengthen and waterproof the stoneware beneath it.", "Workers load dozens of stein bodies into an oven, where they bake at more than 2,000 degrees fahrenheit for 12 hours.", "This hardens the clay, turns the colors vibrant, and transforms the glaze into a protective glass coating.", "After a 12-hour cooling period, the true artistry begins.", "A skilled painter embellishes the design with colorful enamel paints.", "A second firing, this time for just 5 to 6 hours, bakes the paint onto the glass surface.", "Now, to top it all off, the stein's ornate lid.", "It's made of pewter cast in a mold.", "The thumb lift pivots the lid on a hinge.", "To attach the lid to the stein body, they position the thumb lift on the handle, then assemble a small mounting tool over it.", "They pour in molten pewter...", "Then, after a minute or so, remove the device.", "The pewter has hardened into a ring attaching the thumb lift to the handle.", "They clip off the excess, then buff the metal to a shine.", "With their traditional scenes or more contemporary themes, these beer steins are the toast of the town." ]

{ "things": [ "CO2 Cartridges", "Pretzels", "Scissor Lifts", "Skating Rinks" ] }

[ "Today on \"how it's made\"...", "Co2 cartridges...", "Pretzels...", "Scissor lifts...", "And skating rinks.", "Sports like paintball are a pressure release in more ways than one.", "Paintball guns contain pressurized co2 cartridges, and when the gas is released, the force propels the ammunition towards its target.", "The cartridges are used also for things like inflating bike tires and life preservers, as they target new uses for these pressure-filled devices.", "A co2 cartridge packs a lot of punch into a little package.", "This one can propel dozens of shots.", "To make one, they unroll some steel and straighten it out.", "Then, a punch press descends with 110 tons of force, cutting the steel into disks.", "Simultaneously, a machine moves up from below to shape the disks into cups.", "The cups move down a vibrating lane.", "They're delivered to a series of cylindrical punches, each one with a smaller diameter than the last.", "Each successive punch lengthens and narrows the cups as nozzles flush them with lubricant.", "The process is called redrawing, and at the end of it, the cups look more like test tubes.", "In just a few minutes, that piece of steel has undergone several transformations.", "To continue shaping the tubes, they heat the ends by dropping them through an induction coil.", "Intense magnetic fields excite the molecules in the metal, causing it to heat up sharply.", "This machine is called a necker.", "As it revolves, it delivers the tubes to a series of dies that pinch their ends.", "With each pinch, the ends get progressively smaller.", "This creates necks in the tubes.", "As the diameter of the neck narrows, the tube takes the shape of a bottle.", "Now each cartridge goes on a lathe.", "A cutting tool plunge-cuts the neck to shorten it.", "Then it carves out a lip, the same kind of lip that's on any beverage bottle.", "The cartridges now head through a washing station, where soap and water get rid of the oily lubricant.", "A trip under some gas burners dries them off, and they head to the filling station.", "Here there's a tankful of carbon dioxide.", "The filling head pumps liquid co2 into the cartridges and then caps them.", "Inside these cartridges, the gaseous form of co2 is under great pressure.", "Releasing even just a little through a gun will be enough to propel things like bbs, pellets, and paintballs.", "They do spot checks to make sure the cartridges are tightly sealed.", "Now it's on to the next station, where they'll be made to look shiny and new.", "The cartridges are inside this revolving drum, which delivers an electrical charge, attracting zinc from the tank to plate the cartridges.", "The smooth zinc plating doesn't just look good.", "It's a better surface to print information on.", "At this rotary silk-screening station, the brand name and cautionary information are printed onto the sides of the cartridges.", "A quick bake under an ultraviolet light cures the ink.", "And the co2 cartridges are now ready to demonstrate the power of compression.", "How and when the first pretzel came to be depends on whom you ask.", "One story tells of a monk baking rewards for children who were pious.", "Today's bakeries still fold the dough to resemble arms crossed in prayer, but they do it much faster, granting tasty wishes to a lot more snackers.", "Although hard pretzels are more common, this company makes the more traditional soft-baked ones.", "To make enough dough for 4,870 pretzels, a workers first blends shortening, sugar, and salt in a huge mixer.", "The machine automatically adds yeast...", "Corn syrup...", "1,630 gallons of cold water..", "And 760 pounds of flour.", "The cold water helps make the dough elastic so workers can shape it before it hardens.", "A worker then opens the mixer and slows the blades to help the dough fall out.", "He splits the batch on a table, then creates chunks that go into a tank called a hopper.", "It feeds an auger that challenges the dough chunks through little guillotines.", "The blades chop the chunks into 2 1/2 ounce balls to make small pretzels or 5 ounce balls for large pretzels.", "Two conveyer belts squeeze them into 15 1/2 inch long segments called noodles.", "Another machine now grabs the ends of each noodle and twists the ends over each other to create the pretzel's three signature holes.", "To keep this knot from unraveling, the plate then gently flips the pretzel dough onto another plate below.", "That plate carefully flips the doughy creations onto a 118-foot long conveyer belt.", "The raw pretzels now travel on the conveyer for 14 minutes, the time it takes for the dough to rise.", "Next, they move through showers of liquid sodium hydroxide, heated to 180 degrees fahrenheit.", "That seals in the moisture so the pretzel will be chewy when you eat it.", "They go into an oven that's about the length of a city bus.", "As they enter, flames sear and harden the outside.", "This prevents the bottoms from sticking to the mesh conveyer belt during baking.", "After about 3 1/2 minutes at 560 degrees fahrenheit, the pretzels are piping hot and golden brown.", "They drop onto a long conveyer, where they gradually cool on their way to the next step-- a trip through a freezer that's longer than seven olympic-size swimming pools.", "After 30 minutes at minus-28 degrees celsius, the pretzels are rock solid and ready for packaging, but first, a camera scans them so that a computer can track each pretzel and guide a robotic arm to pick it up.", "This arm is one of five operating at separate points on the line.", "The robots process one pretzel per second and clean up after each other until the belt is picked clean.", "The pretzels then fall through a sliding gate, landing on a conveyer that whisks them off to the next step.", "There, a machine drops a packet of coarse salt into each bin of six pretzels.", "A mechanical arm nudges the pretzels over to make room for it.", "The salt packet lets you season your pretzel the traditional way before warming it up at home.", "The machine blows open plastic bags with compressed air.", "Mechanical arms push the pretzels and salt packet inside.", "A robot arm then places each bag into a cardboard box.", "The printing on this package displays the company logo, the nutritional content, the production date, and the heating instructions.", "So, next time you're looking for a salty snack, don't tie yourself up in knots.", "Just have a pretzel instead.", "A scissor lift is a mobile work platform that rises.", "The elevating mechanism consists of arms that connect in the middle like scissors, hence the name.", "Scissor lifts are common sight on construction sites, in big warehouses, and at buildings where workers need a safe way to reach heights to carry out repairs or maintenance.", "The number of arms in the scissor mechanism varies according to the height of each particular model.", "The factory constructs the scissor arms from steel tubes.", "The first step is to cut them to the right length for the model in production.", "A worker uses an air gun to blow off tiny shards of metal the cutting leaves behind.", "The arms go into a press that punches a hole for a hollow steel cylinder called a boss.", "The boss is the housing for a pin that will connect one arm to the other, yet still allow them to pivot like a pair of scissors.", "Workers now use a magnetic crane to move the arm to the welding area.", "They insert the boss into the hole, then tack it in place.", "This piece will go on the end of each scissor arm, but first, they weld on another boss.", "Now fully assembled, this piece is called the male scissor end.", "They tack it to one end of the scissor arm and tack a female scissor end to the arm's other end.", "Robots now weld the two endpieces simultaneously, then the boss in the middle.", "Now workers stack the scissor arms, putting a pin in each middle boss.", "They also install the hydraulic lift cylinder that will raise and lower the scissor stack.", "This manifold activates the lift cylinder by increasing and decreasing hydraulic pressure.", "Workers fasten the connected scissor ends to each other by driving a pin through the boss.", "They secure it with a locking mechanism called a cotter pin.", "Meanwhile, other workers assemble the base of the scissor lift.", "At this stage, it's upside down.", "At the rear, workers bolt in a hydraulic wheel motor.", "Hydraulic pressure turns the motor, enabling the operator to move the scissor lift forward or backward.", "They slide a wheel onto the hub and bolt it securely.", "This is the wheel hub onto which the front wheel bolts.", "It attaches with a pin locked by a cotter pin.", "They install the hydraulic steering cylinder.", "This steel tie rod links the front wheels to each other so that they turn together.", "Now workers hook up the hydraulic hoses.", "They pump a bit of grease in to lubricate the cylinder.", "Next, they assemble and install the hydraulic tray.", "It contains the electrical panel that controls all machine functions, as well as the hydraulic tank and pump.", "The pump forces hydraulic fluid to the wheel motor, steering cylinder, and lift cylinder.", "The hydraulic tray swings closed under the base for protection.", "On the other side, they install the battery tray.", "It houses the four six-volt batteries that power the scissor lift, along with the battery charger.", "The scissor stack, meanwhile, is in the paint booth getting a coat of primer, then a coat of urethane paint.", "This finish prevents the steel from rusting.", "After curing the paint in an oven, they install the scissor stack onto the base.", "Now they connect the two hoses that run between the lift cylinder and the hydraulic pump.", "Through one hose, fluid goes to the cylinder to raise the scissor.", "Through the other, fluid withdraws to lower the scissor.", "They run cables from the electrical panel up through the scissor stack.", "After installing a platform made of painted steel, they connect the cables to a control box on the platform rail.", "These controls enable a worker to operate the scissor lift from the platform.", "After a test drive, it's time to apply the decals, up to 75 of them depending on the model.", "Some are decorative, but most specify safety information, such as the scissor lift's load capacity.", "For the nhl, a regulation skating rink is 200 feet long by 85 feet wide.", "The rink is basic construction, but making the ice is an art.", "You have to get the thickness just right.", "If the ice is too thick, it will tax the refrigeration system and soften on top, but if the ice is too thin, skate blades will cut right through it.", "The rink floor is a concrete slab.", "Covering it with ice begins in the arena's refrigeration room.", "There, a powerful compressor pumps refrigeration fluid, usually methanol or saline, through pipes running underneath the rink's floor.", "The concrete chills to between minus-15.8 and 18 degrees fahrenheit, the temperature range required for water to freeze on concrete.", "This company made its own ice-making machine by retrofitting an ice resurfacer.", "Its onboard water tank feeds 20 sprayers that mist a 13-foot span.", "The water freezes within seconds.", "To make a quality ice surface, you have to build up the ice in layers, each about .", "07 inch thick.", "Driving in the standard outside-inside oval pattern, each layer takes just eight minutes.", "With two layers down, they paint the ice white.", "You'd think it would be simpler to just paint directly on the concrete, but the paint would chip off when they remove the ice at the end of the season.", "They would have to scrape and clean the slab before repainting it-- a messy, expensive job.", "So, instead, the ice maker mixes water and powdered paint in the onboard tank and sprays three layers onto the ice.", "This paint doesn't dry.", "Just like the water the machine sprayed before, it freezes into white ice.", "This metal dioxide-based paint is specially formulated for skating rinks, designed to cling to a base coat of ice.", "And unlike concrete paint, it's nontoxic and biodegradable, so that at the end of the season, the arena can melt the ice and let the water drain without contaminating the environment.", "Now a crew comes in to paint the hockey markings.", "Workers lay down string to mark the borders of the red line, the blue lines, and the goal lines.", "They elevate intersecting lines so that the paintbrush can pass.", "To paint the face-off circles, workers use an anchor, cable, and what's called a paint stick.", "It takes just 20 minutes or so to paint them.", "The paint is in a portable tank.", "It flows down the paint-stick tube to a rectangular pad on the end.", "Now the goal crease at each net.", "First, they trace a template, then fill in with a shade of blue you see in swimming pools.", "They use the same technique to paint the eight red face-off spots.", "Back to the blue line.", "First, they spray water to freeze the strings in place.", "Then, using a brush on the same type of paint stick they use for the circles, they fill in the foot-wide space between the strings.", "Now for the home team's logo at center ice.", "After dabbing a mop in blue chalk, they run it over a computer-generated paper stencil of the logo.", "This transfers the design outline to the ice.", "They spray water on the chalk lines to freeze them in place, then paint the logo.", "Finally, with a garden hose, they spray water over all the markings to seal the paint.", "Then they slowly flood the ice with the larger hose for about a day and a half.", "This adds the final 1.1 inches of ice.", "The now-skateable ice surface is about 1.6 inches thick, containing over 13,000 gallons of water, about 300 bathtubs full." ]

{ "things": [ "Carbon Fibre", "Antique Frame Restoration", "Railcar Movers", "Hood Ornaments" ] }

[ "Carbon fiber is an engineer's dream-- lightweight yet incredibly strong.", "It's a string with thousands of parallel filaments.", "Multiple strings can be twisted into yarns, woven into fabrics, or molded with resin to produce materials called carbon-fiber composites.", "Carbon fiber is five times stronger than steel yet less than half the weight.", "To make it, they take a plastic fiber composed of thousands of filaments far thinner than human hair.", "They then chemically alter it to form a perfect chain of carbon atoms for the final product.", "This mammoth machine lines up dozens of those fibers which then travel through an oxidation oven for a couple of minutes.", "The oven temperature, about 480 degrees fahrenheit, prompts the fibers to pick up oxygen molecules from the air.", "This rearranges the fibers' atomic structure, rendering them resistant to high heat.", "As the fibers oxidize, they change color to eventually turn black.", "They're now primed for the next process, carbonization.", "Furnaces heat the fibers in an oxygen-free gas mixture.", "This expels the non-carbon atoms and transforms the remaining carbon atoms into tightly bonded crystals running parallel to the length of the fiber.", "This gives the fiber its strength.", "The exiting fibers travel through a bath of electrically charged water that etches the fibers' surface so they'll better absorb resin.", "The next station applies a light preliminary coat of resin.", "This will strengthen the fibers' chemical bond to the molding resin.", "A spooling machine winds each fiber, now referred to as a carbon-fiber tow, onto a bobbin which buyers either weave into a carbon-fiber fabric or mix with resin to mold a product.", "Another form of carbon fiber is prepreg-- sheets of resin-impregnated carbon fiber ready for molding.", "It's like ready-to-bake cake mix.", "The resin is a formula of epoxy and various powdered hardeners and accelerators.", "Workers pour the resin into a filming machine which spreads it in a thin, wet layer onto paper.", "The paper is pre-treated with a release agent to prevent the final product from sticking, like spraying a baking pan with non-stick coating.", "Another machine, meanwhile, groups 200 to 300 carbon-fiber tows into a giant band of fibers called a web.", "The width and thickness of the web determines the width and thickness of the prepreg sheet.", "Workers mount two rolls of resin-coated paper onto the resin-impregnation machine.", "A heating element warms up the web as it enters to facilitate resin absorption.", "Then the heated carbon-fiber web is sandwiched between two sheets of resin-coated paper.", "High-pressure heated rollers thin out the resin so it penetrates the millions of carbon-fiber filaments.", "Cooling plates then turn the liquid resin to gel so that the next station can remove the paper, which pulls off easily thanks to the release agent.", "The next station covers the top of the prepreg sheet with polyester film.", "This prevents the prepreg sheet from sticking to itself at the end of the line when it's wound into a roll like a fruit roll-up.", "In the factory's lab, technicians run quality control tests on prepreg samples.", "First they weigh the sample.", "Then they wash off the resin with chemicals and weigh the sample again.", "This verifies whether the ratio of carbon fiber to resin is correct.", "The lab also analyzes samples of composite-- carbon-fiber reinforced resin-- in this tensile strength test.", "The computer measures how much strain the sample withstands before breaking.", "Such testing ensures the carbon fiber delivers optimum strength, durability, and heat resistance, whether it's used to make an auto part, a wind-turbine blade, or a golf club.", "Antique gilded frames have spent many years protecting paintings and enhancing them.", "But over time, grime can obscure the gold-leaf shine and the frame can suffer damage and deterioration.", "But these frames are highly collectible, and restoring them preserves their value.", "With elaborate cast ornamentation and gold-leaf work, this 19th-century gilded frame is itself a work of art.", "But it's in need of renewal.", "Restoration work done many years ago has cracked, and gold leaf is deteriorating elsewhere on the frame.", "The technician carefully pries the cracked acorn casting loose and removes it from the frame.", "He'll make a new one from scratch.", "It will need to completely fill the empty space and look exactly like the others on the frame.", "He starts by making a mold with dental impression rubber.", "He kneads the two putty-like components together to activate the ingredients.", "When the color's uniform and there are no streaks, the rubber is ready for molding.", "He must act quickly because in just three minutes the rubber will cure.", "He presses it around the acorn ornament on the frame to capture the detail.", "He now has a mold he can use to cast a new ornament for the frame.", "He'll use this wood epoxy for that.", "Like the dental impression rubber, it must be mixed thoroughly to activate it.", "He presses the epoxy into the contours of the mold, pushing it from one end to the other.", "This will prevent air from becoming trapped in the casting and compromising its integrity.", "After a 10-minute cure, the epoxy casting is ready, and he extracts it from the mold.", "He examines the detail and confirms that it is an exact reproduction.", "Then, using a scoop chisel, he sculpts the edges and the inside of the casting to shape it to the picture frame.", "In this comparison shot, the shaped part is the one on the left.", "He places the cast epoxy ornament on the frame and nails it down.", "The epoxy is still soft enough that he can drive the nail into it without breaking it.", "He fills the gap between the casting and the frame with more epoxy, providing a seamless transition from new to old.", "After the epoxy solidifies, he brushes something called bole onto it.", "Bole is a mix of clay and rabbit-skin glue.", "It provides a surface that the gold can adhere to, and the rabbit-skin glue will give it flex as the wood expands and contracts.", "He then transfers the 23-karat gold leaf to the casting.", "Before he lays each piece of gold leaf, he wets the surface of the ornament with a gilder's liqueur-- a mix of water, alcohol, and rabbit-skin glue.", "This causes the gold leaf to conform to the contours of the ornament and adhere.", "After the golf leaf sets for an hour or two, he burnishes it to a very high shine using a tool made from agate, a very hard, semiprecious stone.", "Hundreds of years ago, craftsman used dogs' teeth for this job.", "He rubs the shiny, new gold surface with very fine-grade steel wool.", "This removes some of the gold to simulate natural wear so that it matches the patina of the rest of the frame.", "And what a transformation this plain epoxy casting has undergone.", "Newly gilded, and it looks like it's always been part of the antique frame.", "Other sections of the frame require regilding.", "He rubs alcohol onto those areas to get rid of atmospheric residue that would prevent the adhesion of the new gold.", "And after applying gilder's liqueur, he lays sheets of the new gold leaf over the old, working with a steady rhythm to give the area complete coverage.", "He's aiming for more of a matte finish on this section, so he doesn't polish it.", "He brushes a protective coat of shellac onto it.", "He's used a combination of old materials and new to restore this antique gilt frame, and it's picture-perfect.", "Pushing and pulling railcars at the train yard is the job of a large motorized vehicle appropriately called a railcar mover.", "It switches the cars from one track to another, shuttles them in and out of the cargo loading area, and positions them in line behind the locomotive.", "A railcar mover has to drive both on and off the train track, so it has two types of wheels-- four steel rail wheels for guiding it on the track and four wheels with rubber tires for driving on the ground.", "When building a railcar mover, they start with the frame.", "A computer-guided plasma cutter cuts out all the frame parts from a 4-inch-thick steel plate.", "Once all the frame parts are ready, workers begin welding them together.", "They position the deck plate, the mover's floor, upside down and weld on the frame rails.", "These will hold the axles for the rubber wheels.", "Then, to those frame rails, they weld the rail arm mounts.", "These will hold the rail arms which hold the rail wheels.", "After welding several additional components to the frame, workers bolt the axles for the rubber wheels to the frame rails...", "Then the rail arms to the rail mounts.", "Now the frame goes to the paint shop for a coat of primer followed by a coat of automotive paint.", "Workers also roll on a textured floor coating to create a non-slip surface for the driver to safely walk to and from the cab.", "When the paint dries, the frame returns to the assembly line where workers begin mounting the 4.5-foot-wide rail wheels onto the rail arms.", "After mounting each wheel on the spindle, they install a bearing, then a large nut.", "They must tighten the nut to the correct torque yet not over-tighten it, or the wheel won't turn freely.", "Once they've got just the correct torque, they secure the nut with a retaining lock nut.", "They finish off this installation with the rail-wheel equivalent of a hubcap.", "This steel cover holds in the grease that lubricates the wheel and bearing while keeping out dust and dirt.", "Next they mount the four rubber wheels, securing each one with a dozen bolts.", "These steel wheels with rubber tires are about 6 1/2 feet in diameter.", "Workers mount several other components, including a pair of air tanks with gauges for the railcar's pneumatic brake system.", "These are the brakes the driver uses when the mover is coupled to railcars.", "When it's not, the mover has its own separate hydraulic brake system, the components of which workers also install at this stage.", "They attach a hydraulic cylinder to the steer axle.", "This controls the steering of the rubber wheels when the mover is off the train track.", "The rail wheels, of course, don't require any steering, as they simply follow the track.", "Now workers install the 300-horsepower diesel engine.", "It's already bolted to the transmission.", "Then they hook up the electrical wiring, which connects the engine and transmission to the computer controlling them.", "They lower the hood over the engine and transmission.", "The hood has three components already installed-- the engine air intake, air cleaner, and muffler.", "Finally, they install the cab.", "It has a steering wheel for driving off-rail and a control console that rotates 180 degrees to let the driver operate at whichever side of the cab provides the best view of all the railcars the mover is pulling or pushing.", "The finished railcar mover doesn't leave the factory before a burn-in period in the test pit.", "The test is so intense, the rubber tires have to be cooled with water.", "Pulling as many as 40 railcars at a time is no job for a lightweight.", "That's why a railcar mover weighs in at up to 45 tons.", "At first, hood ornaments were used to beautify external temperature gauges and radiator caps.", "They then evolved into signature pieces that embodied the car brand.", "And when the radiator caps were moved under the hood, the ornaments stayed on top.", "A hood ornament is a little piece of automotive art.", "Popular mainly on luxury cars now, these ornaments symbolize the spirit of the car and can make quite a statement on the street.", "Each ornament starts with an aluminum mold that consists of many parts in order to achieve a complex shape.", "An injector pumps specially formulated wax into the mold cavity.", "The wax solidifies quickly.", "The operator dismantles the mold and removes the cast wax model.", "The detail is impressive.", "He examines it for flaws.", "He cools the model in water until the wax firms.", "This wax model will be used to make a mold to cast the metal ornament using a technique that dates back thousands of years.", "He attaches numerous cast models to a wax riser by melting the wax a little so they adhere.", "The next worker then dips the models and riser into specially formulated ceramic slurry.", "He makes sure that the liquid covers every detail.", "Still wet, the models then go into the rain sander, so named because it actually rains grit.", "The grit sticks to the models for a stucco effect.", "He repeats the ceramic dip and grit process three times to build up substantial shells around the wax models.", "These shells will serve as molds to cast the hood ornament.", "In this case, the casting material is steel.", "They melt rejected hood ornaments with steel chunks to transform them into a white-hot liquid.", "The ceramic models have by now been cured and the wax melted out.", "Workers ladle the molten steel into the riser feeder cup.", "The steel flows into all of the ceramic molds.", "They top it off with a manganese mixture that catches fire and keeps the steel hot and liquid a little longer, ensuring that it feeds into all of the molds.", "The steel cools for several hours and solidifies.", "An employee then breaks open the network of molds to reveal the cast hood ornaments.", "He inserts a pneumatic hammer into the feeder cup, and it shakes off most of the remaining ceramic shards.", "This machine blasts off the rest using very fine stainless-steel particles.", "They're ready to cut the cast ornaments free from the main base.", "With the riser on its side, the worker slices off one hood ornament at a time using an aluminum-oxide cutting wheel.", "At this angle, he can't make a clean cut.", "He leaves a fairly thick chunk on the base.", "He grinds off that chunk using an abrasive belt.", "The base of the hood ornament is now smooth and level.", "Next he refines the shape of the hood ornament.", "He grinds away excess material to improve the profile of the piece and generally clean it up.", "This process also adds shine to the stainless steel.", "To give the hood ornaments a real polish, they plunge them into a sulfuric-acid solution.", "The solution eats away impurities to expose the nickel.", "A worker buffs each hood ornament against a cloth wheel until it gleams.", "He examines his work under a magnifying glass.", "Defects won't be tolerated, and even at this stage, the statuette could be rejected and melted into a new one.", "It passes inspection.", "Made of steel, silver, or gold, a hood ornament on a luxury car is a great way to say you've arrived." ]

{ "things": [ "Plastic Bags", "Solar Panels", "Plastic Gasoline Containers", "Hockey Sticks" ] }

[ "Today, on \"how it's made\"...", "Plastic bags-- it's trash and carry.", "Solar panels-- reflecting on energy efficiency.", "Plastic gas containers-- fuel to go.", "And hockey sticks-- mind if we take a shot at this one?", "You can use them for groceries, for shopping, for taking out the trash.", "Chances are there's a growing pile of them somewhere in your kitchen.", "With so many everyday uses, it's easy to see how people can get \"carried away\" with plastic bags.", "The plastic bags we use every day are made from granules of linear polyethylene resin that will be melted.", "They combine the linear polyethylene with another low-density one in this mixer.", "The granules are perfectly blended into a homogenous material.", "Granules melt in the extruder, which heats them to a temperature varying between 356 and 465 degrees.", "This produces a film of polyethylene in the form of a tube.", "It is several hundred feet long, has a minimum thickness of .", "0002 of an inch and a circumference of 20 inches.", "The plastic tube gradually cools down.", "Rollers then flatten out the plastic tube.", "The polyethylene film is now easy to work.", "And now they cut the tube on two sides to obtain different rolls.", "This knife then cuts the film to the required width.", "The excess strip is salvaged in this tube.", "Several hundred of feet of film are produced and rolled up.", "This particular roll contains the required quantity of film.", "When the roll is full, the film is cut.", "This roll moves forward and can be transported to another department.", "An empty roll begins to fill up automatically.", "A full roll weighs 348 pounds and can produce 35,000 bags.", "The next step-- printing on the bags.", "This alcohol-based ink circulates continuously to retain its viscosity.", "Impressions are made by inking rollers.", "Here another color is being applied on the bags.", "Once printing is over, the plastic film is rolled up again.", "The roll is now full, and the cutting of bags can get started.", "This machine makes 150 bags per minute.", "A sealer bonds the edges of the bag together with heat.", "The wheel picks up the bag and puts them on 2 spindles that can hold 250 each.", "Here, they're making bags with a hermetic zipper.", "The zipper is made from a plastic pad which inserts into a slot.", "The zipper is made in advance and is unrolled progressively.", "The zipper strip is cut and heat-bonded to the bag at 356 degrees.", "And here's the zippered bag, all finished.", "In this other department of the plant, they make plastic bags with handles.", "Printed bags circulate on these rollers.", "The machine that welds the sides gives the bags the desired shape.", "Then another machine, with a punch, cuts the handle holes.", "Bags are heat-sealed and cut at 302 degrees.", "Here, they fabricate another product-- packaging bags.", "One end of the bag is heat-sealed.", "This machine makes holes that let air out of the bag when it is being filled, to allow them to be generously filled with items.", "At this stage, a stamper cuts the handle holes.", "Bags are cut to the required size, automatically sealing the other side of it.", "This plant makes eight types of bags, for an overall total of over one million a day.", "Not so long ago, solar energy was a concept that seemed to be torn from the pages of a science-fiction novel.", "But the time has come for this non-polluting energy source to step into the limelight-- or should we say the sunlight?", "The future of solar panels is bright.", "The sun is able to produce electricity.", "Panels covered with photovoltaic cells convert sunlight into electricity.", "This blue plate is a module made of crystalline silicon.", "The grooves are the conductors, and the silicon crystals glisten at its surface.", "To make a solar panel, several modules have to be connected together.", "Then they apply a soldering flux on each module.", "The soldering wire is heated with an iron.", "The modules are placed on a special support.", "Once the soldering is done, the modules are cleaned by ultrasound, in water, at 140 degrees.", "When dried, the perfectly clean modules are ready to be assembled.", "Now they can proceed with soldering the modules by groups.", "First, a flux is applied which improves the quality of the soldering.", "With great dexterity, they assemble four groups composed of nine modules each.", "In this way, 36 modules are soldered and connected in series.", "Modules are assembled end to end.", "They have to be handled with great care.", "Using a voltmeter, the voltage of each module is verified.", "At this stage, it's easy to remake a solder connection if there's a problem.", "If the voltage is adequate, they use suction grips to make handling of the nine rows of modules easier and to keep them clean.", "The modules are placed into position.", "Then this metallic strip is inserted.", "It is a conductor that will link the four groups of nine modules.", "Solder connections are made to link the modules to the metallic strip.", "Then they put on this transparent sheet of layered glass.", "It serves as a rigid transparent form which will support the modules.", "The superposing of parts forms a laminate, that increases the rigidity and solidity of the panel.", "Finally, a sealing film is applied to protect the module.", "To laminate and stiffen the solar panel, it's placed in a heated oven from which air has been vacuumed out.", "The panel will cook at 176 degrees for 15 minutes.", "The oven hermetically reseals to proceed with the vacuuming out of air.", "And here's the finished panel.", "All the components are bonded together.", "They now proceed with a test.", "The panel is placed in a solar simulator.", "Negative and positive contacts of the solar panel are connected to a voltmeter.", "The panel is inserted into the simulator, and a powerful lamp will illuminate it.", "The voltmeter is read to make sure that panels supply the electric current required.", "Here now is the assembly of another kind of solar panel called the amorphous silicon type.", "Its components were made in europe and asia.", "These are the positive and negative connecting wires of the solar panel.", "The panel is placed into a plastic frame and glued in place.", "Then the frame is screwed tight so that it won't move.", "The solar panel, made up of crystalline silicon modules, is put onto an a.b.s. plastic frame.", "It is now finished.", "Fabricating this panel will have required about one hour of work.", "Six of them are made here every day.", "Your needle's dipping past empty, but you're gambling you'll have enough gas in the tank to make it just a little further.", "Well, when you're on that long walk to the nearest gas station, you'll be glad someone had the bright idea of manufacturing these handy plastic gas containers.", "Plastic gas containers are made from these granules composed of a concentrated colorant and a u.v.-resistant additive.", "They're mixed with white granules, which is the primary material, called high-density polyethylene, and recycled plastic, which has been ground up on a granulator.", "It's all dumped into this milling machine.", "These granules are all mixed together and melted.", "The melted plastic will be blown in and will take shape within this mold, made of very high-quality dense aluminum, called aviation type.", "Blow-molding continues and produces a soft plastic tube.", "This is cut and placed in the mold.", "Then this nozzle pumps the plastic into the mold shell.", "The container is unmolded and moves along on a conveyor.", "There's another way to mold plastic-- by rotation.", "This previously colored powder has a 35 mesh size, which is just a little larger than flour.", "Low-density linear polyethylene is poured into the bottom of the mold.", "The mold has a cover that will be closed, then placed on a steel support.", "This support is articulated by an arm on two rotation axes simultaneously.", "This action allows the plastic powder to distribute itself thoroughly throughout the mold.", "The mold is placed in an oven which generates a temperature of 590 degrees.", "About 15 minutes is needed for the polyethylene powder to melt and another 15 minutes to allow the piece to adequately cool before unmolding it.", "The mold cover is lifted off, and the plastic piece is unmolded.", "Gloves must be worn, since the piece and the mold are still very hot.", "Here they fabricate a mechanism cover for a stationary bicycle.", "It's held in place by a cutting pattern, and openings are cut with a pneumatic tool.", "Holes are made with a drill.", "The casing is now completed.", "Now we get back to the previous blow-molding process.", "This type of molding produces residues that have to be eliminated.", "These surplus pieces are cut with this small saw.", "The now-hardened scraps are sent to the granulator to be reduced into granules, which will be newly added into the mixer to make other plastic containers.", "This small pneumatic drill pierces the container's vent hole.", "The container circulates from one step to another on the conveyor.", "The next steps will be accomplished by robotic arms.", "And then the final elements are attached, such as the pouring spout.", "Then a sealing stopper, equipped with a rubber washer, prevents leaks.", "And finally, the cap of the neck is automatically screwed into place.", "Depending on the thickness of the mold, the blowing procedure allows the production of between 30 and 120 containers an hour.", "The rotation process takes between 45 and 60 minutes to make a unit.", "Finished containers are now ready for packing and delivery.", "Few things are as elegant as curved, polished wood...", "Especially at 100 miles an hour and driving a slap shot right past the goalie.", "A lot of engineering goes into packing that punch.", "Call it the science behind \"he shoots, he scores\".", "The irish, some 1,200 years ago, were playing hurling, a form of hockey on grass with simple goal zones.", "In the 17th century, american indians used curved sticks in a game they called \"battagaway\".", "The sport we play today was developed by british soldiers in 1855 in ontario, canada, as a pastime during long northern winters.", "Making a hockey stick requires the assembly of several pieces of wood and fiberglass.", "These sticks are all replicas of those of great hockey professionals.", "The shaft is made of a piece of poplar onto which they glue two thin strips of birch.", "This is placed on a circular conveyor equipped with a press that holds the pieces together while the glue dries.", "Then this multibladed saw cuts the wood into three identical stick-shaft pieces.", "The shafts are moved to a precision sander.", "The shaft has to be reinforced with fiberglass.", "With a roller, they apply a coat of epoxy resin, a kind of glue, onto which they place carbon-reinforced fiberglass.", "The resin has to dry and harden.", "The stick shaft is placed in an individual mold and cooked in this press, heated to 176 degrees for 12 minutes.", "The shaft then goes to a milling machine equipped with diamond-headed knives that round the edges.", "A finish is applied to the shaft for a second sanding, which brings out the grain of the wood.", "Now they glue small blocks to the end of the shaft in order to attach the blade.", "Urethane glue is used.", "It resists water and humidity and is specially made for hockey sticks.", "This glue dries in 15 minutes at 100 degrees.", "This slitter cuts the shaft and wood blocks in order to slide in the blade.", "This machine inserts the glue and the blade into the stick shaft.", "The stick is placed on a conveyor leading it to the next step and giving the glue a chance to dry well.", "Then both sides of the blade are sanded to thin them.", "The sticks are replicas of those used by hockey professionals.", "This computer-controlled digital lathe cuts the blade.", "Data on all the cuts are in the computer's memory.", "The blade now has to be curved.", "It's steamed for a minute, allowing humidity to penetrate the wood and make it flexible.", "Then the blade is placed in this curved mold, where it is heated for 50 seconds at 131 degrees.", "The blade is then worked by hand.", "The new blade is compared with the pattern of a hockey player's stick to obtain precisely the same curvature.", "This is why the company keeps 6,000 blades on hand.", "Now the blade is sanded down to the desired thickness.", "The blade must also be reinforced.", "Fiberglass cloth is soaked with epoxy resin.", "Then they place the cloth on the blade and leave a good margin around it.", "They get rid of air bubbles, then put it into an oven to dry at 90 degrees over 24 hours.", "The surplus fiberglass hardens and is cut with a band saw.", "This step requires quite a degree of manual dexterity.", "Finishing is done with this circular sander.", "Finally, the blade is dipped into this epoxy resin to give it a nice luster.", "All that remains is to paint the stick.", "Here, the company logos are applied via silk-screening.", "Besides the 6,000 personal models of professional hockey players, this company produces 65 other models of hockey sticks.", "Each week, they make about 40,000 sticks, for an annual total of 1,600,000." ]

{ "things": [ "Boomerangs", "Barbeques", "Pinball Machines", "Strobe Lights" ] }

[ "Today on \"how it's made,\" boomerangs...", "Barbecues...", "Pinball machines...", "And strobe lights.", "Boomerang is a throwback to primitive times.", "Back then, people threw sticks to hunt and that's likely how they discovered that certain bent sticks would circle back.", "Boomerangs have come a long way since then and are now finely crafted works of art.", "Boomerangs come in many shapes, but fundamentally, they are all single-wing aircraft.", "Construction begins with a solid piece of wood.", "This tree's growth rings have been highlighted to demonstrate how compressed the outer rings become.", "Because the wood from this section is denser than the inner rings, it's easier to work with.", "A woodworker takes 16 strips of that dense wood and places them in a steam box for 20 minutes.", "The steam makes the strips much more flexible.", "In fact, they're so elastic, they can be bent by hand.", "Watch how he arcs all 16 layers at once with little effort.", "The basic form of a boomerang has taken shape.", "To improve the contour, the strips into a boomerang-shaped mold.", "They'll stay in this mold for a day or two, long enough to dry and harden into the bent form.", "Now it's time to laminate the wood.", "Glue is spread onto each bent strip.", "Then the strips are clamped together again back into the mold.", "This time, the mold has been coated with wax to prevent the glue from sticking to it.", "The strips are left to set overnight.", "The next day, the laminated piece of wood is removed.", "It's solid but far too chunky to take flight.", "A woodworker slices it into pieces 8 to 12 millimeters thick.", "One piece of laminated wood yields about six thinner pieces, each of which will become a boomerang in its own right.", "But it needs more form, and those rough edges have to go.", "So a more refined design is traced onto the wood and cut out.", "But there's an easier way to make a boomerang-- with sturdy aircraft plywood.", "With plywood, there's no need to laminate and then physically bend the wood.", "A woodworker simply cuts out the pattern...", "Then sculpts the tops of the wings with a drum sander.", "He's made the tops of the wings curve upwards but in opposite directions.", "It's this contouring that will make the boomerang fly in a circle.", "On some models, embedded lead weights are added for improved balance.", "That laminated boomerang gets the same contouring but files are used instead of a drum sander.", "Laminated wood responds better to this technique, but it's much more labor intensive and requires specialized skill.", "One mistake in the shape and size and the boomerang's aerodynamics will be thrown off kilter.", "But our woodworker has the job down to a fine art.", "To fine-tune the boomerang, he first softens it over a steaming kettle while twisting the wings into an upward flip.", "This blower dries the wood to ensure it stays flipped.", "Then the woodworker sets it on a flat surface to check the curve.", "A sealant is sprayed onto the boomerang, and finally, it gets several coats of lacquer for a high-gloss finish.", "And now these boomerangs are ready to fly.", "Up next, it's time to get grilling.", "The barbecue's origins are clouded in a bit of a smoky haze, but it's believed that native caribbeans were the first to cook this way.", "Of course, back then, they didn't have charcoal grills.", "They roasted meat over a smoky pit.", "Today, people still love a good cookout, but now we have better equipment.", "Basic charcoal grills begin with big steel disks.", "Rollers coat each one with soapy lubricant.", "Then they're fed into a press that shapes each one into a big bowl.", "Molding steel can be tricky.", "If it's not lubricated enough, it could tear instead of bend, so workers need to make sure each disk gets a generous application of the soapy solution before it goes into the press.", "This is a back view of the press.", "With each powerful thrust, the ram delivers 500 tons of pressure.", "A similar type of press makes the barbecues' lids.", "An operator inspects each part for splits and cracks.", "Then it's over to a press that trims the rim.", "The scrap is tossed into a bin for recycling.", "Next, the barbecue bowl spins around while an automated roller flanges the rim.", "After that, holes are punched into the bowl for ventilation.", "Now it's time to bring in the welding guns.", "The guns fuse metal couplings to the bowls to serve as attachments for the barbecue's legs.", "Here handles are lowed into an assembly machine.", "Below, a turntable swings the barbecue bowls into position, then the handles are welded to each side.", "At another station, the barbecue lids get a handle of their own.", "No chef can check the progress of a burger without this essential part.", "This one will allow the chef to lower the lid, to control the cooking temperature, and then lift it again when it's time to flip the burgers.", "The barbecue parts now travel on an overhead rail to the wash station.", "They're hosed down with soapy water, then rinsed clean.", "Once they're dry, it's off to the finishing department.", "Here the parts are dusted with a glass powder.", "Then it's into a red-hot furnace set to 1,500 degrees.", "The furnace bakes the glass dust into an enamel finish that protects the barbecue from rust and stains so they'll last for years.", "Next, they go under intense lights that expose any defects in what should be a mirror-like finish.", "An inspector examines each part inside and out.", "A punch machine now makes dampers from aluminum.", "It simultaneously cuts the shapes and embosses the company's logo onto them.", "This handy attachment enables the chef to control the flow of air to the grill.", "Nylon grips go onto the handle.", "And the damper is installed over the lid's ventilation holes.", "It's up to the consumer to complete the final assembly, and in just a few minutes, the burgers could be grilling.", "Coming up, a high wire at a pinball factory.", "Before video games, the pinball machine reigned supreme.", "You pull a plunger to get the ball rolling, and as your flippers send the silver sphere flying, the machine comes to life with flashing lights and clanging bells.", "No wonder it's not yet game over for pinball.", "The game of pinball is unprogrammed and unpredictable.", "It all starts with reams of wiring for the game's electronic system.", "There's almost half a mile of wiring in one machine alone.", "The color-coded wire is wound around pins and attached to connectors on the circuit board.", "Technicians follow a detailed set of instructions, and an engineering diagram keeps things from getting in a tangle.", "Once the wires are all laid out, they're removed in loosely tied bunches and dipped into a hot metal soup to solder them together.", "But not all wires are soldered.", "Some get attachments called lugs.", "These connectors are crimped onto the ends of the wires with a hydraulic machine.", "Eventually, the lugs will be used to connect wires to attachments on the play field.", "But first, the cable is hooked up to a testing board where technicians check every circuit.", "Meanwhile, the play field is placed on a bed of nails and foam strips.", "As the nail bed rises and presses against the header, the nails prick the back of the play board, but the foam strips stop them from going all the way through.", "These nail holes will serve as markers for installing pinball targets and tactical features on the play field.", "Technicians drill a few holes, then cover the play field with a metal template and drill some more.", "These holes will be used to mount the pinball gadgetry onto the play field.", "Next, anchors are hammered into place.", "They'll secure the metal railings that keep the silver balls from rolling off the play field.", "A lamppost is fitted into place...", "Followed by some plastic bumpers and 115 flashing lights.", "Now it's time to permanently attach all that wiring.", "Some are soldered directly onto the board.", "Others are attached to switches.", "A speaker is bolted into the cabinet for some major sound effects.", "Then it's time for that essential tool-- the spring-powered plunger.", "Workers attach a toy villain...", "And add a ramp in the shape of a sword, along with a few other characters.", "Finally, it's time for the inaugural run.", "The pinball is rolled into every target and mechanism to test the game's electronic switches.", "There can be 70 switches in a game.", "As technicians press all the buttons, a computerized system diagnoses any malfunctions.", "They rigorously test all of the game's features.", "If everything works, the play field is inserted into its console.", "A shatterproof window slides into place to protect the play field from overenthusiastic gamers.", "A metal bar locks the window into place.", "Finally, the header is attached, and this pinball machine is wired and ready for action.", "Coming up, little lights with lots of flash.", "Strobe lights often conjure up images of '70s discos.", "But you'll also find strobe lamps-- the proper term, by the way-- on aircraft wings, in police lights, and on towers and tall buildings to warn low-flying aircraft.", "Strobe lights even play a role in photography and on factory production lines.", "A strobe lamp emits repeated flashes of high-intensity light.", "At this factory, production begins with glass blowers.", "Using a ribbon burner, they heat glass tubes to almost 3,000 degrees.", "This softens the glass for bending.", "But if it's too soft, the tubes will collapse, so the glassworkers blow air into it through a rubber hose to build counterpressure.", "The size and shape of the glass tubes varies by model, but its job is always the same-- to house a strobe lamp's essential components-- electrodes, lead wires, and xenon gas.", "The electrodes conduct the current, which charges the gas with electricity, making it illuminate.", "This factory makes several strobe-lamp models, some in large quantities for the mass market, others in small quantities, custom-designed for specific clients.", "With mass-produced models, automated machines take over after the glassblowing.", "Custom orders are handmade from start to finish.", "Workers even make the electrodes manually.", "They weigh a precise amount of metal powder and pour it into the cavity of a press similar to what pharmaceutical factories use to make pills.", "This powder is a blend of several different materials, but the company won't divulge the ingredients.", "The press applies 4 tons of pressure, compressing the powder into a pellet.", "The factory inspects every pellet to ensure it meets quality standards.", "The pellets then undergo a hardening process called centering.", "They bake for nine minutes in a hydrogen-fueled oven.", "Hydrogen is one of the hottest types of fuel, and the 3,000-degree heat fuses the powder particles into a solid mass that won't crumble apart.", "Next, workers weld a lead wire to each electrode.", "Then they insert two electrodes, one for the positive current, one for the negative, into each glass tube.", "Then they melt the end of the tube closed.", "Then they attach a wire called a trigger lead.", "It prompts a transformer to send a high-voltage electric pulse to the electrodes, illuminating the gas.", "This automated machine assembles the factory's mass-produced models.", "Before starting it up, workers load the components-- a pair of electrodes followed by a glass tube on top.", "Now the machine takes over.", "It vacuums out the air in the tube, injects xenon gas, melts the tube closed, then cuts off the excess glass.", "The tube's interior must be completely free of contaminants for the gas to illuminate.", "So, just before the vacuum fill-and-seal operation, a hot coil encircles each tube to burn away any impurities.", "On custom-made models, all of these steps are done manually.", "With the strobe lamp complete, it's installation time.", "This model is for the warning lights you see on tow trucks and road-construction vehicles.", "It goes into a glass reflector lined with metallic film.", "A transformer regulates the voltage.", "Its three wires connect to the positive, negative, and trigger leads protruding from the lamp.", "A glass lens covers seals and protects the lamp within the reflector, and then this product is good to go.", "Strobe lamps are also used in stroboscopes-- industrial devices that help factories perform quality-control inspections on high-speed production lines.", "Calibrate the light pulses to the right interval and they appear to stop the action so that cameras or workers can examine the goods.", "It's the size, shape, and configuration of a strobe lamp's components, along with voltage and other electrical specs, that determines how long, how often, and how quickly the light flashes." ]

{ "things": [ "Paving Asphalt", "Marshmallow Cookies", "Loudspeakers", "Electronic Door Locks" ] }

[ "Today on \"how it's made\"...", "Paving asphalt...", "Marshmallow cookies...", "Loudspeakers...", "And electronic door locks.", "Asphalt is a black, liquid substance that's a by-product of processing crude petroleum.", "Asphalt is a key component of waterproofing and insulation materials and roofing shingles.", "But its best-known use is for paving roads.", "Asphalt cement is a by-product of crude oil-- the key ingredient they mix with crushed rocks and other minerals to make paving asphalt.", "So, production begins at the paving plant's quarry, where some 50 feet below ground, workers driving heavy machinery collect boulders of granite that have been blasted off the rock walls.", "Trucks transport the rocks to the paving plant, which is right on the quarry site.", "They dump their cargo into the primary crusher-- a machine whose steel jaws crush these big rocks into pieces smaller than 8 inches.", "It takes mammoth force to crush solid rock.", "The fly wheels that amplify the motor's energy weigh more than 6 tons.", "The primary crusher empties onto a mobile conveyor belt, which transports the crushed rocks to an outdoor storage area.", "When it's time to make the asphalt, the rocks travel, via conveyer belt, from the storage area to a screening building to be classified by size.", "There, the rocks tumble downward over a series of inclined screens whose largest holes are 4 inches wide.", "What's too large to drop through goes to a secondary crusher, that reduces the rocks to 4 inches or smaller, then sends them to a third, or tertiary, crusher that further reduces them to 1 inch or smaller.", "What's small enough to pass through the screens bypasses the secondary crusher and goes directly to the tertiary crusher.", "After this last crushing stage, the largest stones are 1 inch in size.", "Everything smaller than 1/4 inch goes in one pile-- that includes stone dust created by the crushing process.", "Stones that are 1/2 to 3/4 of an inch go into another pile...", "Stones 1/4 to 1/2 inch into another.", "Trucks transfer material from each pile to separate compartments called feed bins.", "Exactly what goes into the paving asphalt depends on what's being paved.", "But, generally, these are the four ingredients...", "Sand...", "Stone dust...", "1/4- to 1/2-inch stone...", "And 1/2 to 3/4 of an inch stone.", "The ingredient proportions vary according to what the paving asphalt will be used for.", "Stones, along with sand and stone dust as fillers, usually make up about 95% of the mix.", "The remainder, added later, will be liquid asphalt cement.", "Each bin releases a specific amount of material onto a conveyor belt running under it.", "The belts lead to a main collecting belt that dumps the ingredients, combined, onto yet another belt that leads to a drier.", "The drying process, which takes about a minute, removes all traces of humidity.", "This will enable the materials to bond better with the asphalt cement.", "Screening equipment then reseparates the dried ingredients, making it possible to precisely weigh out the required amount of each one.", "Everything then goes into a mixer.", "As this demonstration shows, the mixer blends everything thoroughly.", "Then it's time to pump in hot asphalt cement.", "Oil refineries make asphalt cement from what's left over after they've processed crude oil.", "The paving mix contains about 5% asphalt cement.", "This is what happens inside the mixer.", "The hot asphalt cement binds the ingredients in about 30 seconds.", "The result is ready-to-lay paving asphalt.", "The mixer empties directly into trucks destined for the paving site.", "There, a paving machine will spread the hot asphalt on the road bed.", "Then a compactor roller will pack it down.", "The asphalt cools and hardens in about one hour, depending on the weather.", "The next time you bite into a marshmallow cookie, you can thank the ancient egyptians.", "They invented marshmallow candy by thickening honey with sap from the root of the marshmallow plant-- a herb that grows in salt marshes and along large bodies of water.", "Modern marshmallow contains gelatin instead of sap from the mallow root.", "The snap test-- to make sure the coating is hard and thick enough.", "Then, the taste test.", "If you've got a sweet tooth, doing quality control in the marshmallow cookie factory is your dream job.", "To make a batch of dough for the cookie base, they mix wheat flour, salt, baking soda and powder, cornstarch, whey powder, and potassium sorbate.", "Then they add several liquid ingredients.", "This one causes a chemical reaction, making the biscuit lighter.", "This cream-colored liquid is vegetable oil shortening.", "This transparent liquid is glucose fructose, a sweetener.", "The ingredient proportions are also a company secret.", "From the mixer, the dough goes into a machine called the chipper.", "It shreds the big blob into pieces about the size of the cap on a highlighter pen.", "This makes the dough more manageable for the next machine, called a rotary mold.", "Inside that machine, a large roller flattens the dough pieces, forming them into a dense sheet about 1/2 inch thick.", "It then presses the sheet against another roller whose surface is a cookie mold.", "The factory uses the rotary mold machine for many different types of cookies.", "It simply installs the appropriate roller for the cookie in production.", "For marshmallow cookie bases, the mold cavities are round.", "The bases exit the rotary mold and make their way onto a moving baking sheet.", "That transports them to an oven.", "The baking time and temperature are, once again, top secret.", "The baked cookie bases exit the oven and move onto a conveyer belt that transports them to a cooling area.", "Once they cool to room temperature, the bases go into a machine called the base feeder.", "It lines them up like marching soldiers to receive their marshmallow filling and chocolate coating.", "The process does require military precision.", "Factory technicians have to adjust this machine daily to ensure accuracy to 1/32 of an inch.", "A portion of filling has to land perfectly centered on each base, finishing off in a curled peak, this brand's trademark.", "The company won't divulge how much marshmallow filling goes into each cookie, nor will it reveal its marshmallow recipe.", "But marshmallow is usually made from either corn syrup or sugar and gelatin.", "And now for the final layer-- the chocolate coating.", "Not only are the marshmallow and base covered in hot, melted chocolate, the base floats in it, which coats the underside, as well.", "Built-in air jets blow off the excess.", "The chocolate hardens inside a cooling tunnel.", "How long that takes in the tunnel temperature are-- you guessed it-- classified information.", "As the cookies exit the cooling tunnel, a quality-control worker does spot-checks to ensure the coating is thorough, hard enough, and thick enough.", "On the packaging line, the cookies go into plastic trays.", "To keep up to speed, the workers have to grab four cookies in each hand without breaking the coating.", "The trays pass through a machine that wraps them in plastic film.", "This keeps the cookies fresh and also prevents them from falling out of the tray.", "Meanwhile, another machine assembles the boxes-- first folding and gluing one end shut.", "Once workers load the trays, the machine glues the open end closed, as well.", "Then with the go-ahead from quality control, the box's next stop is the cookie aisle of your local supermarket.", "Loudspeakers take an electrical signal and turn it into sound.", "The key to it all is a magnetic wire voice coil and a permanent magnet that attract and repel each other.", "As the coil moves back and forth, it rapidly vibrates a flexible cone.", "This vibrates the air in front of the speaker, creating sound waves.", "Loudspeakers contain at least two magnet-and-cone assemblies known as drivers.", "They're typically housed in a box called a speaker enclosure.", "To build the internal magnetic structure, the factory begins by cutting two plates of iron, each about 1/2 inch thick.", "They go one at a time onto a lathe.", "First, the machining tool smoothes and evens out the surfaces, getting rid of the marks the saw made.", "Then it cuts out a small hole in the center of one plate and a larger hole in the center of the other.", "Next, they cut a smaller and thicker round piece of iron called the core.", "A reamer bores a large hole through it.", "They apply superhigh-strength epoxy glue to the core and to the back plate-- the plate with the smaller hole.", "They glue and screw the pieces together because the bond has to be strong enough to withstand intense magnetic pull.", "They glue a foam filter in the hole to ensure the vibrating cone doesn't draw in dust and cause internal damage.", "Now they spread the glue on the narrow end of what's called the metal basket, a die-cast aluminum frame that will hold the magnetic structure and cone.", "They screw the front plate, the plate with the bigger hole, onto the glued surface.", "Then they glue the underside of the front plate and one side of a ferrite, a ceramic ring made from the iron powder.", "After adhering the ferrite to the front plate, they apply glue to the other side of the ferrite, then flip the basket over to attach the back plate.", "The core fits through the large hole in the front plate.", "They insert shims to center it while the glue dries.", "After screwing terminals to the basket, they put the entire structure they've just assembled into a magnetizing machine with 600 volts of direct current.", "The machine creates positive and negative poles, transforming the magnetic structure into a permanent magnet, meaning it has a constant magnetic field around it.", "Now they wind the voice coil-- the electronic magnet that will interact with the permanent magnet.", "An electromagnet is an object that generates a magnetic field only when there's a current running through it.", "They wind enamel-insulated copper wire, gluing it to a rigid plastic sheet.", "The positive pole of this voice coil will be attracted to the negative pole of the permanent magnet.", "The negative poles will repel each other.", "The key is that the voice coil's poles are constantly reversing position because the electrical current running to the speaker is an alternating current, meaning it switches between a positive and negative charge several times per second.", "This makes the magnets attract and repel each other continuously, causing the voice coil to move back and forth rapidly.", "This vibrates the cone, which creates sound waves.", "After slipping the voice coil between the front plate and the core, they glue on the bottom suspension-- flexible fabric rings that move with the voice coil and prevent it from rubbing on the magnetic structure.", "Next, they glue the cone.", "It's usually made of cardboard, plastic, or metal.", "Then solder the electrical connections.", "The current coming from the amplifier travels by wire to the two terminals.", "The terminal wires connect to the voice coil wires.", "After making sure the cone moves freely without rubbing, they glue on a rigid cardboard cap to keep out dust.", "The last step is to take the speaker for an audio test drive.", "They connect it to a machine that transmits different frequencies.", "They make sure the movement of the voice coil and cone isn't obstructed in any way.", "Then a computer device analyzes the sound wave the driver sends out.", "Two-way speaker systems have two drivers in each enclosure-- a woofer and tweeter.", "A woofer has a large cone that vibrates more slowly for low frequencies.", "A tweeter has a small cone that vibrates quickly for high frequencies.", "Three-way systems have a third driver with a medium-sized cone for the midranges.", "At most hotels, room keys are a thing of the past.", "You're more likely these days to be given a key card.", "When you arrive at the door to your room, you swipe or insert it to unlock the handle and get in.", "Because the room number doesn't appear on the card, this system is far more secure than door locks with a keyhole.", "The metal case that houses the door lock's mechanical and electronic components is called the housing.", "To make it, they begin by melting zinc ingots.", "To melt zinc, you have to heat it to about 734 degrees fahrenheit.", "Die-cast machinery then injects the molten zinc into molds.", "Between injections, sprayers coat the empty mold cavities with a release agent, the industrial equivalent of greasing a baking pan.", "A built-in cooling system hardens the metal.", "Then a trimming die cuts off excess zinc around each piece and in the openings.", "Meanwhile, the electronic circuit board, the brain of the lock, takes shape.", "They call this the \"pick and place\" machine.", "It picks up the 60-odd electronic components and places them in the right position on each board.", "This computer-guided machine installs 15,000 components per hour.", "Next, the boards undergo what's called wave soldering.", "A mix of molten lead and tin surges up from underneath, fusing components in place and creating electrical bonds.", "Then, both sides of each circuit board get a coat of silicon-based sealant.", "This protects the components against the elements.", "Back to the housings now.", "Workers lubricate them with grease and apply what's called a sleeve bearing-- a nylon bearing that enables the handle to turn smoothly.", "Next comes the drive tube onto which the lever will be assembled on the other side.", "There are several clutch components that link the lever to the latch.", "Swipe the right card, and they permit the latch to retract.", "After applying more lubricant, they install an override that enables the hotel to open the door with a key, if, for some reason, the electronics malfunction.", "They install the circuit board and connect it to the various parts it controls, such as the clutch motor, which they install next.", "Now they close up the completed housing with the steel back plate.", "This protects the components inside from rusting.", "The last step is to insert a battery pack.", "It holds three standard double-a batteries.", "The factory tests the lock using a test key card because the lock isn't yet programmed to work with a specific card.", "That's done after installation.", "Elsewhere in the factory, they assemble the mortise-- the part of the lock that goes inside the door.", "When you lock up, the mortise's bolt comes out of the door's edge and fits into the hole of a receiving piece, called a strike plate, in the door frame.", "They close up the mortise with the back plate.", "This demonstration shows how they install the mortise in the door.", "Once it's in, they screw a decorative plate on top.", "This is what the finished electronic door looks like.", "Key cards have instructions on one side, a magnetic data stripe on the other.", "They use a generic card to test every lock that comes off the production line.", "In the quality-control lab, they subject every new design to several rigorous tests.", "They open and close 1 million times.", "They subject the lever, latch, and lock to repeated impacts.", "They also test lock function in extreme temperatures.", "These electronic door locks come in several metal finishes plated over the zinc and even in a painted finish that simulates wood." ]

{ "things": [ "Pressure Cookers", "Mechanical Singing Birds", "Oceanographic Buoys", "Tank Trailers" ] }

[ "When the pressure is on, the juices start flowing for quick results.", "The pressure cooker traps steam inside to raise the cooking temperature and produce a meal in minutes.", "The technology has been around for centuries but was only adapted for household use in the 1930s, when the concept really picked up steam.", "Modern pressure cookers have new lid-locking technology and safety features, keeping it on the front burner in the kitchen-gadget department.", "A pressure cooker starts with a stainless-steel disk.", "A dip of some lubricant will aid the forming process, as equipment pushes the disk over a pot-shaped die.", "That flat disk is now a nicely rounded pot.", "Next, this punch cutter moves in to make notches in the pot's rim.", "These notches will interlock with the pressure-cooker lid, allowing it to hold up tight against steam pressure.", "Next, they submerge aluminum disks in a liquid mix of aluminum and silicon to give them an even coating.", "While the disk is still damp, they arrange it on the bottom of the pot, then set a stainless-steel disk on top of it.", "A turntable delivers the pot to an element that's heated to more than 1,100 degrees fahrenheit.", "This intense heat activates the aluminum and silicon solution to fuse the disk to the bottom of the pot.", "Then it's into a cooling tank, where the pots float towards the next station.", "There, two blades shave away the ragged edges of the fused layers on the bottom of the pot.", "It creates a cosmetic beveled effect.", "That layer of aluminum sandwiched between the steel will improve the pot's heat conductivity.", "And now it's time for some grit and polish.", "In this special chamber, sanding and buffing tools add luster to the pots.", "The pressure-cooker pot then takes a trip through a washing station to clean off the sanding residue.", "And now it's ready for the crowning touch-- the lid.", "It takes six pressing operations to shape it completely.", "The holes at the center are for the pressure cooker's two safety valves.", "To install the main valve, they align a retaining ring with the lid's larger hole, then pop the spring valve into that hole.", "An automated device underneath tightly screws it into place.", "The backup valve goes in the smaller hole.", "These two valves are crucial.", "They'll release excess steam to avert an explosion.", "A rubber ring creates an airtight seal with the pot.", "They test the valves and check the sealing ring, along with the lid's closing mechanism.", "This plastic cooking guide encircles the main safety valve, but doesn't impede its function.", "They weld several bolts into the pot on either side.", "They leave a bit of space between the bolt heads and the pot.", "This allows them to install the brackets for the handles.", "They torque the bolts to tightly secure the bracketed handles.", "After all, a pressure cooker is one thing you don't want to lose your grip on.", "And now this pressure cooker is in the home stretch.", "There's one last test, which they perform on randomly selected pots.", "They pump the pot full of air to simulate the effect of steam and confirm that this pot can handle the pressure.", "Pressure cookers with double walls are another innovation.", "They'll keep that stew warm longer to ease the pressure on the chef.", "Mechanical singing birdsfirst appeared in 1780, adorning snuffboxes.", "The swiss-made novelty soon became the rage among classy europeans.", "A few decades later, a french watchmaker perfected the sound mechanism, making the birdsong virtually indiscernible from the real thing.", "switzerland is home to the last remaining company making these singing automatons.", "The workshop crafts large ones that go in birdcages and small ones that pop out of boxes and clock cases.", "the first step is to adjust the bird's two spring-loaded steel rods.", "One pivots the bird's head and the other its beak and tail.", "Then it's time to dress the bird's body.", "It's illegal to harvest real bird feathers, so the artist uses real antique feathers in a couple of key spots and realistic-looking synthetic feathers everywhere else.", "To craft the tail, she glues feathers onto stiff paper, then folds it over and adheres it to the bird.", "Then she adds more feathers, meticulously creating colorful layers.", "The plumage alone takes about four hours' work.", "No two birds are alike.", "Each is a unique piece of art.", "In the technical department, they screw the windup key to the mechanical movement that animates the birds.", "The movement is made up of 250 brass and steel components assembled manually.", "They connect leather bellows.", "The movement pumps the bellows, which sends air through a tiny whistle, producing the birdsong.", "Now for the birdie.", "This one's the small pop-up kind that goes in a box or clock case.", "They screw him to a lever in the movement, then, using a brass template, position him correctly.", "This rack gear moves the bird from side to side while he's up and singing.", "This pin attaches that gear to the movement.", "This lever pops the bird out of his nest, moves the rack gear, and pumps the bellows.", "A push button on the movement triggers the lever, setting all this in motion.", "now they install the movement into its decorative box.", "Birdcage models require an identical but larger movement.", "The base of the cage sits on top of it.", "The rods that manipulate the birds connect to the movement through tubes in brass perches.", "workers construct the top of the cage over a curved form.", "First, they slide on two brass rings and position a brass disk at the top.", "Then, they feed thick brass wire through holes in the rings.", "They lock each wire onto the disk temporarily, then, with a bit of acid to help the process, solder the wires to the disk permanently.", "After making sure everything's well-positioned, they solder the wires to the rings, as well.", "Once the structure is soldered, the cage can safely come off the form.", "Decorative brass rings cover the structural ones.", "They, too, have to be soldered in place.", "This requires a light brush of acid...", "Lead pellets...", "And a torch to melt the lead, binding the outer and inner rings.", "Every mechanical singing bird this company produces is a work of artistic and technical craftsmanship that delivers a performance on command.", "oceanographic buoys enable scientists to study the sea, help meteorologists predict weather, and rescue teams better to find a search area.", "The top part of the buoy houses instrumentation that tracks temperature, surface currents, and other conditions.", "Its antenna transmits the data via satellite to a base station.", "This model has a ball-shaped surface float with a tether cable connecting a long fabric tube called a drogue.", "The drogue detects water movements several yards below the surface.", "The component that connects the surface float to the cable is called the stress relief.", "The factory makes this part in a mold, casting 10 at a time.", "Workers inject liquid urethane into the mold cavities.", "It's the same material from which in-line skate wheels are made.", "After three hours, they extract the castings, which then cure for a full week.", "The surface float contains a barometer sensor that collects air-pressure data, as well as a temperature sensor and a locating system.", "A 13.5-volt battery pack powers all these instruments.", "Workers build it by arranging 36 standard d-cell batteries.", "Using nickel strips, they make pairs, linking the negative end to a positive end.", "Then, they spot-weld the strips, creating circuit pathways along which electricity will flow.", "Next, they immobilize the batteries by filling the spaces between them with hot glue.", "Then, they weld the final connections and solder on the leads that will connect the battery pack to the instrumentation.", "Now they apply special insulating paper to prevent the battery pack from shorting, should it come into contact with a metal object.", "A wide band of electrical tape safely seals this 13-pound battery pack.", "The nylon/polypropylene drogue is too lightweight to hang vertically in the water, so it needs something to weigh it down.", "That something is a heavy, plastic hoop.", "They make the hoop by blowing sand into a plastic garden hose.", "The sand makes it heavy.", "After capping the hose, they insert it in a pocket at the bottom of the drogue.", "So now the drogue, all 26 feet of it, will dangle straight down into the water.", "Now for that stress relief they molded earlier on.", "It attaches underneath the bottom half of the surface float.", "Inside the bottom half, they install the battery pack...", "Then a control board...", "A transmitter...", "And an antenna.", "The surface float is made of a.b.s. plastic, the top surface coated for u.v. protection, because it will be exposed to direct sunlight.", "They attach one end of the tether cable to the stress relief and the other end to the drogue.", "They reinforce the connection with epoxy.", "This type of buoy is designed to monitor only the top yard of water, so it doesn't have a long vertical drogue like the other one.", "What it doeshave is a parachute, because it's designed to be dropped by aircraft in a search-and-rescue operation, to mark the location of an incident.", "As the demonstration shows, the buoy opens on impact.", "All the components are spring-loaded-- floats made of foam, drogues around the central cylinder housing the instrumentation, and on top an antenna.", "The buoy packaging is water-soluble and biodegradable, so, over time, it simply disintegrates.", "No need to retrieve them.", "Stainless-steel tank trailers carry all kinds of products, from milk, sugar, and animal feed to fertilizer, shampoo, or even wine.", "Some tank trailers only haul chemicals like methanol.", "Made of stainless steel inside and out, they keep all the products they're transporting contaminant-free.", "Stainless-steel tank trailers carry as much as 12,000 gallons of product.", "They start with a laser cutting machine which cuts pieces like this manhole opening from the stainless-steel sheet used to make the tank.", "The laser that cuts the steel is as precise as the pen you use to sign your name.", "Next, they make the larger pieces of the tank by putting two sheets of stainless steel into a machine called a plasma seam welder.", "Using stainless-steel wire as a filler metal, the computer-controlled machine welds the two sheets of steel together.", "A worker then uses a belt sander that rides on a track to smooth out the weld evenly and in a straight line.", "The sheet then goes through a rolling machine that shapes it into a cylinder.", "It takes two to four cylinders to make a tank, depending on the size.", "Meanwhile, a ring-rolling machine makes what's called channel rings that will strengthen the cylinders and help them keep their round shape.", "The rings are also made of corrosion-resistant stainless steel.", "Some tanks need up to 12 of these reinforcement rings.", "A worker then welds the channel rings onto the tank, stopping periodically to inspect the weld.", "Next, they weld tank heads to the cylinder.", "Welding parts on the outside of the tank causes heat discoloration to the steel on the inside.", "That's why a worker then polishes the stainless steel, giving the full interior of the tank a noticeably clean and bright finish.", "Then, they attach polyurethane spacer bands to the tank.", "These create the sections they need to mount fiberglass insulation around the tank, which keeps the product either warm or cold.", "Workers then install thin sections of stainless steel around the tank to protect the insulation.", "This steel is shiny for cosmetic reasons only.", "They hold the sections in place temporarily using leather belts.", "They secure this entire outer wrapper so it fits properly.", "Then, they weld each section of steel to the frame of the tank.", "Next, they prepare the outer wrapper heads using what's called a lock-seam flanger.", "That makes a lip in the edge of the heads.", "They attach the front and rear heads to the outer wrapper by fitting the lip into the outer wrapper's grooved edge and crimping them together using a hammer.", "Next, they install the aluminum fenders over the rear tires.", "After that, they attach a stainless-steel tube ladder that gives access to the manhole at the top of the tank, where they load the product.", "They put the mudguards on next, followed by the reflective conspicuity tape that goes on both sides of the tank and on the two rear bumpers.", "They install the stoplights and taillights into a light box at the rear of the trailer.", "After that, they install the turn indicators on the sides of the trailer and test them to ensure they function properly.", "Finally, they check all the connections used to operate the tank trailer, so when it leaves the plant, it works perfectly and the customer can transport their product safely." ]

{ "things": [ "All" ] }

[ "For this invention, the path to success has been bumpy and rocky, and that's the whole idea.", "The all-terrain vehicle was developed for off-road driving back in the 1970s.", "The first machines were three-wheelers, and then the safer four-wheelers came along, improving on a concept that was truly trailblazing.", "If you're looking for adventure, an all-terrain vehicle will get you out of a rut.", "All that bouncing around won't hurt a bit because the independent rear suspension takes some of the shock out of that bumpy ride.", "To make an all-terrain vehicle, they clamp pieces of the steel framework to a worktable.", "The table flips and lands in a precise position for welding robots to go to work.", "These computerized robots do all the big welds.", "Humans take over for the more intricate work.", "Once the vehicle mainframe is complete, they hang it on an overhead rail, which takes it through a painting station.", "When the paint is dry, they lock it onto rails that will move it down the assembly line.", "They tie the radiator to it with hose.", "It will be attached more securely later.", "The steering axle for the front wheels goes in next.", "At the next station, they bolt the steel handlebars to the front of the vehicle.", "They hoist a 300cc engine into the chassis.", "It's suitable for beginners or smaller riders.", "They fit the carburetor into the engine manifold.", "Moving down the line, they install the suspension system for the front wheels and run the brake lines to the brake disks.", "They brace the suspension with a steel bracket.", "The extra support will come in handy when this atv is on rough terrain.", "They push the outer exhaust pipe onto one that extends from the engine and hook them together with springs.", "They then slide the front and rear clutches onto grooved shafts and connect them with a rubber belt to transmit power from the engine to the transmission.", "The radiator has been permanently mounted to the chassis, and they bolt the coolant tank to the framework above it.", "The 4 1/2-gallon fuel tank goes between the handlebars and seat.", "They insert the air-filter box in an opening behind the tank.", "This much bigger lid goes on the storage box in the front.", "And after a little trademark artwork, they push the instrumentation panel into place between the handlebars.", "Footwells made of rigid plastic flank each side of the atv.", "At the next station, they mount the front grille and headlights.", "They screw a rack onto the back.", "It can be used to tie down anything from camping gear to game.", "Workers then press a comfy vinyl seat onto the center of the vehicle, snapping it into place.", "Now this all-terrain vehicle is ready for its wheels.", "The back ones are larger to provide that cushioning effect over the bumps, while the smaller wheels in the front provide traction and maneuverability.", "They apply reflector decals to the sides and back, so the atv can be seen more easily when daylight dims.", "The tank has been fueled, and this atv is ready to take a ride on the drum tester.", "The operator parks the wheels on a set of drums.", "He activates the computer, and those drums are ready to roll.", "The gate closes, and the atv rides on the spinning drums, reaching high speeds without actually moving.", "It's the perfect opportunity to test the gears, brakes, and exhaust system.", "The operator then gives the brakes a workout because good brakes are critical in backwoods conditions.", "And it passes.", "From the three-wheel machine of the '70s to the flashy four-wheeler of today, the atv continues to be popular off the beaten track.", "Thousands of years ago, scandinavians strapped wooden planks on their feet to glide across snow.", "Those first skis enabled them to hunt and trap in the winter.", "Essentially, they skied to live.", "Today, however, some of us live to ski, and cutting-edge equipment is part of the appeal.", "In the past century, downhill skis have become shorter and curvier for peak performance.", "They start with a squared-off ash log.", "A band saw slices it into several planks.", "Ash is supple, but strong, which makes it the ideal wood for the core of a ski.", "A second blade thins each plank at the end and widens it where the skier's foot sits.", "Sanding establishes subtle angles on the edges.", "Then the planks move along to a machine that cuts teeth into them.", "A ridged applicator applies epoxy glue to the toothy ends of two boards.", "Machinery presses them together for a tight fit.", "As the glue dries, it creates a permanent bond.", "The two planks are now one ski core.", "It still needs some fine-tuning, so a robot positions it on a conveyor, which takes it under a sanding belt.", "It smooths the interlocked section and grinds deep cuts into the core.", "This defines the parabolic shape that helps skiers carve through powder in short, clean turns.", "They silk-screen graphic artwork and logos onto plastic.", "It's a bit of corporate p.r., but the flashy designs can also inspire the skier.", "An operator then brushes a release agent into a mold, as she prepares to build and shape several skis at a time.", "A little vacuuming gets rid of any dust that would sully the work.", "Then she tucks pieces of graphite-fortified polyethylene into the mold.", "It will form the base of the skis.", "She places rubber on the ends to minimize vibrations while skiing.", "Next come layers of special fiberglass that run the length of each ski.", "This material is both flexible and durable.", "It's been formulated specifically for skis.", "The weave varies from layer to layer, depending on the type of ski.", "Strips of rubber reinforce the back ends, followed by pieces of heavy-duty polyurethane.", "The assembler places the curved wooden cores on top of the synthetic layers.", "She installs melamine to build up the ski's sidewalls.", "This improves gripping in hard snow.", "To provide a firm base for bindings, she covers the narrow waist of the ski with more fiberglass, followed by an aluminum plate to hold the binding screws in the ski.", "More layers of fiberglass follow, imbued with epoxy glue, which is about to be activated.", "Once the colorful top sheet is secured, they close the mold.", "Inside, the temperature reaches 212 degrees fahrenheit.", "This causes the glue impregnated in the fiberglass to liquefy, while the mold squeezes the layers into the shape of the ski.", "When the glue hardens, the many layers become one solid ski.", "It's a fusion of synthetic, wood, and metal.", "But it's still a bit rough around the edges, so this robot smooths the tip and tail of the ski against a sanding belt.", "The ski then travels over several grinding wheels.", "This cleans it up and creates angles for precision carving on the slopes.", "Then, like a powerful fist, this machine tests its flexibility and strength.", "Finally, a worker screws a rail system to the waist of the ski to make it easier for the ski shop to install bindings.", "Then it's all downhill from here, which, of course, is the whole idea.", "A laser cutter is a high-tech machine that factories use to cut parts out of metal.", "The traditional way to cut metal is with a stamping press, a slower process that requires a separate tool for each type of cut.", "A laser cutter's computer-guided beam can precision-cut virtually any shape.", "A laser cutter is made up of a laser resonator, which produces the beam, and a mechanical system that moves the laser over the metal in a computer-controlled pattern.", "To build the laser resonator, they mill two blocks of aluminum.", "Each will hold a mirror on opposite ends of the resonator.", "They will reflect light back and forth inside the chamber to form the laser beam.", "All the parts go into a cleaning solution because any contaminants would shorten the laser's life.", "Assembly takes place in a clean room.", "After mounting the aluminum blocks onto separate aluminum tubes, they slide one tube inside the other.", "This forms the resonator's main structure.", "They install an electrical connector on one of the blocks.", "Then they mount a mirror onto each aluminum block.", "A generator pumps electrical energy into a pressurized mixture of gasses, producing particles of light called photons.", "The mirrors at both ends of the resonator direct the photons back and forth, creating the laser beam.", "They now fill the resonator with that pressurized gas.", "It's a mixture of nitrogen, carbon dioxide, and helium.", "For the laser beam to cut well, it has to be the right shape, but the beam is invisible.", "So, to see its shape, they have to shoot it into a plastic cube and observe the formation it makes.", "They gradually fine-tune the beam's shape by adjusting the mirrors on the resonator.", "They keep at it until the laser cuts a cone formation in the plastic.", "On top of the tubes, they install a square housing containing a series of mirrors, which further refine the beam.", "Meanwhile, a robotic welder fuses sheets of steel to construct the laser resonator's housing.", "On the main machine, these large suction cups move the sheet of metal to the cutting area.", "The sheet remains stationary, while a motion unit moves the laser beam over it.", "A rack-and-pinion system propels the motion unit.", "The system's racks must be perfectly aligned for the machine to cut accurately, so a technician uses precision measuring equipment to check the racks, then various tools to make adjustments.", "Once that's done, they set up the guide rails on which the motion unit rides, then mount the motion unit onto them.", "They bolt the motion unit to the front of the machine and the housing that contains the laser resonator to the back of the machine.", "The resonator creates the laser beam.", "Mirrors deliver it to the motion unit's cutting head.", "Lenses inside the head focus the beam on the metal that's underneath.", "They run a series of tests to ensure the machine cuts with ultimate precision.", "It all boils down to whether the motion unit moves accurately, which means the drive-system racks must be perfectly aligned.", "After testing, they enclose the cutting head with a safety cover made of sheet metal and plexiglas.", "The cutting head's copper-tipped nozzle emits the laser beam, while a curtain of brass pins confines that beam to a restricted area.", "The motion unit moves in three axes, enabling the laser beam to cut different thicknesses in two dimensions.", "A stamping machine leaves rough edges that workers must grind smooth afterward, but a laser cutter leaves a smooth edge that needs no further work.", "This saves on time and labor cost, making this technology a cut above.", "It was michelangelo who once said, \"every block of stone has a statue inside it, and it is the task of the sculptor to discover it\".", "Centuries later, sculptors still chisel by those words, using techniques similar to those used by the brilliant michelangelo so many years ago.", "A lifelike image emerges from stone, and that well-chiseled look is the result of a lot of planning and posing.", "The artist first molds the subject in clay, which allows him to capture his impressions quickly.", "His clay model is the sculpture equivalent of a painter's sketch.", "Clay also allows him to make changes that would be impossible once carved in stone.", "When the prototype is complete, the artist is ready to choose a stone.", "The search leads to this quarry in the hills of northern italy, where they've been extracting white carrara marble for centuries.", "A long saw on a track makes a horizontal incision in the bottom of the rock face.", "Once this undercut is complete, the operation moves to the top of the stone.", "A machine pulls a loop of diamond cable down through the rock to cut the back of the slab.", "A constant spray of water cools the cable and flushes the cut.", "When the two cuts intersect, this marble slab is ready to be extracted.", "Equipment gently tips it onto a soft pile of dirt intact.", "The supervisor gives the slab a production number and draws lines to indicate how it should be cut to prepare it for sculpting.", "Once cut down to size, it's into the studio, where it's positioned beside a plaster version of a clay model.", "With calipers, an artisan measures the proportions of the plaster cast and transfers them to the marble slab.", "His pencil marks define the main mass and outer limits of the form that's to be sculpted.", "This artist chips away big chunks of the stone to give the rough size and shape of the plaster model.", "The penciled measurements ensure that he doesn't chip away too much and destroy the slab.", "Once the general shape has been achieved, it's time for the detail work.", "The sculptor measures the plaster prototype with a tool called a pointing machine.", "He transfers the measurements to the marble sculpture, ensuring that all the details will be to the correct scale.", "Of course, pointing tools can only show the artist whereto carve-- there's no substitute for skill.", "With a pneumatic chisel, the artist shapes the foot of the figure.", "Next, the artist switches to a series of rasps and files, so he can shape the smaller details and eliminate any chisel marks.", "The fingers require a gentle approach.", "They're delicate and could be broken easily.", "It takes about four months for a sculpture to go from the rough form to the finished.", "And now for the final touches-- he rubs oxalic acid into the marble.", "This seals it and protects it from stains, but also gives the sculpture a polished look.", "The result is a translucent effect that gives the sculpture visual depth.", "Like ghosts in the attic, there's an incredible array of plaster casts on this studio's upper floor.", "Many of them are replicas of famous classical works.", "They're all on standby to serve as prototypes for sculptural reproductions.", "And once these images are carved in stone, they should live on forever." ]

{ "things": [ "Bowling Balls", "Barber Poles", "Felt", "Radar Guns" ] }

[ "The bowling bowl has undergone a lot of changes over several centuries to become such a striking success.", "From a crude stone to carved wood to rubber to molded polyester, it's been reinvented numerous times.", "But the latest version has turned out to be a real winner.", "Technological advances have reshaped the bowling ball at its very core.", "No longer round, the nucleus is asymmetrical, which causes the ball to curve towards the pins as it rolls down the lane.", "They make the cores from polyester resin, blending in minerals like barites, silica powder, and limestone.", "The result looks like chocolate milk, or make that hot chocolate, because a catalyst triggers a chemical reaction that heats it up.", "As they pipe it into the molds, it quickly starts to cure and solidify.", "In just two minutes, it's ready to extract.", "This core is oblong-- flat on one side with a knob.", "There are different versions of this core design, each one carefully calculated to manipulate the bowling ball's performance at a specific skill level.", "They now drill toward the center of the core to make a pinhole.", "This allows the core to be suspended in just the right position in a second mold.", "This asymmetrical core is about to be encased in a more uniform sphere.", "They tamp the core into the bottom part of the mold and then lock down the top half.", "After all, they don't want any leaks as they pump it full of plastic.", "It's a liquid-polymer blend.", "A special chemical in it causes the mix to solidify slowly.", "It can take days for it to harden around the core, depending on the formulation and type of bowling ball being made.", "When they knock it out of the mold, all is revealed.", "That asymmetrical core is now sealed in a very symmetrical polymer shell.", "Next, it's into a third mold.", "This one will seal the bowling ball in an outer skin called the veneer.", "This veneer has been scientifically formulated to enhance the ball's traction as it hooks towards the bowling pins.", "It's made of colorant, plasticizer, a chemical called i.s.o., and urethane.", "Blending these ingredients produces high-performance polyurethane.", "As the mix flows into the molds, a chemical reaction causes it to heat up and solidify in just seconds.", "Then it's into an oven to boost the chemical reaction.", "Next, a spinning grinder shaves off the bump, which was formed by overflow at the mold's intake tube.", "The removal of this bump rounds off the shape of the bowling ball.", "With its three layers, this bowling ball looks a bit like a big bonbon when it's sliced in two.", "And while it may look sweet, it needs a bit more work before it's ready to take on the competition.", "A lift system delivers the bowling ball to a sanding operation, which roughs up the surface.", "The coarseness of the sanding varies, depending on the performance goals of the particular ball.", "This machine heat-stamps trademark information onto the ball.", "They do one last sanding, as a constant flow of water removes the powdery residue.", "The more polished the surface, the less pronounced the ball's hooking action will be.", "Even this last sanding is geared to a certain performance standard.", "Once they buff the surface, all that's left is to custom-drill the finger holes.", "With this bowling ball in hand, success should be within striking distance.", "Barber poles go back to a time when barbers also performed surgery, tooth extractions, and bloodletting.", "Some believe that the idea for the red and white strips came about because of bloody and clean bandages that twisted together in the wind as the customer held onto a pole during a procedure.", "Over time, barber poles have come to lose their gruesome connotation but not their place as an historic symbol.", "There's only one company left in north america that makes them.", "They begin by rolling a printed liner onto a wooden mandrel.", "The mandrel they use depends on the size of the pole they're making.", "Using a knife, they score the liner at both ends.", "The liner is made of paper and vinyl treated with u.v. protection to prevent it from fading.", "Scoring the liner helps guide the worker as he trims the familiar red-white-and-blue material to the required length.", "Next, he rivets the company logo to a support frame.", "Then with bolts, he attaches a top and bottom support casting.", "The frame and castings are made of aluminum, so they're virtually rustproof, which is a big plus since barber poles have to weather the elements.", "After ensuring the assembly is level, they install the glass cylinder, which can be made out of extruded or handblown glass.", "After a final tightening, they double-check that everything fits snugly.", "Next, they add water to a special caulking powder and mix it to a smooth consistency.", "The caulking must be just the right thickness to properly fill the cavity between the aluminum casting and the glass cylinder.", "Five minutes later when the caulking is dry, they carefully trim off the excess on both ends of the cylinder, leaving behind a smooth, watertight seal that helps secure the glass cylinder in place.", "Cleaning the glass by hand is just another example of all the artisanal handiwork that goes into making these time-honored barber poles.", "Next, they mount the assembly on a hook and paint the caulking with a colored sealer that matches the casting and makes the caulking waterproof.", "After that, a worker puts in a motor mechanism.", "The motor will rotate the printed liner inside the glass cylinder.", "Once the motor is hooked up, he takes an inner cylinder, which has the printed liner mounted on it, and installs it on top of the mechanism that makes it rotate.", "He then installs a two-socket light fixture with a bulb that illuminates the liner.", "To keep the printed liner straight as it turns, he then attaches what's called a top-cylinder bushing.", "All that's left to complete the pole is to attach a rustproof aluminum cover and the second light bulb that lights up the white glass globe.", "Finally, he hooks up the pole to electricity and makes sure the motor, both lights, and the inner liner are working properly, creating the illusion of movement.", "Modern barber poles come in various sizes and styles, with or without illuminating globes, but they always keep their link to the past.", "When production hits a snarl at the felt factory, things are going well.", "That's because felt is made by entangling fibers into a matted material.", "Felt has actually been around for thousands of years and may be the first fabric ever produced.", "These days, mechanization puts a new twist on felt.", "Boot liners are an example of the way felt layers our lives.", "They begin with bales of polyester fibers.", "Sometimes they add wool or synthetic fiber.", "This machine is about to sink its teeth into those fibers.", "It's a rotating bed with hundreds of fierce-looking spikes protruding from it.", "An operator loads the bales of fibers onto a feeder conveyor.", "It shuffles the clumps toward that spiked conveyor, which snags the fibers and takes them up to another spiked rotating belt.", "But this one moves in a different direction to grab and pull the short, springy fibers apart.", "The process fluffs and blends the fibers, transforming the dense clumps into something that's the consistency of cotton wool.", "Now that the fibers have been loosened up, it will be easier to extract any metal bits that may have contaminated the bales early on.", "A magnet pulls out these contaminants, which would otherwise cause damage to equipment down the line.", "With the metal bits removed, the fibers move into another machine.", "This one has a series of pinned rollers that are close enough to almost touch.", "They rotate in different directions to align the fibers.", "This creates a uniform web of fluff.", "Then it's over to the cross lapper-- a system of conveyors that move back and forth to neatly fold it up.", "They then travel between rollers, which squeeze several layers down to a thickness of a little more than a centimeter.", "10,000 long needles repeatedly stab the compressed web to entangle the fibers.", "Each needle is equipped with nine barbs to snare the polyester fibers.", "This process is how they become enmeshed.", "It transforms the compacted fluff into felt.", "Rollers pull the matted material out of the machine...", "As they wind it onto a big roll.", "You can see that the fibers are now a solid mass.", "Next, they layer two piles of felt onto a metalized nylon film.", "This shiny film will reflect the outside cold, and the three layers combined will provide extra thermal protection that will even insulate against arctic temperatures if need be.", "More long needles punch into the three layers and entangle the fibers to create one sheet of material.", "It's a form of laminating without glue.", "The needles leave little holes in the reflective film that improve the breathability of the fabric.", "Next, a worker uses a 25-ton press to punch boot-liner patterns out of the felt.", "The press bears down on dyes that cut out various-sized insoles and boot-liner sidepieces.", "This felt is now ready to add a little warmth to someone's life.", "All they have to do is sew the parts together.", "The seamstress stitches the two sidepieces, using an industrial machine with needles that easily penetrate the thick, stiff felt.", "The top of the boot liner is finished.", "But without its sole, it's incomplete.", "They sew the felt sole onto it with a neat loop stitch-- the only stitch that would hold this configuration together.", "From a pile of synthetic fibers to a rigid liner that's ready to protect you against the elements, it's been quite a journey, and it's far from over, as felt continues to keep its foothold in the world of layers and liners.", "If you see one of these, it's likely connected to the long arm of the law.", "Police have been using radar guns to nab speeders ever since the 1950s.", "They bounce radar off your vehicle and analyze the returning signal to get a reading, and that's when sirens wail and the officer says, \"do you know how fast you were going\"?", "If you're a speeder, the police have probably got your number, thanks to the radar gun.", "When operated properly, radar guns boast an accuracy rate of plus or minus half a mile per hour.", "But of course, you can always try arguing with the officer.", "Making a radar gun starts with cable wire-- lots of it.", "Rollers straighten it, then automated blades cut it to length and strip the plastic casing at both ends.", "With the wires now exposed, they're ready for the metal contacts that will allow wiring interconnections.", "A technician places the exposed wire in the contact, and a machine crimps them together.", "They then assemble wires in various harnesses.", "These connect to a power cable and communications port.", "The technician inserts wires into a plastic connector to allow them to easily hook into a circuit board later.", "This little gadget is a microwave transmitter and receiver.", "It sends radio-frequency energy to moving vehicles and then receives it when it bounces back.", "The red wires being soldered to its post will deliver power to it.", "The white ones will return the radar signals.", "This special plastic lens will focus the radar beam.", "She attaches the transmitter-receiver unit to the funnel-shaped antenna at the back of the lens.", "Next, she solders wires to a circuit board.", "Some will carry power to it.", "Others will deliver the returning radar signals for analysis.", "This second smaller circuit board will process power from the police vehicle to operate the radar gun.", "And an insulated metal plate shields the unit from interference from things like the police radio.", "The technician secures it with cable ties, and this radar module is now complete.", "She moves on to the display and control panel and snaps the keypad onto a little circuit board just below a light-diffusing display window.", "She inserts the control-panel hardware into a plastic faceplate and secures it with screws.", "As another safeguard against electrical interference, this plastic faceplate has been infused with metal.", "He wires the control panel to the power board to run a test.", "He checks all the digits and icons to confirm they display correctly.", "This machine presses melted plastic into the shape of casing for the radar gun.", "A static discharger worn on the wrist dissipates any static electricity from the technician's body.", "This prevents damage to sensitive electrical components, so it's worn throughout the assembly process.", "She links the two computer boards, ensuring a good connection, because one will power the other.", "Then she installs the radar gun in the molded casing.", "She plugs the display assembly into connectors on one of the computer boards.", "Then she slides it into grooves in the casing.", "Now she hooks up this radar gun to a power source for a trial run.", "She taps the lens with a tuning fork.", "The gun responds to it as it would to a moving vehicle.", "If it functions properly, she installs the trigger switch.", "She closes the radar gun, securing the two-part casing with screws.", "A serial number and other identifying information goes on the side.", "In a final test, she connects the radar gun to a computer and aims the lens into a chamber.", "The chamber sends signals to simulate the effect of a moving vehicle, and the computer analyzes the gun's performance.", "You only have to look at a 35-year-old radar gun to see that this technology has come a long way.", "So it's ready if you try to pull a fast one." ]

{ "things": [ "Brushes and Push Brooms", "Blackboards", "Smoked Salmon", "Zippers" ] }

[ "Today on \"how it's made\"...", "Brushes and push brooms...", "Blackboards...", "Smoked salmon...", "And zippers.", "Nothing scrubs or sweeps quite like a good, sturdy brush.", "Cleaning brushes in north america date back to about the 1830s.", "Their bristles were usually made of wire twisted into wood.", "Today we have many different bristle materials, both natural and synthetic.", "The first factory manufactures the brush block-- the hardwood base that holds the bristles.", "It's usually made of maple, but sometimes oak or beech.", "After cutting the planks to the required width, they use a special wax crayon to mark lines on both sides of any cracks or knots in the wood.", "A laser then reads the marks, guiding a saw to cut out the faults.", "At the same time, the saw chops the planks into block-size lengths.", "The next step is called \"molding\".", "A series of saws trims the blocks to the required thickness.", "Now they contour the pieces, using a machine appropriately called a shaper.", "The machine revolves, running the block's outside edge against a cutting head.", "This profiles half the block.", "Workers then turn it around and line it up for a second pass to profile the other half.", "There's a different shaper machine for each model.", "This type is known as a dauber-- a brush for waxing shoes.", "For the cuts to be accurate and smooth, it's essential that the machine's cutting heads remain sharp despite repeated use.", "That's why they're made of carbide, a material stronger than steel.", "Workers run certain models against an extra cutting head to carve a groove in the block's edges.", "The groove gives your hand a better grip on the brush.", "These 2 1/2x24\" blocks will become push brooms-- those wide, rectangular brooms janitors use to sweep floors.", "The blocks go to an automated machine that drills a hole through the middle and carves two grooves in the underside.", "These are for the steel adapter that will hold the broom's wooden handle.", "Rounded push brooms sweep more easily in corners.", "To produce those, workers take the rectangular push broom blocks and round the corners against a cutting head.", "At another factory, the blocks go onto a machine that pierces holes for the bristles, using a computer-guided drill.", "This particular model of push broom needs 240 holes.", "It takes barely a minute to drill them all.", "Next, the blocks go to the bristle-installation machine.", "Bristles can be made of horsehair, vinyl, plants or tree leaves, or synthetics such as polypropylene.", "The bristle-installation machine is fully automated, as we see here in slow motion.", "It takes about 40 strands at a time, folds them in half, then inserts and staples them into a hole.", "Here's what that bristling action looks like at actual speed.", "The machine fills four holes per second.", "The factory uses this same process regardless of the style of brush block or type of bristle.", "Computer software guides the machinery to follow the correct pattern, making possible a sweeping array of brushes and brooms.", "Chalk one up for the blackboard.", "This trusted teaching tool goes back centuries, yet still remains the focal point of the classroom.", "Today's blackboard-- or chalkboard, as it's also called-- hasn't changed that much in appearance, but the materials used to make it have changed.", "Our lesson begins at the blackboard factory, with thin sheets of galvanized steel.", "These will eventually form the front and back surfaces of the blackboard.", "They arrive at the factory already precut to standard sizes-- 6, 8, 10, or 12 feet.", "First stop is a machine that blasts the sheets with acid.", "This removes any dirt that would prevent paint from adhering to the surface.", "As the sheets exit the cleaner, powerful fans dry them off.", "The paint is a type of acrylic enamel designed especially for blackboards.", "The factory adds a powdered mineral formulation to make it dry to a rougher texture.", "This helps chalk adhere better.", "Traditional slate blackboards were naturally black.", "Today's steel-surface boards come in several colors.", "The most popular, though, are black and green.", "Some companies use colored porcelain instead of paint.", "Here, spray guns apply three coats of paint, one after another, with no drying time in between.", "For the paint to harden properly, it has to be heat-set, so the sheets go into an oven at 420 degrees fahrenheit for 10 minutes.", "A strong fan cools them off as they exit the oven.", "Next, a worker sprays contact cement on the backs of two painted sheets.", "One sheet will form the front of the board, the other, the back.", "Sandwiched in between will be what's known as the blackboard's core.", "It can be made of materials such as particleboard or, as we see here, 1/2-inch-thick fiberboard.", "Workers feed the three assembled layers through a high-pressure roller.", "It forces out any trapped air and bonds the layers tightly.", "They make the blackboard's frame out of one long strip of aluminum molding.", "It has a stainproof satin finish.", "They make a series of 45-degree-angle cuts.", "This enables them to bend the strip around the board's perimeter, creating neat corner seams.", "Workers file down and polish any sharp edges left by the cutting.", "After verifying that it's perfectly square, they fasten the frame, using either rivets or screws, depending on the model.", "Then, they attach an aluminum rail along the bottom to hold the chalk and erasers.", "This model happens to be a reversible mobile blackboard-- the type typically rolled into conference rooms.", "It has a few extra components-- a pivot mechanism, enabling the board to be flipped to the other side...", "And a latch system for tilting the board to different angles.", "The blackboard stand is made of painted steel tubing.", "It rolls on rubber- and chrome-plated steel castors.", "The factory takes samples from the production line and subjects them to rigorous quality-control testing.", "These tests ensure that the painted surface is glare-free and can withstand everything from chemical solvents and extreme humidity to heavy impact and hard scratches.", "The company has even designed this special machine to conduct a killer durability test.", "It applies 100,000 chalk and brush strokes, using the typical amount of pressure a person would use.", "For the production batch to make it to market, surface wear on the sample has to amount to less than 1/100 of a millimeter.", "And that's not all.", "The paint finish must still be matte.", "A writing test has to produce chalk lines that are clear and dark enough, and the writing has to erase cleanly and easily.", "For thousands of years, smoked fish was a survival food.", "People would cure their catches by salting them and hanging them to dry or by smoking them over an open fire.", "This enabled people in cold climates to stockpile nutrient-rich fish for those long winter months.", "Today we smoke fish primarily to enhance its flavor.", "This is wild sockeye salmon that was gutted and frozen on board the fishing trawler to preserve maximum freshness.", "The smokehouse defrosts the fish for over 15 hours in running water that's just 2 degrees above freezing.", "This slow, cold water thaw helps prevent bacteria from forming.", "Next step, filleting.", "First, they slice off what's known as the collar-- the fish version of a neck.", "Then, they cut each fish in half lengthwise, separating two fillets from what's called the control bone-- the fish equivalent of a spinal column.", "The tail is attached to it.", "They feed the control bones into a machine that strips off any remaining scraps of flesh.", "The machine grinds these bits into minced salmon, which is used to make salmon pie.", "They trim the fillets using a razor-sharp knife, slicing off the fins, any excess fat, and any control-bone fragments left behind.", "After this, the fish will be ready for curing-- a preservation process that also enhances taste.", "Workers coat the fillets in a mixture of salt and 26 spices, then let them sit for roughly an hour and a half.", "This short cure time will limit the salmon's salt content to less than 1%.", "To stop the curing process, they rinse off the coating with cold water, then glaze the fillets with maple syrup to neutralize any remaining salt residue.", "Some companies use a less costly mix of boiled water and brown sugar.", "The fillets go into a huge smoke oven.", "Workers load its combustion chamber with sawdust-- maple-tree sawdust for the first 8 hours of smoking, cherry-tree sawdust for the next 8 hours, and apple-tree sawdust for the last 8 hours.", "This particular sequence is a major factor in flavoring the fish.", "They douse the fire with water to generate smoke.", "This process is called \"cold smoking,\" because the oven temperature is 50 degrees fahrenheit-- significantly lower than the industry norm of 77 degrees.", "Smoking at this lower temperature takes at least 24 hours-- 3 times longer than the norm-- but the company says it produces a moister product.", "When the fillets come out of the smoke oven, they're thoroughly cooked but still have the consistency of raw fish.", "Workers remove the fin bones-- 40 fin bones per fillet-- located between the head and fin.", "The fillets then go through a skinning machine, which neatly slices off the skin without removing any flesh.", "Then, it's into a freezer at 27 degrees fahrenheit.", "This firms up the fillets, making them easier to slice.", "The manual slicing machines cut them into pieces about 1/10 of an inch thick.", "Workers weigh out the amount they're packaging-- in this case, 2 1/2 ounces.", "They place each portion on a tray made of aluminum-coated cardboard.", "Aluminum blocks the fat from seeping through.", "To kill off any remaining bacterial, they vacuum-pack the wrappers, then deep-freeze them for about an hour at negative-31 degrees fahrenheit.", "They store and ship at a milder zero degrees-- the temperature of your home freezer-- where this preservative-free smoked salmon stays fresh for a full year.", "Zippers can be found on clothing, on bags, even on footwear.", "The zipper started out as a closure mechanism for boots and tobacco pouches.", "The fashion industry didn't put them on clothing until the 1930s-- some 80 years after the invention of this fabulous fastener.", "An american, elias howe, was the first to patent a zipperlike clothing fastener in 1851, but he never ended up marketing it.", "It wasn't until 1893 that another american, whitcomb judson, designed a similar device, called a clasp locker.", "He eventually hired a canadian engineer, gideon sundback, to simplify the original complex design, which had never really taken off.", "In 1917, judson and sundback patented the modern zipper.", "Zipper teeth are made of metal, plastic, or nylon.", "The fabric part of the zipper is called the tape.", "It's usually polyester, but sometimes cotton or fireproof fabric.", "To make metal zippers, the factory feeds a long, continuous roll of tape into what's called the teeth machine, along with a long roll of metal ribbon known as \"flat wire\".", "As we see here in slow motion, the machine cuts off a tiny piece of flat wire, forces it through a die that forms into a tooth shape, then clamps it onto the edge of one side of the tape.", "The machine does all this at a rate of 45 teeth per second.", "These zipper teeth are aluminum.", "Sturdier zippers are made of stronger metals like brass and nickel.", "Depending on the model, teeth can range in width from about 1/10 of an inch to 4/10 of an inch.", "The wider the teeth, the thicker they have to be.", "Workers now feed two tapes with metal teeth into what's called the joining machine.", "The teeth interlock, meshing the two halves of what's now a continuous zipper.", "From there, it's into a cleaning machine, which washes the zipper, removing any shards of metal left behind by the tooth-cutting process.", "After drying the zipper, the machine applies a coat of hot wax.", "This lubricates the teeth so the slider will glide over them smoothly.", "Next stop is the gapping machine.", "It removes a 2-inch-long section of teeth at regular intervals.", "They'll later cut the tape at these gaps, dividing the continuous zipper into several shorter zippers.", "There are two main types of zippers.", "Closed-end zippers are the kind whose two halves don't separate at the bottom when opened-- purse zippers, for example.", "These need a part called a bottom stop-- a thick piece of flat wire positioned at the base of the zipper.", "When you unzip, it stops the slider and prevents the two halves from separating.", "Open-end zippers are the kind whose two halves doseparate at the bottom when opened-- jacket zippers, for instance.", "At the bottom of these zippers, a machine applies a clear reinforcement strip.", "This stiffens the tape so that the next machine can apply the pin and box.", "The pin is that vertical piece of metal on one half of the zipper that you have to align in the box on the other half before you can pull the slider to zip up.", "The next machine installs the slider.", "Watch in slow motion as it opens each gap and hooks a slider onto the track of teeth.", "The next machine inserts what's called the top stop-- a thick piece of flat wire that stops the slider at the top of the track when you zip up all the way.", "The machine then slices the tape at each gap, separating the finished zippers.", "Plastic zippers are made quite differently than metal ones.", "The tape is the same, but the teeth are made from plastic pellets.", "A machine melts them, then injects the liquid plastic into a mold that's the shape of a strip of zipper teeth.", "The mold cools almost instantly, hardening the plastic.", "The machine then stamps the teeth onto the tape, automatically gapping the desired zipper length at the same time.", "The excess plastic in the middle is remelted.", "There's no joining machine to mesh the two halves of plastic zippers.", "Workers do this manually so that they can inspect the plastic teeth to make sure they're well formed.", "Then, automated machines install the remaining components." ]

{ "things": [ "Pressed Glass", "Pickup Truck Caps", "Alpaca Yarn", "Utility Knives" ] }

[ "Today on \"how it's made\"...", "Pressed glass originated in 19th century america and england, and it revolutionized glassware.", "It offered the look of crystal on a budget, adding elegance to a humble meal.", "It became known as \"poor man's crystal\".", "Today, this affordable glass still has class.", "Pressed glass or cut crystal...", "Invented in the 18th century, pressed glass can still impress company and keep them guessing.", "Pressed-glass ingredients include lime, sodium nitrate, soda ash, silica sand, mineral or chemical colorants, and leftover or rejected glass from the factory.", "They melt the ingredients in a furnace heated at over 2,900 degrees fahrenheit.", "A worker twirls a rod with a ceramic bowl on the end into it, and the hot liquid glass clings to it.", "Then it's ready for transfer to the iron mold.", "When the mold is partly full, a worker snips the liquid glass with scissors to cut the flow.", "He places a ring with pegs on the rim to align the mold with a plunger.", "He lowers the plunger and applies physical pressure to a lever to squeeze the glass into every crevice.", "This transforms the glass blob into a berry bowl with elaborate impressions on the outside.", "As it cools, the bowl hardens just enough to be extracted, but it's still quite soft.", "Careful to not distort the shape, he transfers the bowl to two bricks.", "A hose below the bricks pumps air to cool the glass further.", "Over a period of four hours, the team makes 250 berry bowls.", "Some of the bowls will be flattened to turn them into dessert plates, while others will be worked into the shape of candy baskets.", "Once the glass has firmed up enough, the bowls take a couple of trips through the glazer, first upside down, and then right side up.", "A gas flame melts the outer layer of the glass to make it shine both inside and out.", "He clamps the bowl onto the end of a rod called a snap, and places into a second smaller furnace briefly.", "This softens the glass to prepare it for another transformation.", "Still clamped on the rod, a worker spins the bowl.", "With a stick of wood, he applies pressure to the upper part to flatten and flare it out.", "He then draws the piece between two pipes to bend the sides upward.", "The pressed-glass berry bowl has now become a candy basket, but baskets need handles, so it's back to the furnace to gather more glass.", "He collects a little less this time.", "He moves the molten glass around on a metal table to roll it longer.", "He inserts it in a mold that gives the glass a rib pattern.", "He heats the glass in the furnace one more time.", "Soft and sticky, the glass handle adheres to the basket.", "He pulls the handle longer as he twirls the basket, and then attaches the other end of the handle to it.", "The handle is a bit saggy, so before it cools, he improves the shape using an iron roller.", "As he works the glass, he pulls the handle up and makes it more well-rounded.", "Unclamped from the gathering rod now, he smoothes the outer surface of the handle and tweaks its shape until satisfied.", "Using a torch, he melts the glass a bit where the handle meets the basket to improve the adhesion.", "And now it's over to the oven.", "Here, the pressed glass is heated and then cooled to room temperature over a period of three and a half hours.", "This gradual heating and cooling is critical.", "It releases stress in the pressed glass to make it less likely to shatter.", "For generations, molds have been used to mass produce pressed-glass pieces that can look like expensive crystal.", "With all that practice, they have this down to a fine art.", "Some works are reproductions of vintage pieces, others are new patterns.", "The appeal is timeless.", "Pickup trucks are ideal for transporting tools and materials, but often these items have to be covered and locked away to protect them from the elements and theft.", "That's why many pickup owners install caps, hard top covers typically made of fiberglass or aluminum with optional built-in storage.", "This truck cap is made of durable fiberglass and is designed to fit every full-sized pickup on the market.", "A truck cap has to be both practical and attractive, so it first takes shape on a car designer's sketch pad.", "Engineers use computer software to translate the design sketches into technical drawings for producing several molds, one for each of the various parts of the truck cap.", "The first step is to wax the mold's surface, so that the truck cap part will extra easily.", "The mold is made of colored fiber glass to contrast the white materials they'll apply to it.", "The first of those materials is gel coat, a polyester resin that produces a smooth and shiny finish on fiberglass.", "They spray on a half millimeter thick coat.", "The beauty of gel coat is that a nick or crack can be easily repaired with a bit of grinding and filling.", "So the truck cap's surface can always be restored to an impeccable state.", "The gel coat cures in about 45 minutes, at which point they begin shooting chopped up fiberglass that's impregnated with resin.", "They compress this new layer with rollers to about five millimeters thick.", "Roughly two hours later, the resin has hardened and it's time to use special extraction jacks to remove the now solid roof from the mold.", "They repeat this same molding process for all the other parts.", "Because this particular truck cap model has double doors on both the back and side, there are 10 different parts to mold.", "A robotic circular saw trims each molded part.", "This is the truck cap's air deflector.", "The saw blade has diamond particles affixed to its edge, enabling it to cut the fiberglass without shredding it.", "By the time the robot finishes trimming, the part meets exact specifications and has neat, smooth edges.", "With all the parts ready now, it's time to assemble the truck cap.", "First, they unite the roof and the universal fit base.", "Both slide into an aluminum trim.", "Workers clamp them in position from the inside.", "Next, as required by motor vehicle regulations, they install brake lights at the top of the rear doors.", "Then, on the right-side rear door, they mount a chrome-plated door handle.", "The plating has been treated with an anti-corrosion coating.", "For the sake of convenience, the door handle lock is designed to work with the truck's ignition key so the driver doesn't have to carry around a separate key for the cap.", "The doors mount with sturdy hinges is made of stainless steel, which is rust resistant.", "Next, using a template to get the positioning just right, they glue the company and model name logos to the right rear door.", "For aesthetics, these plastic logos are chrome plated to match the door handle.", "After mounting the doors, they install gas struts on each door to provide resistance to control the door swing.", "Workers also install a pair of three-foot-long l.e.d. lights.", "They're on a magnetic switch, turning them on and off when the doors open and close.", "Once it's fully assembled, it undergoes a thorough inspection.", "A truck cap weighs about 660 pounds, so you need a mechanical lift to mount it on a pickup.", "It affixes with four tie-down levers that hook under the rails, running down the interior sides of the truck so there's no chance of the cap lifting off.", "Before shipping out to the customer, every truck cap goes through a water test, subjected to a torrent for three minutes straight to make sure no water leaks inside.", "Truck caps can be ordered with a pull-out cargo bed, shelving, storage bins, and other features, transforming an ordinary pickup truck into a workshop on wheels.", "What's warm, soft, water repellent, and, as an added bonus, hypoallergenic?", "Something made of alpaca yarn.", "Similar to sheep's wool, it's smoother due to the scale structure of the individual fibers.", "And it doesn't contain lanolin, a natural wax in sheep's wool to which some people are allergic.", "Alpacas come in 22 different colors, ranging from pure white through various shades of beiges, browns, and grays, to pure black.", "Breeders shear their alpacas and sell the fleece or send it to mills for processing into yarn.", "White fleece is in greatest demand, and it can be dyed any number of colors.", "Before sending out the fleece, the breeders pull off hay, leaves, and other stuck-on vegetation.", "When the fleece arrives at the mill, it undergoes repeated washes with natural soaps until it's pristine.", "After the fleece air dries, a conveyer belt feeds it into the picker.", "The machine's tooth drum pulls apart the clumps, a process called \"opening the fibers\".", "The drum then shoots those fibers into a compartment called the picker closet.", "Once all the fleece has been opened, they turn off the machine and spray the fluffy fibers thoroughly with a blend of conditioners.", "These conditioners are left to absorb overnight to reduce static electricity the next step generates.", "The fiber separator combs the fibers with a series of fine tooth rollers.", "This simultaneously straightens the fibers and separates them by grade.", "The first set of rollers removes any remaining bits of vegetation, while the second set removes coarse fibers so that only very fine fibers exit the machine.", "The next step is to divide these fine fibers into bundles of equal weight.", "The set weight varies according to the grade of fiber that the next machine, the carder, will be processing.", "A fine fiber requires heavier bundles.", "The conveyer belt feeding the carder is marked in sections.", "They place one bundle in each section.", "This steady, even input ensures that the machine produces a consistent output.", "Inside the carder, a series of combs spreads the fibers over a drum, aligning them parallel to each other.", "This produces a thin, flat layer of fine fiber called web.", "Web can be stacked in several layers to make batting, the stuffing material in quilts and duvets.", "Batting can be further processed into felt.", "Web can also be processed into roving, a long thick stream of fiber which crafts people hand spin into yarn, or which high-speed machines here at the mill spin into store-bought yarn.", "The roving deck on the carder compresses the web into a stream while rotating it to hold the aligned fibers in a snake like shape.", "To make what's known as woolen yarn, the roving goes directly to the spinner.", "However, to make what's called semi-worsted yarn, this machine, called a draw frame, must first combine two or more rovings into a consistent stream called a sliver.", "The thinner the yarn, the more often the rovings pass through the draw frame.", "Finally, several slivers simultaneously enter the spinner, which twists each one separately through a combination of pressure and speed.", "The next machine, called the plyer, then forms the yarn by twisting multiple singles together in the opposite direction.", "Twisting two singles, for example, makes a two-ply yarn.", "The mill produces different weights of yarn from lace to bulky, by varying the volume of fiber per ply, as well as the spinning speed.", "They mount the spools of finished yarn on the skein winder.", "A skein is a bundle of yarn that's first wound then twisted.", "They set the machine to wind a specific length of yarn.", "When it stops, they tie the skein on two ends and remove it.", "Then they dye the yarn or leave it its natural color.", "Some mills dye their fleece after washing, prior to processing it into yarn.", "The final step is to hand-twist the skein.", "They also wind yarn into balls and cones.", "Warm and water repellent, this silky, smooth alpaca yarn is all set to be knit or woven into a cozy woolen.", "The utility knife is known by many other names-- carpet knife, box cutter, sheet-rock knife, and craft knife are just a few.", "All those names reflect the many uses for this retractable knife and its incredible versatility.", "It comes in handy every time.", "In 70 years, the design of this retractable utility knife hasn't really changed much.", "Why mess with a concept that works?", "A hollow case with an interlocking nose for the blade, held together by a single screw.", "It can be easily unscrewed to access spare blades inside.", "To make the blades, carbon steel uncoils into a die press.", "A roller takes up the slack as the steel inches forward for each forming.", "The press scores the steel to rough out the shape of the blades, punches notches for attaching them to the handle, and stamps product information onto them.", "At this point, the steel is just a little stiffer than tin foil.", "A trip through a 25-foot-long furnace toughens it up.", "Exposed to scorching heat and then quenched by water, the steel hardens significantly.", "After the brand name has been printed on the steel, the ribbon of blades rides through a grinding station with different stone-grinding wheels.", "They sharpen the steel edge.", "The steel now passes under an induction coil that radiates heat to further harden the cutting edge.", "A machine called the breaker snaps the steel along the score lines.", "It spits out the unwanted triangular bits between the blades for recycling.", "The blades flow out of the breaker and into a steel channel.", "A pusher moves them down the channel into a tray.", "This system snaps and packs 250 blades a minute.", "They insert one blade from every production run into this tester.", "The tester moves the blade back and forth repeatedly to slice through thick stacks of paper strips.", "This gives them a measure of the blade's sharpness and durability.", "The transformation from blunt metal to razor sharp blade is complete, and the utility knife blades are ready for the gripping part-- the zinc case.", "They cast the back and front of the case in a die.", "The parts then bounce around in a vibratory bowl along with pyramid-shaped ceramic rocks.", "The friction smoothes the rough edges.", "After about a half hour in the vibratory bowl, the casing parts are blemish free.", "They head into the next station.", "Here, workers collect them and examine them for defects as they hang them on moving racks.", "The racks will take the utility knife parts through a wash station to get rid of a dusting of zinc and ceramic residue.", "It's kind of a power wash for the knife case parts.", "They ride by a high-pressure sprayer for a thorough cleaning.", "After that, they take a trip through a dryer to prepare them for a powder coat finish.", "Once the powder coat is baked on, it will protect the zinc utility knife from corrosion.", "The powder coat gives the utility knives a finish that's tougher than conventional paint.", "Heading into the unload station now, a blast from an air gun knocks the parts off the rack.", "Thanks to the tough finish, they land without a scratch.", "The utility-knife parts are ready for assembly, and the worker uses a special fixture for that.", "She places the bottom half of the knife in a recess in the fixture.", "Handling the blunt side of the blades, she inserts three of them into the case's storage compartment.", "She also tucks the tab of an information card into it.", "Next, she installs the retractable mechanism for the utility knife blades.", "She places the other half of the case on the assembly and then actuates an auto-screw gun to close the knife.", "They assemble over 40,000 utility knives per day at this factory.", "Now, that's cutting edge." ]

{ "things": [ "Deep Cycle Batteries", "Tins", "Optical Lenses" ] }

[ "Today on \"how it's made\"...", "Deep-cycle batteries...", "Tins...", "And optical lenses.", "A deep-cycle battery is what you find in such vehicles as trains, boats, r.v.s, and forklift trucks.", "Whereas a car battery provides a quick surge of current to start the engine, a deep-cycle battery provides a steady amount of current over a long period of time.", "Deep-cycle batteries range from 2 to 48 volts.", "Their power is generated by cells, a group of lead plates coated in lead oxide and acid.", "This casting machine produces lead grids that will become the plates in the power cells.", "The machine pours molten lead into grid-shaped molds.", "Water circulating through the mold hardens the metal in just five seconds.", "The machine casts two types of grids-- negatives and positives.", "The next machine coats the grids with a chemical paste that contains lead oxide and acid.", "The positives get one paste formulation.", "The negatives, a different one.", "The grids are now called plates.", "Workers stack them in cases, alternating positive and negative, then drop them in tanks of sulfuric acid to charge.", "The lead oxide and acid in the paste store the power.", "After charging for 24 to 72 hours, depending on the model, the plates go into a machine that washes them three times to remove acid residue, which, if left, would corrode the metal.", "The charging process blackens the plates, which are now called dry-charge plates.", "A machine wraps each positive in glass-strand matting, an insulation material similar to fiberglass, then in a plastic envelope.", "These coverings protect the plates from short circuits.", "Workers stack the plates again-- positive, negative, positive, negative.", "This time, though, each stack contains a specific number-- from 5 to 33 plates, depending on the battery model.", "Each stack will become one cell.", "A cell provides 2 volts of electricity.", "Each plate has a tab.", "A robotic machine cleans the tabs with a wire brush and a chemical solution called flux.", "Then it dips the tabs in molten tin.", "This tin coating will improve the bond when they solder the tabs together.", "The robot wipes the tabs on a flux-imbued sponge to clean their surface once again...", "Then drops the cells into a mold containing molten lead.", "This solders the tabs together, bonding the plates within each cell.", "The process casts two lead posts on the cell's positive side and two on its negative side.", "These posts will connect the cells and build the required voltage.", "Next, each cell goes into a polypropylene casing called a jar.", "They test each cell to make sure it functions.", "This also shows if the cell is positioned correctly in the jar so that the positive and negative signs on the cell cover will be on the corresponding posts.", "They heat-seal the cover and seal the protruding posts with lead.", "To test the seals, they pump air into the cell, then brush soapy water over the cover.", "Any bubbles indicate a gap to be resealed.", "In another part of the factory, workers manually mold various small components from molten lead.", "Among those parts-- the connectors that link one cell to another.", "Workers weld them to the posts.", "These are 8-volt batteries, so for each one, they connect four cells inside a polyethylene case.", "Now that assembly is complete, the case cover goes on.", "These rubber grommets keep water from seeping inside and shorting the battery.", "Now they fill the inside with sulfuric acid, which functions as an electrolyte, the medium that helps the lead in the plates conduct electricity.", "The tin can was invented back in the 1800s to preserve and protect.", "We still rely on this trusty container to keep a range of perishables fresh-- everything from food to blood plasma to military supplies.", "And after all these years of use, the tin can still has an airtight reputation.", "It's time to lift the lid on this traditional container and get the inside story from the factory.", "To make a tin, they take a strip of tin steel and weld it to join the ends.", "The resulting cylindrical shape is the body of the tin, and it's about to be hermetically sealed.", "The rotating tools on this machine stretch out the edges of the cylinder, forming a flange.", "They top off the tins at this station, where a spinning head presses the cylinder into these lids.", "It simultaneously rolls the flanged edges together to make an airtight seal.", "This container is for classified military use, but over on another production line, they're making a more standard tin-- the kind you would put coffee in-- so this assembly is more mechanized.", "In a fraction of a second, an automated welder rounds and joins metal to create the body of a tin.", "The tins travel forward and upward on a magnetic conveyor system.", "They're going to the other side of the plant, where they'll get tops and bottoms.", "This kind of tin has a reusable slipcover lid and gets some decorative work.", "Like a big cookie cutter, a punch press cuts out designs that have been preprinted on metal.", "At the same time, it pushes the cut design onto a die to form the lid shape.", "A magnetic conveyor pulls them forward and flips the lids to stack them for packing.", "Elsewhere in the plant, they're making cans to go with some other lids.", "A lineup of circular blades slices through tin sheets.", "The cut pieces accumulate in stacks.", "They load the flat pieces of tin into a cylinder, where they're curled into tubes.", "As they exit, robotic arms make seams in the rolled tins, and a press applies force to lock them.", "This lock seam is an alternative to the welded one we saw earlier.", "Now, another magnetic conveyor pulls the tin tubes forward, and they go for a spin while rollers flange the edges so that the bottoms can be attached.", "Then a punch cutter makes the bottoms, making sure to recycle the scraps.", "The can bottoms spin out of the punch cutter before landing on the next magnetized conveyor.", "They get a squirt of liquid rubber, which will harden into a gasket to prevent leaks in the can.", "A folding machine now locks the bottoms to the tubes as they spin.", "More than 12,000 cans per hour can be made on this high-speed line...", "From a blank piece of steel to a very useful container.", "Whatever their contents, these tins are destined for a full life-- that is, until someone decides to empty them.", "It's time to turn our camera's eye on the camera's eye.", "Optical lenses are really several lenses combined into a single unit.", "Together, they re-create an image by bending light rays, so they converge into a common point called the focal point.", "These television lenses start with a very precise design.", "A diamond blade slices up a block of specially selected optical glass, while coolant prevents the blade from burning it.", "The slices then go under a diamond drill, which cuts several puck-sized disks from one glass slice.", "The operator is careful to keep waste to a minimum.", "Optical glass costs up to $1,000 for 2.2 pounds.", "During the drilling, the optical glass sits on a thinner piece of glass covered with wax.", "As the wax is melted, the disks are easily pulled away.", "Next, a device spins one of the disks, while a wheel overhead sculpts it into a lens.", "The operator checks each lens for chips, and this one looks smooth.", "This tarlike substance is called pitch.", "The edges of the lens have been built up with tape to contain the pitch.", "They completely coat the underside of the lens with it.", "Several pitch-covered lenses are now in a metal shell.", "A worker picks up a hot aluminum dome called a blocking body.", "He presses it onto the pitch-covered lenses, and the pitch melts onto it.", "Dousing it with water causes the pitch to harden, sealing the lenses to the blocking body.", "The blocking body is now upside down and acting as a holding device as it oscillates on a spinning grinding shell.", "The grinding makes the surface of the lenses uniform and smooth.", "They place a polisher on the lenses.", "It's lubricated with a very fine abrasive.", "For about an hour, the polisher oscillates while the block spins.", "Polishing makes the lenses smooth and transparent.", "It also gives them an even more curved profile.", "The lenses have been removed from the block, and it's time to cut the diameter down to size.", "Using a microscope, a technician centers a lens between two brass chucks.", "A diamond blade at the back cuts the lens as a technician monitors it.", "He's making sure the diameter and axis of the lens have a common center.", "Next, they group some lenses on round racks called planets.", "Their universe is a vacuum chamber.", "The technician closes the door, and the planets continue their orbit.", "Inside this vacuum, an electron beam evaporates coating materials.", "The vapor rises to give the lenses a protective coat.", "A computer monitors the rate of evaporation and the coating.", "But there's much more to come.", "Up next, this process really gets visual as all the pieces of a camera lens come together.", "The optical lens is the ultimate image maker.", "Along with cameras, you'll find them in projectors, microscopes, laser scanners, and x-ray equipment.", "They give us a closeup view of so many things.", "It seems only appropriate that we take a closeup look at the optical lens itself.", "The lenses have just spent three hours getting a protective finish.", "It's time to wipe any residue and make sure they're perfect.", "This particular lens is concave.", "She covers it to protect it while she cleans and inspects the lens with the opposite profile-- convex.", "Then the convex lens goes to another technician, who places it in a holding device.", "He looks into a microscope and adjusts the position of the lens until it's optically centered.", "He uses wax to keep the lens from shifting in the holding device.", "They give the lens another cleaning.", "Each one must be absolutely spotless before they proceed to the next step.", "Otherwise, dust particles could become trapped within the optical system and affect image quality.", "Now that the surface of the convex lens is immaculate, she dabs optical cement onto the center of it.", "She gives the other concave lens a little more scrutiny before she cements it onto the convex lens.", "She applies pressure to spread the cement between the two lenses.", "Cementing them together means they'll be less likely to shift around in the lens barrel.", "She checks for dust one more time.", "Then it's under the microscope for an optical alignment of this double lens.", "Because the cement isn't yet dry, he can push the top lens around and adjust its position.", "Next, they prep the barrel that will hold the lenses.", "A technician traces out lettering using a stylus attached to a sharp tool that engraves information onto the lens barrel.", "It prints technical details that will tell the photographer just what the lens will do-- things like focal length, the f-number, and the size of the aperture opening.", "These reference points allow the user to pull a picture into focus at the desired magnification.", "Now they double-check the design for this complex optical system and begin to pull all the pieces together.", "This singlet, or single lens, goes into the metal barrel first.", "Other lenses with various curvatures and dimensions follow.", "She places metal spacers between the lenses to separate them.", "Proper spacing will prevent aberrations in the image, such as blurring.", "Between installations, she covers the barrel with a piece of lint-free plastic because eliminating dust continues to be a necessity.", "One fleck could ruin this entire assembly.", "Using tweezers, she coaxes the last lens into the barrel.", "She installs a retaining ring to hold the stack of lenses down.", "Then she locks it into place.", "There's one final inspection.", "She examines the assembled optical lens from all angles.", "It takes a total of six weeks to make one of these optical lenses, and in the end, it's picture-perfect." ]

{ "things": [ "Precast Concrete Walls", "3D Printers", "Telescopic Cranes", "Kerosene Lamp Burners" ] }

[ "Precast concrete walls are made in a controlled plant environment, where weather can't interfere with the curing process.", "They're cast with insulation before they arrive at the construction site.", "All that's needed is a crane to do the heavy lifting.", "Precast concrete walls have a tough exterior that holds up to all kinds of weather, but making these structural wall panels is an inside job.", "By manufacturing them indoors, they can better prepare them for the outdoors.", "Production starts with a mix of crushed rock and sand.", "This collection is limestone-based.", "The mineral mix can be altered for different strengths and finishes.", "A conveyor delivers the collection of minerals to a huge mixer.", "They inject cement, water, and additives to improve the flow of the concrete, accelerate the cure, and give it a brownish hue.", "Beaters whip the ingredients into a thick, gritty mix.", "They cast some of the concrete into cylindrical shapes for testing.", "After a one-day cure, they crush the cylinders with a ram.", "The amount of force it takes to crush the cylinders is a measure of the concrete batch's strength.", "Before they cast the wall, a crew arranges giant foam letters to make an imprint in the mold.", "They position the letters in the center of the casting form and secure them with silicone.", "A release agent is sprayed onto the casting form and letters.", "High-strength steel cables are strung throughout the form.", "With a hydraulic device, they pull each cable to a specific tension.", "Then, they bend a rebar rod into a loop.", "The rebar loops are linked, creating long cages.", "They place one cage at the top of the form and one at the bottom.", "Then, the team inserts a sheet of welded wire mesh.", "It's been cut to fit the size of the form.", "They're now ready to pour concrete.", "A truck dispenses the concrete directly into the form.", "The concrete flows around the steel reinforcement.", "The steel will keep the wall strong when the concrete expands and contracts as the weather changes.", "The team spreads the concrete and levels it with a tool called a screed.", "This first layer of the wall panel is essentially one side of a sandwich.", "It will be the exterior part of the wall.", "At the center of the sandwich is this rigid foam insulation.", "It's studded with protrusions to secure to the concrete.", "More steel-reinforced concrete completes the wall sandwich.", "This final layer will face the inside of the building...", "So the crew takes extra care to ensure that there are no pits or crevices.", "After about 12 hours, the wall is solid enough to be handled.", "They take it outdoors, where a worker sandblasts a small section of the exterior side.", "This removes the surface cement to expose the aggregate, creating a decorative band next to the embossed lettering.", "After a three-day cure, the precast concrete wall is ready for the construction site.", "A crew guides it onto footings.", "They align its design to the one on the next wall.", "When the two walls match up perfectly, they bolt it down.", "The concrete continues to cure over time, so these precast walls will stand strong for many years.", "Would you like to print a toy, a circuit board, or a replica of a famous work of art?", "Thanks to the development of the 3d printer, what used to be the stuff of science fiction is now a reality.", "These objects were produced by 3d printers, proof that, for printing technology, the world is no longer flat.", "To make 3d printers, this company actually uses 3d printers.", "A technician starts by loading a reel of plastic filament into a printer.", "The printer melts the plastic into a thick goo.", "The 3d printer layers the plastic, following a pattern from a digital file.", "This particular part is the extruder body.", "In real time, it takes about an hour to print the extruder.", "Even complex patterns, like this octopus, can be made with a 3d printer.", "40 different components of this 3d printer are produced using 3d printers.", "At this facility, 135 printers run nonstop, producing gears, brackets, and mechanism housings.", "This technology is truly self-replicating.", "Now, a worker drills a hole in the extruder body.", "It serves as a conduit for the plastic filament during printing.", "He bolts a gear to the extruder body.", "He screws the motor to the extruder body and installs a second, smaller gear on the drive shaft.", "A part called the hot end is installed next.", "It contains a heater for melting the plastic filament.", "The worker attaches the hot end to a 3d-printed plastic mount and extruder.", "This completes the 3d printer tool head.", "Another worker feeds glass to rubber rollers.", "The rollers gently apply adhesive-backed polyester film to the glass.", "The glass will serve as the printer bed, and the film will protect it from scratches during use.", "To build the printer's aluminum frame, the worker secures the joints with 3d-printed plastic parts.", "He installs two rods horizontally.", "They'll serve as rails for the printer tool head to move across.", "He clips the tool head to the rails.", "Then, he loops a rubber belt around the motor on the side of the frame and links it to the tool head.", "The belt will drive the tool head along the carriage.", "He confirms the tension is good and that the tool head moves freely.", "Next, he attaches the print bed and its sliding support structure to the base of the frame.", "He connects a cord to the power supply and links it to the tool head.", "It will power both the motor and the hot end.", "He clips the glass to the print bed and tightens the clips with screws.", "He connects the print bed to the electronics and confirms that it slides freely.", "In the testing department, a technician pushes the end of a plastic filament reel into a drilled channel in the tool head.", "He snaps a retainer around the feed point.", "Now, he is ready to activate the 3d printer.", "He prints a test pattern to confirm that the printer bed is level and the tool head prints consistently.", "For two-tone printing, they use two filament reels that feed into a double extruder tool head.", "The tool head layers the plastic, one color at a time.", "This process takes about an hour, but that's not too long when you consider that it's printing a 3d object.", "Talk about generating solid results.", "Tower cranes can be found at most large construction sites, but they're usually secured in a concrete slab that can take days to set up.", "If you need a crane for some quick maintenance work, a truck-mounted telescopic crane might be a better solution.", "Telescopic cranes can support loads of up to 6 tons and lift objects over 30 feet in the air.", "The steel cable or wire rope winds and unwinds on a hydraulic winch.", "The crane operator can extend or retract the boom extensions and adjust the angle of the main boom.", "Stowing the crane in the travel position takes just a few minutes.", "Assembly begins when a carbon steel sheet is loaded into a cnc laser cutter.", "A high-energy light beam cuts through the steel plate to make several parts of the crane assembly.", "A computer program maximizes the number of pieces cut out of a single sheet of steel.", "A welder places parts on a position fixture.", "Then, a cnc weld robot bonds the side plates to the winch mounting plate and base plate.", "The welded crane mast goes to the machining center.", "A machinist positions it on the horizontal mill jig.", "The cnc mill drills holes around the base plate with a carbide drill bit and sprays coolant to prevent the piece from overheating.", "Then, the machine levels the surface under the base plate with an end mill to fit it to the crane mast bearing.", "Another worker bends tubes with a hydraulic press brake.", "He makes boom segments by forming high-strength carbon steel plates into open c shapes.", "Grounded electrostatic paint racks carry the parts into the painting department.", "A worker applies a coating of anti-rust, low-friction electrostatic paint.", "The paint eases the movement of the crane parts.", "As the boom extensions come out of the paint shop, the painted mast is ready to go to the assembly department.", "A worker positions the mast on the base bearing assembly.", "He attaches the mast to the bearing with high-strength steel bolts and uses a pneumatic torque wrench to tighten the bolts.", "These bolts bear most of the load of the crane.", "A worker positions the winch on the mount plate and tightens the bolts.", "He rotates the mast to check its movement on the base bearing.", "He inserts a bushing and fits it with an arbor.", "He applies lubricant inside the bushing before he brings in the main cylinder.", "The worker positions the cylinder between the side plates and pins it to the mast.", "The pin allows the cylinder to move vertically when elevating the boom.", "Hydraulic actuators are now installed inside the mast.", "The actuators direct oil flow to the cylinders and motors, controlling the movement of the crane.", "A worker installs the boom extensions into the main boom.", "He pushes them all the way in before assembling the main boom to the crane base.", "The main boom fits right between the mast side plates.", "Workers insert a pin to connect the mast to the main boom.", "They gently tap it in place with a soft mallet and bolt it on with a pneumatic wrench.", "A worker threads the wire rope along the boom and around the top pulley, then pulls the cable down and runs it through the snatch block.", "He closes a safety pin on the snatch block and pins the eye of the cable under the top pulley.", "Another worker activates the winch motor to roll the cable in.", "The main cylinder elevates the crane into operating position.", "The extension cylinder extends the boom, and stabilizers support the back of the truck for safe operation of the crane.", "In a world lit by incandescent, fluorescent, halogen, and l.e.d.s, there are some people who still like their lighting the old-fashioned way.", "Nothing quite matches the warm glow of a kerosene lamp.", "Kerosene lamps date back centuries.", "They're fueled by kerosene, with a wick as the light source.", "To light the lamp, you remove the glass chimney, light the wick, then turn a key attached to the burner to raise or lower the wick.", "The height of the wick adjusts the height of the flame.", "This burner's components are made of brass.", "Many of them are stamped by a press.", "The press rams the lubricated brass sheet against the die, forming the metal to the required shape.", "The component passes through a second stamping press, this time receiving five successive strikes.", "This component is the midsection of the burner's gallery, the ornate support fixture that holds the glass chimney over the flame.", "After the component passes through the first two presses, workers mount it on a third press.", "This one punches ventilation holes around the perimeter, allowing air to feed the flame.", "Workers mount the gallery's bottom section onto another punch press.", "It cuts an intricate design along the perimeter.", "This machine cuts out the bottom so the part can fit around the burner mechanism.", "The next machine carves threads into it.", "The threads enable the gallery to screw onto the burner mechanism.", "Now it's time to assemble the gallery sections.", "It has grips to hold the bottom of the chimney.", "Next, they fasten the bottom section to the middle section.", "This method of joining parts by compressing one against the other is known as a press fit.", "They also stamp the brass adjustment key that raises and lowers the wick.", "The die stamps the manufacturer's name and cuts teeth along the perimeter, making the key easier to grip.", "To build the burner mechanism, they solder a notch plate, called a shutter, to a component they refer to as the candle.", "It's called the candle because the wick will run through it.", "They attach the adjustment key to a pair of gears...", "And solder that to the shutter.", "They turn the key to make sure the gears rotate freely.", "They place a base into an assembly tool and insert the candle containing the adjustment key assembly.", "Then, they solder on a wick guide.", "They check the gears again to make sure they rotate freely.", "The burner mechanism is finished.", "Now, they dip it into a chemical degreaser to remove any lubricant or soldering residue.", "Next, they submerge it in a vat of acids to brighten the brass.", "Then, they rinse it in water three times.", "Now, they assemble all of the burner parts.", "They insert a cotton wick into the guide at the bottom of the mechanism and turn the key to feed it up through the burner.", "They screw on the gallery and complete the burner by inserting a disk that will help shape the flame.", "To install the burner in a lamp, the insert the wick into the font and screw the burner to the font's threaded collar.", "The glass chimney is the finishing touch.", "To fill the lamp with fuel, remove the chimney, unscrew the burner, pour kerosene into the font, then screw the burner back on.", "This lamp is now ready to light." ]

{ "things": [ "Magnets", "Cooked Ham", "Silver Teapots", "Crash Test Dummies" ] }

[ "Today on \"how it's made\"...", "Magnets...", "Cooked ham.", "Silver-plated teapots.", "And crash-test dummies.", "You can't see or feel the force causing this globe to levitate, but it's not magic, it's magnetic.", "An essential part of our daily lives, magnets are used for a lot more than just sticking stuff to the fridge.", "They help run motors and generators and are also found in computers, televisions, and microphones.", "Magnets occur in nature.", "But only two centuries ago, scientists figured out how to make them using metal and electricity.", "Production at the magnet foundry begins with a creation of a mold.", "A tray containing four magnet shapes is loaded into a machine that fills it with sand.", "A worker removes the pattern and smoothes the surface dimpled by the machine's lid.", "Then it's back inside.", "This time the machine pumps in gases that chemically alter the sand, hardening it in a matter of seconds.", "The sand slab is now a durable mold.", "And these molds are made in a wide variety of shapes and sizes.", "Now it's time to mix together the ingredients for the magnets themselves.", "They include copper, cobalt, sulfur, nickel, pure iron, aluminum, and titanium.", "All of these metals are loaded into an electrical induction furnace.", "It generates a pulsating electromagnetic field that heats the metal to almost 3,000 degrees fahrenheit, melting everything into a molten soup.", "The metal is poured into the molds.", "Because the gases that harden the sand are highly flammable, the molds burst into flames.", "Still ablaze, they slide to another part of the foundry where workers knock them to the floor and bust them open with sledgehammers.", "This lets the air in, cooling the molds and allowing the gases to burn off.", "All of the pieces are shoveled into a bin, and workers separate the metal from the sand chunks using what else?", "A magnet.", "But these metal pieces aren't yet magnetized themselves.", "That will come later.", "A set of rings designed for use in electric motors is threaded onto a copper pipe.", "The ring-covered pipe is placed in a tube.", "Then, silica sand is packed in to hold the rings in position.", "Both ends of the tube are sealed with concrete.", "Then, it's into an electrical furnace.", "It heats the tube until it's red-hot.", "This superheating primes the rings inside to accept an electromagnetic field which will be delivered by this metal rod.", "The rod slides down the center of the copper pipe and is clamped into place.", "Water keeps the pipe from melting as a low-voltage, high-current charge is delivered to the rings inside.", "Workers break open the seal.", "The process has left the rings mildly magnetized.", "Any rough edges are smoothed away.", "At this point, the magnets are pretty useless.", "But this machine empowers them with a strong electromagnetic charge.", "The establishment of that weak magnetic field earlier ensures that the magnetization is now properly oriented.", "Now, that's some serious magnetic muscle.", "The wide array of magnets manufactured today are critical to our daily lives because their invisible power helps keep so many things running.", "Up next-- turning raw pork into a succulent smoked ham.", "Ham comes from the hind leg of a pig.", "You can buy it raw and cook it yourself, or you can buy it already cured and smoked.", "You can buy your ham boneless or with the bone still intact.", "Bone-in ham has more natural flavor.", "The process starts with raw hams fresh from the slaughterhouse.", "The factory's automated sorting system weighs each one, then knocks it into the appropriate vat.", "By grouping hams of similar size together, the factory can better control the quality of the curing and cooking processes.", "Each vat empties into a tumbler which spins the hams for about five minutes.", "This loosens the skins so that workers can quickly remove them.", "They use an automatic trimming machine to skin the back portion, called the butt.", "In keeping with traditional style, the machine leaves just a small amount of skin on the thin part of the leg, called the shank.", "Now the circular wizard knife does its magic, removing all but a thin layer of fat.", "Finally, the base of the shank, called the hock, is chopped off.", "Now a curing solution is prepared, made of water, sugar, salt, and a few secret ingredients.", "This mixture gives the ham its trademark flavor and pink color.", "Without it, the meat would end up looking and tasting like a pork roast.", "Pipes feed the curing solution to an injection machine armed with 138 needles.", "As the hams pass below, they're thoroughly and evenly injected with solution.", "And all that piercing tenderizes the meat.", "Next, workers load a machine called the stuffing horn, which fires each ham into a heat-resistant cotton net.", "Workers seal each one with an aluminum clip, then cut off the excess netting.", "Cooking hams on trays would flatten the underside.", "But hanging them by nets keeps them nice and round.", "The cooking racks are transferred to a food-processing oven, the industrial equivalent of a traditional smokehouse.", "Hickory wood chips go into the oven smoker.", "Then a worker starts her up.", "For the next 12 hours, the hams slow cook at temperatures ranging between 150 and 180 degrees fahrenheit.", "This tenderizes the meat and gives the smoke ample time to seep in.", "After cooking, the hams get a cold ten-minute shower.", "This rinses away the drippings that fall from the higher hams onto the lower ones.", "Then it's on to the chill area, where over the next 36 hours, the hams cool to around 30 degrees fahrenheit.", "Next, the nets come off and packaging begins.", "The factory sells hams whole, or, using a band saw, slices them into halves or smaller sizes such as single-portion ham steaks.", "Workers bag the ham in plastic, then position a soft, plastic pad over the bone to prevent any sharp edges from ripping through the airtight seal.", "Each bag is positioned for sealing.", "Then, an automated vacuum chamber descends over each bag, sucking out the air and sealing the plastic.", "A robotic arm transfers the hams to a conveyor belt leading to a hot-water bath.", "Just five seconds in hot water is enough to shrink the plastic tightly around the ham.", "This airtight seal will keep the ham fresh in your refrigerator for three months, and up to nine months in your freezer.", "Coming up-- the artistry behind some of the world's finest teapots.", "The mayans started using pots like these 2,600 years ago, probably for hot chocolate.", "They've evolved since then.", "And today, aficionados consider them essential for that perfect cup of tea.", "Silver-plated teapots come in many different styles, and making them requires the talent and skill of an old-world master.", "A century-old hand-circling machine cuts a perfect circle out of a brass sheet that's 6/100 of an inch thick.", "Then the disk heads to the press.", "After lubricating the press surface with vegetable oil, the disk is positioned and covered with a polyurethane stopper.", "As the press applies its three tons of pressure, the die moves upward, shaping the disk from underneath.", "The stopper, meanwhile, provides a counterpressure to keep the die from breaking the brass as it thins and stretches.", "They call this the draft shape.", "It then goes into another die that produces the final shape of the teapot's base.", "Next, they solder on the teapot rim, which was made the same way.", "A craftsman then hammers the metal to remove any imperfections left by the pressings and punches in the maker's mark.", "Spinning is another technique used to form metal teapot parts.", "Here, a craftsman shapes a copper teapot mounted on a lathe.", "The metal is decorated using a technique called hand chasing.", "With a paper stencil, he applies the design in white powder.", "He pencil traces the pattern, then hammers in the design with a variety of tools.", "This intricate process requires the talented hands of an expert artisan.", "For the teapot spout, workers press brass plates into left- and right-side dies.", "A quarter-ton press produces the final spout shape.", "Soldering paste is brushed onto the halves.", "They're wired together, then fired to 600 degrees fahrenheit.", "The spout gets an acid bath to remove all of the impurities left behind from the soldering process.", "Workers polish the teapot with three progressively finer grades of pumice, which is crushed volcanic rock.", "One final buffing ensures the surface is perfectly smooth.", "With diamond-tipped hand tools, engravers can etch anything onto the teapot from custom designs to company logos.", "Workers now screw on the lid, wire up the teapot, and immerse it in cleaning chemicals followed by a silver-plating bath.", "Just before shipping, they attach hardware and perform a final cleaning.", "Finally, the teapots are wrapped in acid-free cellulose to prevent the silver from tarnishing.", "It takes a highly skilled team of craftspeople to create these unique teapot designs in styles ranging from elizabethan to ultra modern, beautiful and functional.", "When we return-- bringing crash-test dummies to life.", "Crash-test dummies may look human, but they're actually high-tech guinea pigs for a wide range of impact tests.", "So, how do they make dummies whose form and structure mimic the human body?", "You're about to find out.", "Crash-test dummies are designed to take some serious hits.", "Automakers use the data they provide to build safer cars, vans, and trucks.", "A dummy's anatomy is pretty simple.", "Beneath its vinyl skin, there's a metal skeleton made of steel and aluminum bones.", "Those bones contain load cells, electronic devices that measure crash force.", "Production of the load cells begins with a machine that shapes steel bars using a solid carbide end mill.", "Lubricant cools the intense heat and washes away the metal particles.", "Using a precision tool called the dial indicator, workers verify the load cell's dimensions to within 2/1,000 of an inch.", "Next comes the strain gauge-- the component within the load cell that measured crash force.", "The hair-width wires that connect the strain gauges are so delicate that soldering them requires a microscope.", "The vertebra in the dummy's neck also contains a load cell.", "The strain gage soldered inside it measures not just lateral and vertical forces, but also twist, or torsional force.", "The completed bones and corresponding load cells are laid out, but they can't be connected until the dummy's rib cage is complete.", "To make the rib cage, steel bands are bonded to a flexible damping material.", "This material was originally designed to deaden sound in nuclear submarines.", "It allows the dummy's rib cage to compress just like the real thing.", "A technician bolts the entire rib assembly to the spinal column and covers it with a plastic chest plate called a bib.", "The long bones and load-cell forms are inserted into aluminum molds.", "Workers then bolt the molds shut and pour in liquid vinyl.", "The molds bake at around 350 degrees fahrenheit for 10 to 20 minutes.", "When they come out, workers cut away any flash-- the excess vinyl that oozes out during the baking process.", "Then, a technician inspects the components to ensure an accurate fit.", "This is no ordinary vinyl.", "It's specially designed to resemble human flesh in consistency and density.", "This gives researchers realistic crash data.", "Now, it's time to install the bones into their respective vinyl compartments, starting with this tibia or shin bone.", "Zippers allow the engineers to easily remove the components after performing a crash test.", "A technician bolts all the dummy's joints in place and ensures they have a human-like range of motion.", "Using a neck-compression tool, a technician lines up a load sensor with the neck vertebrae and fashions the completed neck assembly to the dummy's head.", "Next, the upper body is completed.", "The thorax is bolted onto the pelvis, the head and neck assembly onto the thorax.", "Then, the vinyl jacket is fitted over the chest.", "Finally, the technician bolts on the limbs.", "Crash-test dummies range in size from newborns all the way up to 225-pound adults so that auto manufacturers can be sure their seat belts and air bags protect everyone equally well.", "It took a full 12 weeks to make this dummy, and now he's ready for a life of hard knocks to make traveling safer for all of us." ]

{ "things": [ "Steel Wool", "Ranges", "Carved Candles", "Slot Machines" ] }

[ "Today on \"how it's made\"...", "Steel wool...", "Ranges...", "Carved candles...", "And slot machines.", "With so many rough edges, steel wool is very abrasive.", "That's what makes it so useful for heavy-duty cleaning and other chores.", "Mechanics were the first to use steel shavings for cleaning and polishing parts.", "By the early part of the 20th century, equipment was invented to mass produce the stuff.", "Then steel wool became a household name.", "There are thousands of metal threads in each steel-wool pad.", "Manufacturers start with a coiled steel rod that unwinds through metal guides into a 16-foot-long die machine.", "As the rods travel through six progressively smaller dies, it gets narrower and more uniformly shaped.", "Spools wind up the rod after it passes through each die to prevent any snarls in production.", "The progression through the dies reworks the steel's basic structure, doubling its tensile strength.", "When it reaches the end of the die machine, the steel rod has been narrowed by a little more than half.", "The slimmer, stronger wire will be easier to process.", "To check its tensile strength, a technician places a wire sample in a testing device.", "Clamps pull from both directions.", "It takes over half a ton of force to snap it, an indication that it's tough enough to be machined.", "So, it's over to the steel-wool cutting machine, which spans 50 feet.", "Here, the wire travels over a series of drums, while 29 blades shave it.", "Each blade produces shavings thinner than a human hair.", "Streams of the shavings exit the machine and join the river of steel threads flowing through the factory.", "Each of these steel threads has been cut in a pyramid configuration, making it razor-sharp.", "The shaved steel winds onto large rolls.", "Workers align several of these rolls onto racks, then secure them in place.", "The ends of each roll are bunched together...", "And threaded through a series of bobbins.", "Finally, the ends are fed into a needle-punch machine.", "Here, hundreds of fish-hook shaped needles weave the steel threads together.", "This very basic crochet job produces a long mat of wool that's of suitable density for woodworking.", "To make household cleaning pads, workers bulk up the steel wool even more.", "They insert layers of needle mat into the streams of steel fibers.", "This gives the pads extra strength for big scouring jobs.", "This multilayered stream then heads over to the needle-punch machine to be woven together.", "Once the steel wool goes onto a final roll, it's ready to be turned into pads for cleaning, sanding, or polishing.", "Next, see what's cooking with today's high-end ranges.", "The range is where the action is in the kitchen.", "It's where we whip together meals-- baked, broiled, roasted or sautéed.", "High-end ranges like this one are hot, and not just in the obvious way.", "They're an upmarket trend that make home cooks feel like the chef of their very own restaurant.", "The construction of one of these double-oven ranges starts with a big sheet of galvanized steel.", "A machine flips it and feeds it to a press.", "The press folds the sheet twice to make the oven walls, closing it around the framework.", "The oven bottom is placed into position, and automated welders fuse everything together.", "The back section goes on next.", "Those holes are for the oven's fan.", "The oven shell gets a porcelain finish on the inside, and then the heating element goes in.", "Fans are fitted into those precut holes.", "More heating elements run along their perimeters.", "The oven is then wrapped with synthetic insulation to keep it from scorching nearby cabinetry.", "Side panels cover the insulation and help support the oven's structure.", "This piece of steel will reinforce the range bottom.", "Several feet are attached.", "The front ones have wheels so the range can be moved without tearing up the floor.", "Workers cushion it with packing foam, flip it, and hoist the oven onto it, next to a smaller second oven that's part of this double-oven range.", "Next, a technician hooks up the microprocessor board that controls everything from the oven's fans to their timers.", "And all of that wiring needs to be double-checked.", "On this range, the burners are fueled by gas.", "This electrical board will sense gas-flow problems.", "Workers assemble the igniter boxes that will spark the burner's flames...", "Then mount them on the cooktop.", "After installing the gas valves on the framework...", "They slide connectors onto some gas lines and attach them to the valves.", "On this upscale cooktop, there are two gas lines for every knob-- one for a low flame, and the other for a high flame.", "With the installation of the burners and the porcelain drip pan...", "The cooktop is now ready to be lowered onto the oven.", "This is where the knobs fit.", "It's called a bullnose, and it's a bit of a showpiece.", "So, workers grind and polish it to give it a gleaming finish with no sharp edges.", "For handling purposes, the bullnose is protected with plastic.", "This machine punches and bends the edges of panels so they can be attached to the sides of the range.", "At another station, the oven doors get a good buffing so they'll match the shiny bullnose.", "With the side panels and doors attached, all that's left are a few more finishing touches, and the final product is ready to be fired up.", "Coming up, an art form where every second counts.", "Carving candles is an old german craft still practiced by artisans.", "It involves layering different-colored wax...", "Then carving designs to expose those luminous colors.", "It's hard to beat the radiant beauty of a carved candle.", "Carved candles are known for their swirls and curls, a look so elaborate that lighting one is an occasion in itself.", "The process starts with vats of hot wax in various colors.", "The candlemaker stirs them to circulate the specially formulated dyes.", "She dips a star-shaped wax core into clear wax and then yellow.", "The clear wax dilutes whatever color wax follows it.", "The layers are hardened in cool water.", "She repeats this process between 30 and 35 times, building up different-colored layers on the candle core.", "As the dipping continues, the candle becomes warmer and softer, which will allow it to be carved.", "The quick water dips only cool the outer layers.", "Partway into the dipping, the candlemaker deepens the candle's grooves.", "And she resumes dipping, she has to keep a close watch on the candle's temperature.", "If it absorbs too much heat, it will be too soft to carve.", "But if it's too cool, the wax can splinter.", "Achieving the right consistency is crucial.", "It's almost time to get carving.", "But first, the candlemaker squeezes the drippings together....", "And slices them off.", "They're too attractive to waste, so she quickly shapes them into a mushroom candle.", "She pokes a hole in the center for the wick, and, within moments, the candle is complete.", "With the big candle at the perfect temperature, the clock is ticking.", "It has to be carved in just 15 minutes, or it will be too hard to work with.", "The candlemaker slivers the bottom and curls the pieces back.", "She dunks the row of curls into water to harden them a bit so they don't sag.", "On the second row, she curls each row in the opposite direction to the one before.", "She carves a total of four rows, with the last curls fixed upright.", "Using the square-edged gouging tool, she cuts a windmill design into the upper section of the candle.", "Then she shapes the wax cutout into a base for the windmill.", "Tulips and other designs decorate the top of the candle.", "She must work with a quick but steady hand.", "It takes at least a year of training to learn to carve with such confidence.", "This one is a neat trick.", "She jiggles the straight-bladed knife to cut the fluted edge of a hummingbird wing.", "One last character, and this carving job is complete.", "Now she presses a cookie-cutter-like device around the wick.", "This forms a well that will allow the wax to burn down the center instead of dripping down the sides, which would ruin the carving.", "She spins the candle in a hot pan to melt the bottom so that it's level.", "And while it's still hot, she attaches the company sticker.", "Finally, an acrylic glaze seals the candle's decorations and protects the finish.", "Once lit, the light from the clear core shines through the design for a real glowing beauty.", "When we return, a gambler's dream come true-- peeking inside a slot machine.", "A san francisco car mechanic invented the first slot machine in 1895.", "Its heavy cast-iron cabinet housed three spinning reels.", "Each one had 20 playing-card symbols and an image of philadelphia's famous liberty bell.", "If you were lucky enough to line up three bells in a row, you won the big jackpot-- 50 cents.", "Today's slot machines have come a long way.", "They've got computers for brains and endless themes and configurations all packaged in a light-weight sheet-metal cabinet.", "Workers first assemble what's called the bulkhead, the upper part of the cabinet that contains all the game-playing components, such as the audio amplifier...", "The circuit boards...", "The speakers...", "And what's known as the meter, the electromagnetical counter that keeps track of the coins and credit going in and out of the machine.", "At the base of the cabinet, the machine gets a serial number, as required by law.", "Workers install the machine's bill acceptor, then the ticket printer.", "When there's a win, it spits out a voucher that the players can redeem for cash, or insert in any machine's bill-collector slot.", "Next comes the arm mechanism players pull to spin the reels, then the upper door that frames the reels and the lower door that frames the button panel.", "Slot machines have several illuminated buttons for different types of bets.", "Workers plug a tiny l.e.d. behind each button, then wire up the panel.", "A plastic insert labels each button.", "Once the panel is assembled, it's installed in the lower door.", "Workers now turn their attention to the metal panel that accommodates the spinning reels.", "On the back, they install two circuit boards-- one to operate the machine's digital scoreboard, the other to illuminate the reels.", "Then they cover the panel with special glass.", "It's been treated with a chemical that conducts electricity.", "Should a cheater try to rig the reels using an electronic gadget, this glass will ground the charge.", "A decorative window goes over the anti-tampering glass.", "Then workers place the whole unit into the upper door.", "In the lower door, they install a touch-screen video monitor to display the payout information.", "Casino technicians also use it to configure the machine.", "Then workers install panels with slots for receiving tickets and for inserting either money or debit cards.", "And now for the slot machine's most famous feature-- the reels.", "After a machine tests the spinning motion and lights, a worker attaches a plastic strip with printed symbols-- 18 to 22 symbols per reel.", "The reels easily snap into a waiting electrical connection.", "Next comes what's called the top box.", "Workers mount it onto the bulkhead, then install fluorescent bulbs.", "These will light up the eye-catching artwork on the glass front of the box.", "Nearing completion, the slot machine is finally ready to receive its brain-- an internal computer with its operating system on a programmable microchip.", "The software that runs the game is installed on a memory card.", "It randomly determines the course of play within defined parameters.", "Essentially, it's preprogrammed to pay out a certain amount at random intervals over a given period of time.", "But less money, of course, than the machine takes in overall.", "Before embarking on its spinning spree, each slot machine undergoes extensive quality-control testing.", "Casinos demand that these one-armed bandits are durable and reliable because slots generate more than two-thirds of casino revenues." ]

{ "things": [ "Endoscopes", "Megaphones", "Uranium" ] }

[ "Today on \"how it's made\"...", "Endoscopes...", "Megaphones...", "And uranium.", "An endoscope is a tube with optical glass fibers and lenses inside attached to a video camera.", "Doctors feed the endoscope through the patient's mouth or other opening or insert it through a tiny incision then watch what the camera captures on a video monitor.", "An endoscope lets the surgeon see inside the patient during an examination or surgical procedure.", "Its light-transmitting optical fibers work like a flashlight inside the body.", "The optical fiber manufacturer suspends glass rods from the top of a tall oven, which heats them to a melting temperature of 1,652 degrees fahrenheit.", "Each rod drips downward in the form of a thin strand.", "A guide wheel turns this glass fiber in a horizontal direction.", "The fiber then winds on to a drum, whose rotation speed stretches it to a specific hair-thin diameter.", "A worker combines several single fiber spools on to a large winding wheel to make a bundle containing thousands of fibers.", "To make the cable that connects a light source in the operating room to the endoscope, a worker inserts an optical fiber bundle into a silicon cable sheathing.", "This one has nearly 9,000 fibers.", "She screws a stainless steel fastener, called a ferrule on to each threaded end of the sheathing.", "After saturating the ferrules and optical fibers inside with glue and curing the adhesive with heat, the worker trims off excess fibers and hands off the cable to the next station, where a work polishes both ends.", "Polishing finalizes the dimensions and enables light to shine through.", "This quality control test, one of several, ensures the fibers can withstand a prescribed amount of pressure without cracking.", "The optical fiber manufacturer also supplies fiber spools to the endoscope manufacturer for the light transmission system inside the endoscope.", "Workers cut the bundle of optical fibers to the length required for the endoscope model they're making.", "Endoscopes vary in length and diameter, depending on the part of the body they're designed for.", "After verifying that the diameter of the bundle is correct, they tie the optical fibers with string to hold them together during insertion.", "Then workers insert the fiber bundle between the inner and outer stainless steel sheathes that make up the main body of the endoscope, pushing the fibers down the length of the inner sheath.", "They attach a stainless steel adaptor.", "This will connect the light cable from the operating room light source to the endoscope, transferring light to the optical fibers inside the endoscope.", "A worker inspects those fibers under magnification for black spots.", "Black spots indicate broken fibers, which would interrupt the transmission of light.", "An endoscope transmits an image much like a telescope does.", "Optical lenses send reflected light, which produces the image, from inside the patient all the way up to your eye peering through the top.", "The lenses in the endoscope are glass rods.", "After cleaning them with chemical solution, workers line them up in a fixture with brass spacers of various lengths in between.", "Depending on the length of the endoscope, there are five to seven lenses.", "The spacers create specific distances between them.", "Once workers have assembled the image transmission system, they gently slide it off the fixture into the inner sheath of the endoscope.", "Then, they screw on an ocular cap to hold it all in place.", "A worker cleans the cap's glass top, then attaches an eyepiece.", "This gives the surgeon the option of either looking directly into the endoscope or looking at an operating room video monitor which receives the image via a small camera attached to the eyepiece.", "This demonstration shows how it all comes together in the operating room.", "After securing the endoscope in a holding fixture, the surgeon attaches the light cable coming from the nearby light source.", "The light travels down and out the endoscope, illuminating the area that surgeon's working on.", "The lenses reflect the image to the top of the endoscope, where a camera transmits it to a video monitor that's mounted in front of the surgeon.", "In the beginning, megaphones were simply cone-shaped devices that focused sound forward so it went further and could be heard more clearly.", "In the 20th century microphones, an amplifier and a speaker were added to the cone, and that really ramped up the volume.", "With a megaphone, there's no need to shout.", "Just speak, and you will be heard.", "This waterproof version is designed for coaching, law enforcement, and military uses.", "Production starts with a panel of four digital circuit boards that have little gold pads on them.", "An assembler places a stencil over the panel and aligns the stencil holes with the gold pads.", "He then squeegee's solder paste down the stencil, and it flows on to the exposed gold pads.", "This is before and after the solder past application.", "Robotic arms install electrical components on the solder-coated pads, creating circuitry.", "Various reels unwind to deliver these little parts.", "The robotic arms suction them off liners and transfer them to precise locations on the boards.", "The parts will run the megaphone's sirens, horns, and microphones.", "A technician clamps one of the completed circuit boards in a tester.", "Spring-loaded pins underneath make electrical contacts with the components and probe their performance.", "The system runs a full test of the circuitry.", "At the next station, an assembler attaches a part known as the front can to the end of a flared speaker cone.", "He then turns his attention to the speaker.", "The assembler inserts screws in the base.", "He threads wires from the speaker through a hole in the cone and through the front can.", "The assembler then places the speaker in the cone, and he screws it in place.", "He attaches a connector to the protruding speaker wires.", "The worker places a mesh metal screen over a hole in the rear can.", "The assembler taps a nut driver with a hammer to force the mesh into the hole, and this shapes the mesh into a microphone cover.", "He removes the newly-formed mic cover and fits it to the mic, manually crimping it around the sides for a snug fit.", "He now tucks the microphone into a tube that has a sliding inner sleeve.", "The assembler inserts the tube into the microphone hole in the rear can.", "He slides the inside tube down to push the microphone in the hole.", "He secures the knob for turning the megaphone on and for adjusting the volume.", "The assembler installs a mini-circuit board that's linked to the siren and horn button.", "These small spring pins will mate to a battery to power the megaphone's circuitry.", "He tucks the pins into molded protrusions inside the rear can and waterproofs them with rubber o-rings.", "This megaphone subassembly is now ready for the main circuit board.", "The assembler threads wires for this switch trigger, microphone, siren, and horn through holes in the board.", "He then screws the board to the rear housing.", "He fits a silicon o-ring around the rim of the rear can to seal it.", "The assembler then joins the rear can with all the working parts to the front can and cone assembly.", "He connects the speaker wires to the circuit board.", "This megaphone is now ready for a sound test.", "The technician connects it to a temporary battery and powers it up.", "Check, one, two.", "One, two.", "Check, testing, testing.", "One, two, test.", "More sensitive testing is needed.", "He encloses the megaphone in an insulated chamber to shut out background noises.", "A computer runs the megaphone at different frequencies and analyzes its performance.", "Once the megaphone passes these tests, they install handles.", "And now it's ready for anything you have to say.", "Uranium is a metallic element that was discovered by a german chemist in 1789.", "The significance of this discovery wasn't understood for a century and a half.", "In 1938, scientists figured out that uranium atoms could be split to produce energy.", "The size of a fireplace log, this nuclear fuel bundle generates a lot more heat.", "It's packed with enough uranium to power 100 homes for a year.", "To obtain the uranium, the tunnel 1,640 feet underground at this site in northern saskatchewan.", "This mine is the largest source of high-grade uranium in the world.", "The uranium ore lies beneath a bed of water-saturated sandstone.", "To reach it, they use drill bits studded with tungsten carbide buttons.", "Like knuckles on a fist, the button bits punch into the rock face.", "These first holes are for pipes that will pull heat out of the ground and freeze it around the ore.", "The miner operates the equipment by remote control.", "It transfers a new piece of pipe to the end of the drill roughly every five feet to penetrate 426 feet into the sandstone bed.", "It takes up to eight days to install just one length of pipe, and there are 200 of them.", "Workers configure the pipes so they surround the ore deposit.", "These freeze pipes will stabilize the ground, and they'll also turn high-pressure ground water to ice, so it won't interfere with the actual mining.", "A freeze plant above ground chills calcium chloride brine to minus-22 degrees fahrenheit and sends it through the freeze pipes.", "The brine absorbs heat as it freezes the ground and loops back to be chilled again.", "Above the uranium deposits, workers now gear up to mine the ore.", "They'll use this bit to chew into the ore body in order to make an initial small-diameter hole known as a pilot hole.", "The pilot hole maps out the drill route to ore, and it creates an entry point for larger mining equipment.", "From a raised position, the bit bores vertically into the rock to drill the pilot hole and reach a specific level below the ore body.", "They're now ready for the reamer bit.", "The reamer has numerous button-encrusted wheel tentacles.", "As this animation shows, the drill pulls the reamer up the pilot hole, widening it.", "And the broken ore falls into what's known as an extraction chamber.", "Here, a tram operated by remote control scoops up the rock.", "This remote control system keeps miners a safe distance away from falling rock hazards.", "It also minimizes their exposure to the radioactive uranium in the ore.", "As another precaution, workers continuously ventilate the mine, introducing fresh air every 20 minutes.", "Steered by the operator's joystick, the tram delivers the ore to a scanner.", "By measuring the amount of radioactivity in the ore, the scanner determines the uranium content is about 15%.", "In much of the ore, the uranium content is even greater-- on average, around 18%, and that's considered to be very high-grade.", "The train now empties the ore into a chute.", "Cameras follow the rocks' journey to the next station.", "Then from a control room, an operator manipulates a hydraulic hammer to smash the ore to bits.", "The broken ore then migrates to a mill that grinds it into a fine sand.", "They add water, and it becomes slurry, which they then pump to the surface.", "Trucks then transport the uranium ore slurry to a mill nearly 50 miles away.", "They pull into a special off-loading facility.", "The support for a vacuum system aligns with the tote that encases the slurry tank.", "Once in position, a vacuum pipe drops into the tank and suctions up the slurry.", "Cameras provide a live feed of the unloading progress to a control room almost 23 feet away.", "After a wash and a radiation check, the truck leaves.", "Stay tuned for the transformation of uranium into nuclear fuel.", "Just one fuel bundle of uranium contains the same amount of energy as just over 71,000 gallons of oil.", "But uranium can't simply be chipped away from the rock it resides in.", "It must be chemically separated and processed to make it into usable fuel for a nuclear reactor.", "Acid dissolves the uranium, but not the rest of the rock.", "It settles to the bottom of these tanks.", "The uranium-acid solution flows forward, leaving the unwanted minerals behind.", "Using a series of chemical reactions, they further purify the uranium.", "They then roast it at 1,562 degrees fahrenheit.", "This concentrates it into a jet-black powder.", "The uranium powder flows into 55-gallon steel drums.", "A worker taps the lip of the drum to remove residual powder.", "He then puts the lid on and activates a press that secures it tightly to the drum.", "As an extra precaution, he seals it with a steel ring.", "He labels it to indicate the drum's contents, weight, and radioactivity.", "Workers stack the drums in a warehouse to await shipment to the next processing plant.", "There, the uranium goes from black to yellow as they convert it to uranium trioxide, an interim chemical form in the processing chain.", "They ship the uranium trioxide in specially designed inverted cones.", "Upon arrival at the next facility, a valve opens at the bottom and the powder flows into conveyor tubes that take it into the plant.", "Inside, workers dissolve the uranium trioxide powder in acid.", "A worker takes a sample to test the density and the chemistry and confirms that both are acceptable.", "They then add a chemical to turn the dissolved uranium back into a solid.", "After more processing, the uranium trioxide becomes uranium dioxide, the chemical form required for nuclear fuel.", "Spinning the uranium dioxide mixes the different sized particles to make it a more homogenous blend.", "The chemical processing has also caused the uranium to change color again.", "It is now a fine black powder.", "Using several tons of pressure, tools shape the uranium dioxide into pellets.", "A revolving wheel with protrusions guides the pellets into a channel conveyor.", "The conveyor takes the pellets into a furnace.", "Over 24 hours, the heat removes pores in the pellets.", "The pellets shrink, increasing the density of the uranium.", "The particles fuse together and harden into a ceramic.", "Here's a pellet before and after baking.", "A robot arm now loads the pellets on to a tray and levels them.", "A conveyor moves the tray forward.", "Ahead, another robot places zirconium fuel tubes on a rack.", "Zirconium is a metal that's highly resistant to both heat and corrosion, but neutrons will pass freely through it during the fission reaction.", "The rack of tubes meet up with a tray of incoming pellets.", "A robotic loader pushes the stack of 30 pellets into the tube.", "Another robot delivers the rods one at a time to an automated welder that caps the ends.", "The next robot retrieves the completed uranium fuel rods and transfers it to an assembly fixture.", "It arranges a total of 37 rods in an upright position within the fixture.", "After the rods have been welded and the bundle capped at both ends, a robot transfers it to a scale.", "This weigh-in confirms that there is the correct amount of uranium in the bundle.", "Prior to burn up in a reactor, the amount of radioactivity emitted by nuclear fuel bundles is very low, and they're safe to handle as workers prepare them for shipping.", "They're now on their way to the power plant, where they'll be sure to generate a reaction." ]

{ "things": [ "Alligator Bags", "Lockers", "Bench Planes", "Deployable Flight Recorders" ] }

[ "Alligator bags enjoyed their first wave of popularity at the end of the 19th century.", "The material was chosen for its exotic look, rich texture, high pliability, and durability.", "Since then, many legendary designer handbags have been made with alligator skin.", "For some women, a handbag is more than a practical accessory.", "It's also a way to express their personal style.", "Depending on the bag's size, shape, and desired look, many exotic animal skins can be used-- alligator, lizard, python, or ostrich.", "This red skin is from the nile alligator.", "The cutter maintains the pattern in place with a weight.", "He cuts out the shape of the bag, leaving a border, called a turning-in, all along the pattern.", "The skiving machine delicately shaves the back of the alligator skin to make it thin and pliable.", "A polishing jack creates a sheen.", "A plating machine applies heat and pressure to remove creases and make the skin shiny.", "Now it is placed on a hot plate for a few seconds to raise the skin and create what is called french bombay.", "They brush rubber cement on the back of the skin and apply it to a thin piece of leather called a pliver.", "This will keep the bombay from flattening over time.", "Then he cuts off the excess skin, creating a turning-in.", "This heavy paper and foam will go inside the bag's cover to give it structure and a cushiony feel.", "He removes the center part of the paper to help the cover fold easily.", "He uses a bone folder to fold the turning-in over the paper...", "Then carefully hammers it in place.", "Now he's making the sides, called gussets, and the bottom of the bag.", "He applies thin muslin and rubs it in place under a protective paper.", "Both gussets are sewn to the bag's bottom using a very fine needle.", "The stitches must be as discreet as possible.", "The bag's lining is made of soft lamb leather called cabretta.", "The top half contains a magnetic circle which serves to close the bag.", "The brand's nameplate is also attached to the lining.", "The nameplate sits inside the bag so it will only be visible when the bag is open.", "The pocketbook maker delicately glues the lining to the bottom of the bag.", "He folds the leather over with the bone folder and uses the hammer to make the juncture as thin as possible.", "Since the covers are glued in place, there are no stitches visible on the front and back of the bag, giving it a more luxurious look.", "Now he scratches the border to remove the sheen, which will help the glue adhere to the leather.", "He applies the back and front cover to the lining of the bag, making sure all the covers line up perfectly.", "This step is only performed by experienced pocketbook makers, as it is crucial to the final look of the bag.", "Anything less than perfect would look like a cheap imitation.", "Custom-colored paints will fill in any gaps and cover any variation in the leather.", "They finish by polishing the bag, using a small amount of shoe polish and a buffing cloth.", "They must use very little polish to avoid buildup in the grain of the leather.", "This also removes any dirt or cement.", "It takes about seven hours to make an alligator bag.", "All the time, effort, and materials result in a stylish fashion accessory that's made to last for years.", "Lockers are a familiar sight in high-school corridors, gym changing rooms, and many workplaces, and in the world of professional sports, lockers are the backdrop to many a post-game interview.", "The latest trend is buying lockers for kids' bedrooms as cool and practical storage furniture.", "While they vary in size and design, all lockers have ventilation holes.", "These help air circulate, which prevents odors.", "Lockers are made of a hard type of steel that's just flexible enough for presses to bend to the required shape.", "The steel sheets are 1/10 of an inch thick.", "Workers feed one at a time through a cutting tool called a square shear.", "It slices from one end of the sheet to the other, cutting pieces with the required width.", "Each door piece goes into a 100-ton punch press, which stamps out the ventilation holes.", "The next press punches screw and rivet holes around the edges and a hole for the cup that houses the locker's closure.", "The first bending press simultaneously folds over the top and bottom edges, forming flanges.", "This bend sets the finished height of the door.", "The next bend sets the finished widthof the door.", "The press folds the side edges over twice, forming a box-shaped rim.", "Next, workers position a steel reinforcement panel against the hinge side of the door.", "They affix one side of the panel using a welding machine that fuses 12 spots simultaneously.", "Then they weld the other side manually.", "Now they mount the door in an alignment fixture hinge-side up and clamp a piano hinge to the edge.", "They fuse the hinge to the door by welding it to the top row of screw holes.", "Meanwhile, they bend pieces of steel to form the locker's top, bottom, back, and sides.", "Now they weld those parts together.", "Then they weld the hasp, the steel loop through which you hook a padlock to lock the locker.", "The hasp goes on the edge of the body and protrudes through a slot in the closure cup in the door.", "Next, the locker's interior shelf.", "They set four rivets onto a positioning fixture-- two in the center, two on the edge-- then position the shelf on top, aligning the shelf's four holes with the four rivets.", "They position a single hook over each edge rivet and weld it on.", "Then they take a double hook and position it over the two center rivets...", "Then weld that on.", "Then they weld the shelf into the locker body.", "All the parts now head into the factory's paint shop.", "The powder paint they use for this model contains electrically charged silver particles-- a natural disinfectant that kills any bacteria, viruses, and fungi on the locker's surface.", "Once coated, the parts go into an oven for a half-hour to bake the paint.", "Then final assembly begins.", "First, workers mount the closure cup and the door hole with a screw and a retaining washer.", "Next, they install magnet catches to hold the door closed...", "And apply an adhesive sticker indicating this locker has an antimicrobial paint coating.", "Then they attach the door to the body by driving rivets through the lower row of holes on the piano hinge.", "They make sure the door moves smoothly and that the hasp aligns with the slot in the cup.", "The factory makes lockers of various sizes, shapes, and configurations.", "Some models even have built-in combination locks.", "Since roman times, woodworking planes have been part of the carpenter's tool kit.", "And despite the invention of power tools for wood surfacing, many still prefer the hands-on approach of this simple tool.", "Using it is a skill that can take a piece of timber from rough to refined.", "If wood needs shaping, it's time to reach for the bench plane.", "On the push stroke, it shaves down bumps and high spots on wood to make the surface level and true.", "Production begins with bench-plane patterns.", "They place several in a box and pour fine sand, mixed with a bonding chemical, over them.", "The bonding chemical solidifies the sand.", "They poke holes to vent gases later on.", "And with the patterns removed, it's clear that the bonding chemical has worked its magic.", "The patterns have left a definite impression in the hardened sand.", "They apply glue to one half of the mold so it adheres to the half with the impressions in it.", "They then glue two square-shaped spouts around holes in the sand mold.", "Next, they fire up the foundry furnace and melt iron into a white-hot liquid.", "Workers then carefully pour the molten metal down the square spouts and into the sand molds.", "Gases are released through the holes poked in the sand earlier, while weights keep the lids from lifting from the pressure.", "After a two-hour cooldown, they break the molds and pick out the cast-iron parts.", "The planes have a knobby protuberance, formed as metal flowed into the mold.", "They slice that off.", "And after strengthening the cast iron's physical properties, they mill the bottom of the bench plane to make it reasonably flat.", "They also expose a slit formed during molding.", "They now lock the bench plane in position to allow the spiked teeth of a cutting wheel to carve into the molded slit.", "It enlarges the slit to form the mouth of the bench plane, the opening through which the plane's blade will protrude.", "Some precision work is needed, so a tapered and serrated tool is forced through the mouth.", "This opens it up a little more to give it the exact dimensions required.", "Coolant now flows to prevent overheating, as a grinding wheel machines the base of each bench plane until it's completely flat.", "They now try to slip a very thin steel strip between a level bar and the base of the bench plane.", "Failure confirms it's perfectly flat.", "Next, a cutting tool evens a sloped pad molded onto the front of the bench plane.", "This pad, called the frog, will hold the sliding wedge that sets the angle of the plane blade.", "Production now focuses on the blade.", "They heat a steel rod in a furnace until it's white-hot and malleable.", "They then place it under a mechanized hammer which pounds it until it's flat.", "They turn the flattened steel sideways, and the pulsating hammer squares the edges.", "Then another tool stamps the company's insignia onto one end of the blade.", "The steel rod has been flattened, squared, and stamped.", "It's then cut to the desired shape and dimensions and given a beveled cutting edge.", "The next part is called a lever cap, and it will be used to clamp the blade to the bench-plane frog.", "They sand it smooth to improve its look and function.", "They then buff each part of the bench plane against a cloth wheel to a mirror-like finish.", "It's now time to fit the bench-plane frog into the pad machined especially for it.", "They secure it with screws.", "The cutting blade, by now reinforced by a part called the cap iron, fits flush to the frog.", "They top off the assembly with a lever cap and clamp it all together with a spring system.", "They fit a knob made of tropical wood on a threaded rod on the front of the bench plane.", "The knob and the back handle will allow the user to firmly grip the bench plane and push it forward.", "And with the blade now protruding from the base on an angle, it's ready to level any piece of wood, leaving only shavings in its wake.", "A flight data recorder, or a black box, records every detail of an aircraft's operations, from engine speed to cabin pressure.", "After a crash, investigators extract the data to determine what went wrong.", "Black boxes are actually bright orange so they'll stand out amid the wreckage.", "These black boxes are the deployable type, meaning they separate from the aircraft upon impact.", "This makes them easier for search-and-rescue crews to recover.", "To make the outer shell that houses the components, they use a two-part mold, first waxing it to ease extraction later on.", "Then they brush on an orange-tinted gel coat, a liquid that, after four hours, hardens into a durable, waterproof finish.", "Over the hardened gel coat, they apply pieces of fiberglass cloth, saturating them with orange-tinted resin.", "They apply extra pieces in the corners for reinforcement.", "They continue until they've built up three layers of fiberglass.", "The rectangular box on this mold half-casts a cavity in the shell that will house the device's key components.", "They embed aluminum plates within the fiberglass to reinforce the area where screws will attach the cavity cover.", "A computer-guided milling machine contours a piece of foam that will fit the empty space inside the shell.", "This foam absorbs the force of impact so the flight data recorder can survive a crash.", "They coat one side of the foam core with resin paste, then lay it into the mold.", "They fill voids with a temporary retaining block to prevent the foam core from collapsing inward during the vacuum process that comes next.", "They wrap the mold in felt to protect the surface, put it in a plastic bag, attach a hose, then start the suction.", "Over four hours, the vacuum slowly extracts the air, drawing the fiberglass tightly against the foam core without any wrinkles or puckers.", "It takes another four hours for the resin to completely cure.", "Then they remove the mold from the vacuum bag, coat the other side of the foam core with resin paste, and embed steel reinforcements.", "Besides absorbing the force of impact, the foam core makes the flight data recorder buoyant should the aircraft go down in a body of water.", "The device contains two antennas, the first of which gets pasted into a designated spot in the foam core.", "One antenna transmits a distress signal, the other a homing signal to help search-and-rescue crews locate the downed aircraft.", "Now they mate the two parts of the mold, carefully sliding the antenna that protrudes from one half through and out an opening in the other half.", "They bolt the mold closed and leave the paste to air-cure overnight.", "The next day, they unbolt the mold and extract the shell, the two halves of which are now bonded with the first antenna inside.", "Now they can install the other components, such as this memory module containing the circuit boards that record the flight data and cockpit audio.", "All the components, prior to installation, undergo extensive testing to ensure they operate properly when subjected to vibration and extreme temperatures.", "The memory module goes into a fireproof box, along with the transmitter that sends out the locating signal via the antennas, the second of which they now install into the component cavity at the top of the box.", "Then they install the battery that powers the transmitter for 150 hours.", "They connect the battery to the transmitter in the fireproof box...", "Connect the transmitter to the antennas, then screw the cover to the aluminum plates embedded around the cavity's perimeter.", "The finished device undergoes a series of performance tests.", "This one, in a special echo-free chamber, verifies the signal the transmitter sends out via the antennas.", "The chamber's receiving antenna is connected to a computer that analyzes the signal's frequency and transmission pattern-- critical factors in recovering the box that provides vital clues for crash investigators." ]

{ "things": [ "Cement", "Caskets", "Soft Drinks", "Glider Rockers" ] }

[ "Today on \"how it's made\"...", "Cement...", "Caskets...", "Soft drinks...", "And glider rockers.", "Many people confuse the terms \"cement\" and \"concrete\".", "Cement is a fine, gray powder that's used to make concrete.", "It's also an ingredient in the mortar that masons use to lay brick and stone.", "Cement also goes into soil cement, a material that's used in paving roads, building dams, and lining reservoirs.", "The action begins at the limestone quarry.", "The limestone near the surface has a high content of the minerals silica, iron, and aluminum oxide.", "Deeper down, the limestone is more pure, containing less of those minerals and more calcium carbonate.", "The plant uses both types of rock, altering their proportions to make different types of cement.", "Workers drill holes in the rock wall, in which they plant powerful explosives.", "For safety, the workers have to position themselves behind the area they're blasting, maintaining a distance of at least 150 feet.", "After the explosion, loaders move in.", "They transfer the limestone rocks to 50-ton-capacity dump trucks.", "The trucks then haul their cargo to the cement plant nearby.", "At the plant, the trucks dump the rocks into what's called the primary crusher.", "The rocks can be as big as a piano.", "The primary crusher reduces them to about the size of softballs.", "There's a constant spray of water to keep the dust from billowing up and settling on the chutes.", "From there, a conveyor transports the rocks to the secondary crusher.", "It reduces them further to about the size of golf balls.", "Rock high in calcium carbonate and rock low in calcium carbonate are crushed separately.", "Now it's time to mix the two.", "The ratio varies according to the type of cement they're making.", "This overhead machine, called a tripper, makes piles of the required proportions.", "They call this the raw mix.", "Then a reclaimer loads the raw mix into a grinding machine called a roller mill.", "Depending on what minerals are already naturally in the crushed rock, the factory adds extra minerals such as silica and iron.", "Certain types of cement also require aluminum oxide.", "The roller mixes and grinds the ingredients uniformly, producing a dry rock powder called the raw meal.", "Now the powder goes into a preheater.", "The temperature of the powder is 180 degrees fahrenheit upon entering.", "Within 40 seconds, it gets more that 10 times hotter.", "This begins the process of binding the minerals together so that they'll later harden when hydrated with water.", "The preheater is equipped with what's called a flash calciner.", "In about 5 seconds, it removes 95% of the carbon dioxide in the powder through a chemical reaction.", "This isolates the lime, which is the most important element in cement.", "From there, the powder moves into a rotary kiln, a huge, cylindrical furnace.", "It's set on an angle so that the powder moves from top to bottom, a distance of 160 feet.", "The kiln rotates about 2 turns a minute to ensure the materials travel through at the right speed.", "The burner's gas flame at the bottom reaches a scorching 2,900 to 3,000 degrees fahrenheit.", "As the powder approaching it reaches the 1,500-degree mark, it fuses into pieces about the size of marbles.", "These pieces are called clinker.", "As the clinker leaves the kiln, large fans cool it down to between 140 and 180 degrees fahrenheit.", "It's important to cool the clinker quickly in order to have quality cement.", "From here, the clinker goes to the storage area.", "The last stage of cement making is called finish grinding.", "They add some gypsum to the clinker.", "The precise amount varies with the type of cement they're making.", "Gypsum delays the cement's setting time, so it can be worked for up to two hours before hardening.", "The cement mills are called ball mills because they contain metal balls, about 150 tons of them, in the largest mill.", "As the mill rotates, the balls crush and grind the clinker and gypsum into a fine powder.", "The terms \"casket\" and \"coffin\" are often used interchangeably, but there are distinct differences between the two.", "Coffins are actually those eight-sided burial boxes that are narrower at the bottom-- think \"dracula\"-- whereas caskets are rectangular.", "They can be made of metal, plastic, or wood.", "Whether the wood is ash, oak, mahogany, or something else, the casket's construction is generally the same.", "First they run wood slats through a machine called a molder.", "This profiles the edges, carving a tongue on one side of each slat and a groove on the other.", "A worker applies glue to these edges, then positions the slats in a rounded vise that locks the tongues and grooves together.", "The glue dries in an hour and a half, bonding the slats permanently into a large, curved piece.", "This piece will form the top and long sides of the casket's rectangular cover.", "To complete the rectangle, a worker now makes a v-shaped cut on each side and glues in a triangular piece of slatted wood.", "While a press clamps the components tightly together, he secures the end pieces in place with joint fasteners, which are like heavy-duty staples.", "Now a machine carves a groove into the cover's underside at the midpoint.", "A worker glues in a wooden piece, securing it with joint fasteners.", "This piece is called the bridge, and it's the point at which the cover will be cut in half later on.", "They transfer the casket cover to an automated machine that gives it a rough sanding, then a finer sanding.", "The next step is to attach a decorative molding to the base of the casket cover.", "This molding has a groove on the inside into which they'll later tuck the edge of the casket's upholstery fabric.", "A worker glues a small piece of wood in the groove at the midpoint so the groove won't show when the cover is open.", "Now he saws the casket cover in two, right through the bridge.", "Meanwhile, another worker assembles the bottom of the casket, called the box.", "He glues together the sides and applies a bottom molding, securing everything with joint fasteners.", "At this point, the box is upside down.", "He attaches the bottom, then flips the box right-side up.", "Now it's time to join the cover and box, using four hinges.", "They spray the casket with one of countless shades of wood stain, then rub it in equally over the entire surface.", "The casket goes into an oven for an hour to dry the stain.", "Next a worker sprays on two coats of lacquer, with 40 minutes drying time between applications.", "This happens to be a high-gloss finish, but many models have a duller sheen.", "Once the lacquer dries, a worker attaches handles.", "The more expensive the casket, the fancier the features.", "This higher-end oak model with decorative corners has wood and metal swing handles.", "Other models have all-metal swing handles or fixed bars made of wood, metal, or both.", "The fancier caskets also have an adjustable wooden bed inside, with a mechanism to adjust the height.", "A worker covers the bed in fabric.", "The base-model bed is made of absorbent paper laid over a product called wood wool, which is simply shredded wood.", "The upholsterer lines the inside of the casket with foam, covering it with either velvet, satin, or silk polyester crepe.", "By folding, nailing, and stapling this fabric a certain way, she creates pleats, tufting, and other design details.", "Generally, the more expensive the casket, the finer the fabric, and the more ornate the upholstery.", "A decorative trim hides the staples.", "Fabric straps, or metal elbow brackets, hold the cover open.", "There's just no limit to how beautiful and elaborate caskets can be.", "The soft drink was born at the drugstore soda fountain, where pharmacists would serve up various flavors of carbonated water, initially considered a medicinal drink.", "These sodas became so popular that customers wanted to be able to buy them in bottles to take home.", "That demand spawned the soft-drink industry.", "In 2003, almost 195 billion liters of soft drinks were sold around the world.", "That's 30 liters for every person on earth.", "These 2-liter plastic bottles have just arrived from the bottle factory.", "Even though they're brand-new bottles, the soft-drink plant still has to clean them before filling them.", "This rinsing machine turns the bottles upside down, then flushes them with water the plant filters on-site.", "Once the water drains out, the machine turns the bottles right-side up again.", "And they make their way to the filling station.", "Meanwhile, in the mixing room, technicians prepare whatever soft drink they'll be bottling in this production run.", "Each recipe begins with filtered water.", "It makes up 86% of the drink.", "The rest is syrup.", "Each syrup recipe is a combination of carefully measured ingredients, natural and artificial coloring and flavoring, and one or more various types of sugar, such as glucose or fructose extracted from beets, corn, or cane.", "This machine releases the right proportion of syrup to filtered water, creating the final soft drink minus the bubbles.", "The drink now travels to a pressurized tank called the carbonator.", "There an injection of carbon dioxide infuses the drink with gas bubbles.", "The carbonated soft drink now travels to the reservoir of the bottling machine.", "The bottles arrive and travel its carousel.", "The machine removes the air in each bottle, then fills it with, in this case, two liters of cola.", "Now on to the capping machine.", "The caps come down a chute propelled by filtered air.", "The machine twists a cap on the part of the bottle called the crimp, intertwining the threads of the cap and crimp tightly to hermetically seal the bottle.", "Next stop, labeling.", "The machine's roller applies cold glue to one metal plate after another.", "Each plate then grabs a label and applies it to a bottle.", "Brushes smooth edges down, ensuring the labels adhere well.", "Elsewhere in the plant, a machine called the uncaser unloads cases of refillable glass bottles that have come back to the factory.", "The cases continue toward a case-washing machine.", "The dirty bottles head toward the bottle-washing machine, where devices called cells line them up in rows of 16.", "Each bottle tilts and enters the washer neck-first.", "Inside, a combination of powerful water jets and soap remove dirt and germs.", "Then water jets rinse off all traces of soap.", "As they exit, they pass in front of a neon inspection light.", "Workers pull any problem bottles off the line.", "Now the bottles head to the same bottling machine as before, only now it's been adjusted to fill each bottle with 10 fluid ounces of drink-- in this case, orange soda.", "This factory takes a sample from each production run for quality-control testing.", "The lab technicians check such things as the dilution ratio of syrup to water, the carbonization level, and the airtight seal.", "They also analyze the purity of the drink and container by running the sample through a paper filter.", "They put the filter in a petri dish containing the nutrients needed to grow micro-organisms.", "Then they incubate at a precise temperature and observe if any bacteria grow.", "These glass bottles have old-fashioned bottle caps, not the twist caps the plastic bottles have.", "As each cap drops down onto a bottle, the machine squeezes it tightly, creating an airtight seal.", "Once the bottles are filled and capped, they go into shipping cases.", "A glider rocker combines the back-and-forth movement of a traditional rocking chair with the gliding motion of a swing.", "Parents often buy them to rock their infants to sleep or soothe them while feeding.", "Other models are designed for people who like to rock and glide while having a conversation, reading a book, or watching tv.", "Glider rockers come in a few different styles.", "Some are made of solid wood with a variety of cushions.", "Others have a metal frame that's partially or fully upholstered.", "The first step is to cut the dried wood to the required dimensions using laser- and computer-guided saws.", "The species this factory uses for its wooden models are maple, oak, and ash-- hardwoods known for their strength and durability.", "Then a computerized, industrial router/shaper forms tenons.", "A tenon is a projection on the end of one piece that fits into a cavity, called a mortise, on another piece.", "Another shaper profiles the seat-frame pieces four at a time.", "Workers glue each tenon and mortise together by hand, then clamp the joint.", "Once the glue cures, these joints will be virtually indestructible.", "With the glue dry, the seat frame moves on to the next phase.", "Another automated router/shaper gives it the final contour.", "Next they smooth the surface of the wood using successively finer sandpapers.", "Now they bore a series of holes for attaching the armrests and back of the chair.", "Precision is critical here.", "They assemble those pieces in a custom-made assembly jig to ensure their exact position and angle before screwing them in place.", "Now they attach what's called the multiposition mechanism.", "This enables the glider-rocker to lock in six different comfort positions.", "This part, called a trammel, controls the angle.", "Ball bearings located at the top and bottom of the chair's arms are key to a smooth, gliding motion.", "Secured solidly, they'll last a lifetime.", "Workers assemble the parts that make up the rocking/gliding mechanism.", "Finally, they slide it under the seat frame and attach it to the multiposition mechanism.", "It's critical that the fit be precise for the chair to operate properly.", "Meanwhile, work is under way in the upholstery department.", "There are many different styles and colors of fabric available.", "Workers stack several layers of seat-cover fabric for a given model in a pile to cut several in one shot.", "The pile lies on a textured rubber mat held steady by a vacuum press so it won't move while the computerized cutter does its work.", "After the pieces are cut, a seamstress sews the zippered seat cushions.", "Another vacuum press temporarily squashes the seat cushions, enabling workers to insert one in each cover.", "The cushion isn't a simple block of foam.", "Rather, it's a triple-decker sandwich composed of two different densities of foam glued together with a multilayered polyester fiber.", "The fiber gives the cushion more depth and smoothness.", "The different foams maximize comfort and durability.", "The plastic wrapping has no structural role.", "It's merely part of the vacuum system.", "Relaxing in a glider rocker can be a very soothing experience.", "Picture yourself in front of the fireplace, legs resting on a gliding ottoman, relaxing your back after a long day, reading, listening to music, or just daydreaming." ]

{ "things": [ "Combination Wrenches", "Deli Meats", "Golf Carts", "Airships" ] }

[ "Whether tightening the wheels on your bike or working on your car, a combination wrench can make the toughest jobs safe and easy.", "The best combination wrench gives you reach and strength and won't bust your knuckles when you're working in those hard-to-reach places.", "A high-quality combination wrench can last you a lifetime.", "A combination wrench tightens and loosens nuts and bolts using its u-shaped open end or its enclosed box end with a hexagonal shape.", "Combination wrenches come in imperial and metric sizes.", "To start, a steel bar travels into a die-cutting machine that cuts it into lengths called billets.", "Each billet will become a wrench.", "One by one, a machine feeds the billets into an induction heater.", "It heats them to more than 1,800 degrees fahrenheit, then sends them into a forging press, where the first die creates the wrench's general shape.", "The second die gives it its finished shape.", "And the third trims off the excess metal.", "The wrenches exit the forge press and cool off on their way into a collection box.", "Then a worker grinds off the trim line, a thin line of excess metal created when the top and bottom dies come together.", "He loads the wrenches into an automatic edge-polishing machine.", "Using an 80-grit sanding belt, the machine grinds the trim line on both sides of the handle.", "The wrenches leave the edge-polishing machine trim-line-free.", "A worker then places each wrench onto a 75-ton hydraulic press, which stamps it with the brand name, size, and part number.", "This bend machine gives the box end a 15-degree angle.", "A vertical milling machine then drills a hole into the box end, using coolant to keep the drill from overheating.", "This is a hydraulic hex broach machine.", "The broach tool is what gives the hole a hexagonal shape.", "Open-end wrenches also go through a broaching operation.", "In this case, the broach tool shapes the open end into the desired size.", "A worker then grinds the open end of the wrenches and makes sure they're perfectly smooth.", "The wrenches now undergo a three-stage heat-tempering procedure to harden and strengthen the metal.", "For some combination wrenches, a sliding machine cuts an opening out of the box end that has the hex shape broached into it.", "This turns the wrench into a flare nut wrench that's ideal for working on hard-to-reach bolts, like on a hydraulic line.", "Ceramic stones and a chemical solution polish the wrenches for eight hours, giving them a bright luster finish.", "A machine then dips the wrenches into a nickel-plating solution that helps make them corrosion-resistant.", "This series of baths then plate the wrenches with trivalent chrome, which is a safer, more environmentally friendly alternative to traditional plating methods.", "After a final rinse in water, the wrenches come out with a bright cosmetic finish.", "Combination wrenches are available in a variety of sets, all conveniently organized and neatly stored.", "Since the 1920s, this company has been making combination wrenches of all shapes and sizes for jobs of all shapes and sizes.", "In a time of health-conscious eating, deli meats remain a mealtime favorite.", "Almost everyone loves a great-tasting sandwich or sausage hot off the grill.", "Today, the best deli meats are prepared from the leanest cuts.", "They have no trans fat, they are low in sodium and saturated fat, and contain no fillers.", "Some companies prepare deli meats largely by hand to maintain that old-world tradition.", "Sausages begin as cuts of fresh meats in a grinder.", "The ground meat falls into a collection tub...", "Which then deposits the meats into a mixer.", "Adding ice keeps the meats cold and fresh.", "A worker then adds salt and all-natural spices and seasonings.", "The mixer blends it all together.", "A worker feeds a natural sausage casing into a machine called a sausage linker that forms and links the sausages.", "A look inside the sausage linker reveals where the meat is pumped into the natural casing and shaped into the desired sausage size.", "As the sausages come out of the linker, they hook onto a conveyor system.", "They're ready to go into the smokehouse for cooking.", "Workers send the cooked sausage into an oven that destroys any possible surface bacteria.", "They pack the sausages into plastic bags, which are date-stamped.", "Then a machine vacuum-seals the packages, making them ready for the store.", "An olive loaf begins with a mixture of olives, pickles, and pimientos.", "Again, a worker adds salt and all-natural seasonings, mixing it together with blended fresh beef and pork.", "This stuffer machine fills loaf pans with the season-blended meats.", "Another worker puts a rack filled with uncooked olive loaves into a smokehouse oven.", "After an initial cooking that sets the loaf shape, he removes the loaves from the oven.", "At this time, only the exposed part of the loaves is browned.", "After he takes them out of the pans, they will go back into the oven to brown all sides.", "It takes about 10 hours to cook these special european-style loaves.", "Another worker loads pepperoni into a machine called a revolving horn.", "It stuffs a casing with a mixture of beef and pork seasoned with italian spices.", "The horn stuffs the casing with the precise amount of meat and seals both ends.", "The pepperoni is then hung up on a rack and taken into a smokehouse for cooking.", "Another worker prepares german bologna by slipping a natural beef casing onto a machine called a stuffing horn.", "He stuffs the casing with a mixture of beef and pork and all-natural spices and seasonings.", "He seals the end of the casing with aluminum clips.", "Another worker, using a paddle with spikes, perforates the casing to allow air to escape during cooking to ensure even cooking and browning.", "Now it's the german bologna's turn for a stay in the smokehouse.", "About eight hours later, the german bologna is evenly cooked.", "Using a guide, a worker slices the sausage into even cuts, which are then packed and date-stamped.", "From authentic german bologna to all types of sausages and distinctive deli loaves, deli meats are served around the world.", "Scotland is the birthplace both of golf and the motorized golf car, invented in 1946 by a dentist named john \"doc\" keegan.", "Since the late 1950s, golf cars have become widely used on courses everywhere.", "They're built low to the ground to remain steady, even over the most uneven terrain.", "This battery-powered golf car has everything to get you around in comfort and style.", "It can't help you with your swing, but it canget you to the next hole in a jiffy.", "To make a golf car, the first step is to build the frame with lightweight aluminum i-beams.", "They go through two separate machines to bend them into shape.", "Metal forms press down into vinyl and stretch it into the shape of the front and back seats.", "Workers cut and staple the vinyl over a plywood base covered with a layer of foam padding.", "They trim away the excess vinyl and set the finished seats aside.", "Now it's time to assemble the power train.", "Here, workers place an axle onto the differential, which rotates the wheels.", "They cover it with a staff ring...", "Then bolt the car's 48-volt electric motor onto the transaxle, the assembled transmission, differential, and drive axle.", "They assemble the car's frame on a fixture, starting with the driver side, then the passenger side...", "Then the center i-beam that holds the two sides together.", "They set the assembled frame onto the power train and bolt the car's front suspension mechanism onto it.", "As the car moves on to the next assembly station, a plastic underbody comes down to cover the front part of the frame.", "Workers now set in the accelerator and brake pedal.", "Then they lower the power compartment that holds the car's battery at the vehicle's rear.", "They connect the battery to the motor with four separate wires, then hook them up to the electric control module that commands the engine.", "Now they can cover the rear working parts with the plastic underbody.", "The underbody provides the support on which to install the car's working parts, like this pedal mechanism or the steering column.", "All the electric tools that apply torque are computer-monitored.", "If the amount of torque applied at any of the 130 assembly stations is incorrect, the system prevents the car from advancing to the next station until they get it right.", "This eliminates any problems that might arise with over-tightened or loose bolts.", "Workers now tighten the battery wires, then check the accelerator.", "Golf cars may not attain speeds higher than 15 miles per hour in compliance with industry regulations.", "Next, they set in the front and back seats that fit snugly into the molded plastic rear body and screw in the front fascia that covers the underbody.", "They set the brake rod in place, make sure it moves the brake pedal properly, and tighten it.", "The screen located overhead indicates when they've applied just the right amount of torque.", "Finally, they hammer in the hubcaps and set in the front beauty panel, also made of molded plastic.", "The car's now fully assembled and ready to roll.", "The finished golf cars offload automatically from the assembly line thanks to a hydraulic lift.", "They get a final inspection from every angle-- even under the seat.", "Finally, workers drive them to an outdoor lot.", "No worries-- their aluminum chassis ensures they can endure even the harshest weather conditions.", "Soon, they'll carry eager golfers across courses throughout the world.", "An airship is basically a large helium balloon with an engine for propulsion.", "The passengers and crew ride in a gondola suspended underneath.", "When there's an inside frame supporting it, the airship is called a rigid type.", "When there's no framework, it's called a nonrigid type, or blimp.", "The envelope material is made of five polyester-based fabrics bonded together.", "It's lightweight, yet resistant to harsh weather and u.v. rays.", "The crew inflates the envelope with helium, an inert, nonflammable gas.", "At the back of the envelope are a rudder and fins for steering.", "The factory constructs each fin's frame out of tough, lightweight carbon fiber.", "Workers coat it with adhesive, then apply a polyester aircraft fabric, adding extra adhesive to seal the seams.", "Then, using an iron, they heat-shrink the fabric until it's taut.", "They repeat this process with two additional layers of fabric, then paint it white.", "They mount the fins to the airship envelope with a combination of steel cables and rope.", "The steel cables are rigid, but the rope has some give when the envelope flexes in flight.", "A system of cables and pulleys connect the rudder and fin to the cockpit.", "The pilot manipulates them with yokes.", "The flaps control up-and-down movement, the rudder, sideways movement.", "Engineers inspect the envelope inside and out for pinholes to ensure no helium can leak out.", "To repair a pinhole, technicians first cover it with a piece of tape, then brush on some adhesive in a circular pattern.", "They apply a circular patch made of the same five-layer fabric as the envelope.", "Using a spatula, they push out air and excess glue to ensure airtight adhesion.", "The airship runs on two gasoline-powered engines.", "Workers hoist them into the engine bay at the back of the gondola.", "The propeller's sharp blades are encased in a duct for safety.", "One propeller goes on each side.", "The blades of the propeller pivot to move the airship in reverse without having to stop the engine.", "The cockpit electrical panel has gas-management gauges because as the airship rises, the helium expands.", "So the pilot has to reduce air pressure inside the envelope to keep it from bursting.", "In a pinch, the pilot can also open a valve to vent helium.", "To test the helium valve, technicians blow in pressurized air while brushing liquid along the edge.", "Any bubbles indicate leaks that need sealing.", "The valve opens and closes with levers and cables.", "Unlike electronic controls, cables can be repaired in midair if something breaks.", "Inside the envelope, they install air sacks called ballonets, the gray areas in this diagram.", "The pilot deflates the ballonets to rise and inflates them to descend.", "Workers attach the envelope and gondola with cables, belts, and braces and fill a ballast tank under the gondola with water.", "In an emergency, the crew can dump the water for a boost of buoyancy.", "The gondola also has compartments for shot bags, 22-pound bags of lead.", "Before takeoff, the pilot checks the weight with passengers, equipment, and fuel on board.", "Then the crew loads enough shot bags to balance the airship.", "To park the airship, they lock its nose onto a mast.", "Just before flight time, a truck tows the mast out of the hangar.", "Then it's all hands on deck.", "Well, actually, all hands on gondola, until takeoff." ]

{ "things": [ "Combination Locks", "Pottery", "Recreational Vehicles", "Erasers" ] }

[ "Today on \"how it's made\"...", ".combination locks...", "Pottery...", "Recreational vehicles...", "And erasers.", "Combination padlocks are what students depend on to protect their lockers from thieves and pranksters.", "Combo locks are functional yet fashionable.", "Like everything else marketed to teenagers these days, they come in a variety of trendy colors and designs.", "The combination lock's main locking mechanism is called the baseplate, and it's comprised of seven components.", "That black piece, called the lock bolt, is what slides open to free the shackle when someone dials the correct combination.", "They rivet the baseplate components into place so the lock will stand up to repeated use.", "Here are those components before assembly and after.", "They secure the assembled baseplate into the casing.", "Then they install the trip-lever spring.", "It's what automatically scrambles the mechanism every time the lock is closed.", "They fit the shackle through holes in the casing, positioning one end against the trip lever.", "They fasten the other side with a tiny steel bar called a yoke.", "The lock's combination function is made up of three stacked disks called tumblers.", "Here, the first two go in.", "Next, they grease the shackle so it will slide in and out easily.", "Sometimes they customize the face of the lock.", "Those numbered dials used to come in just boring standard-issue steel.", "Today, they can have colorful designs-- even a school's logo.", "The printing machine uses a four-color printing process, applying one color at a time.", "The painted dials get two coats of clear varnish to harden and protect the paint.", "While that's happening, other workers assemble the dial components.", "First they take the indicator button and attach it to the dial.", "Then they take the third tumbler and rivet it to the back of the dial.", "This tumbler will control the movement of the two other tumblers inside the lock's casing.", "All three tumblers have \"v\"-shaped indentations.", "The correct combination aligns those v's, allowing the lock bolt to slide over and free of the shackle.", "Each tumbler has a code number stamped on the back.", "The number corresponds to the location of its indentation.", "They program each lock's three tumbler codes into a computer.", "The computer then randomly creates a combination that will align the three indentations.", "There are more than 50,000 possible combinations.", "The system prints the combination on a sticker along with a bar code.", "The bar code is programmed into a central computer, where it's recorded with the lock's serial number.", "The guts of the combination lock are finished.", "Now it's time for the final assembling.", "They put the dial onto the casing.", "Then a forming tool presses down on the casing's rim, folding it tightly over the dial.", "A computer-guided machine then engraves a serial number on each lock.", "Some factories do random quality-control checks, but this company verifies each and every combination lock by hand.", "That's quite the procedure, considering this plant produces more than 10,000 locks a day.", "You can bet somebody's got pretty sore fingers by quitting time.", "As early as 11,000 b.c., man was making utensils out of clay.", "This was the birth of pottery.", "Modern pottery is divided into three categories-- porcelain, stoneware, and earthenware.", "What differentiates them is the mixture of clays and the firing process.", "This earthenware piece starts with a technical drawing based on an artist's conception.", "Following the specs, they use a series of specialized tools to sculpt a plaster model on an electric potter's wheel.", "They check the diameter with calipers.", "The model is 7% larger than the finished piece will be to compensate for shrinkage that will occur during drying and firing.", "They sculpt some parts by hand and glue them on.", "Using this model, they cast a master mold, made out of a rigid type of plaster called gypsum.", "They now use this master mold to cast a production mold out of rubber or, in this case, plaster.", "First they pour in the plaster, using their hands to break up any air bubbles that would cause defects in the casting.", "The leave it to air-dry in a warm room overnight.", "Once it's ready, they can extract it-- a delicate operation that takes 15 minutes.", "This production mold has to cure for 48 hours before going into service.", "It will be good for 200 castings.", "And it will be identified by the model number on its side.", "Earthenware is made of talc, a mineral called nepheline syenite, a dark-beige clay known as ball clay, another mineral called silicon, and a white clay known as kaolin, all mixed with 40% water.", "They pour the mix into the production mold with careful, even pressure, again to avoid creating air bubbles.", "The plaster mold slowly absorbs the water, leaving behind a moist earthenware lining 2/10 of an inch thick.", "After about a half-hour, this lining hardens, and they can dump out the surplus liquid.", "They cut off the excess earthenware at the top...", "Then, after another 45 minutes or so, extract the piece from the mold.", "Workers have to handle the earthenware gingerly with even pressure.", "If one finger presses just a bit too hard, it will show up as a dent, but only after the piece is fired.", "After a 24-hour drying period, workers then carefully shave off the seam left by the two halves of the mold.", "They rub the piece on a wet stone to even out the top and bottom.", "Then they smooth the surface with a wet sponge.", "Unlike stoneware, which comes out glossy after firing, earthenware remains dull.", "So, to make it shiny and colorful, they apply specialized glazes and enamel paints.", "Finally, they spray the piece from top to bottom in a transparent glaze to give it an overall sheen.", "Then it's off to a room-sized oven called a kiln for an eight-hour firing, during which time the temperature climbs to more than 1,800 degrees fahrenheit.", "Then a two-hour cooldown.", "The intense heat activates the pigments in the paints and makes the colors come alive, turning what was once a lump of clay into a work of art.", "Traveling in a recreational vehicle is like having your own personal motel on wheels.", "R.v.s are either motorized or towable.", "Towable ones range from folding-tent trailers, known as pop ups, to more elaborate travel trailers complete with fully equipped bathrooms and kitchens.", "To make a travel trailer, workers first cut steel bars to build a frame.", "The saw has to be drenched in coolant, or it will overheat due to the intense friction.", "They drill holes for the bolts and screws they'll later use to attach certain components.", "Then they weld the frame parts together.", "They run electrical wires through the frame, lining the holes with rubber grommets to keep the wires from rubbing on the sharp metal edge.", "Next they install metal brackets to hold the water and septic tanks in place underneath the trailer.", "Then they torque the wheels to the axle.", "Now they install the gas lines.", "The stove, the fridge, and the heating system all run on propane.", "Next come the water and septic tanks, made of polyethylene, a heavy-duty plastic.", "They cut a hole in each tank and screw on a fitting.", "The tank sits directly on the frame.", "The white one's for drinking water.", "The first black one's for the shower and sinks, and the second black one's for the toilet.", "To build the floor, they put down a waterproof membrane, then a spruce frame insulated with fiberglass wool, then 5/8 plywood, cutting vent holes for the forced-air heating system.", "After sanding the joints and gluing down linoleum, they install the cabinetry and furniture.", "The plumbing fixtures come next.", "They connect to water lines coming up from the tanks beneath the floor.", "The water system is driven by an electric pump.", "While some workers put up the preassembled walls, others run wiring for lights and appliances.", "The inside wall surface is vinyl paneling.", "Drywall would be far too heavy for an r.v. the paneling's mounted on a pine structure insulated with fiberglass wool.", "They cover the outside in aluminum siding, then they complete the electrical wiring for the lights and appliances.", "Now it's time to install the roof-- another pine structure with fiberglass-wool insulation covered with a thin wood called lauan that's reinforced to withstand the extra weight of roof cargo.", "They cut out the various ventilation holes...", "Then apply a layer of glue...", "Then lay down a high-performance waterproof rubber membrane...", "Nailing it down along the perimeter.", "They install vents for the toilet, the refrigerator, and for air circulation.", "They caulk all the joints and around all the vents.", "Last but not least-- the windows, doors, awnings, and any optional equipment.", "Workers check the water, gas, and electrical systems, then do what's called a seal test.", "A special machine applies air pressure from the inside out.", "Wherever water bubbles, there's a leak to be repaired.", "With all the upholstery and other decorative elements in place, this comfortable travel trailer is ready to hit the road.", "Make no mistake about it-- an eraser is a student's best friend.", "Whether it's attached to the top of a pencil or on its own, only an eraser can quickly rub out an error.", "White erasers are made of flexible vinyl, while pink erasers are made of synthetic rubber.", "In 1736, a french explorer observed south american native indians using a certain tree resin to make bouncing balls.", "He brought this resin back home, and before long, europeans discovered it could rub out lead pencil marks, hence the term \"rubber\".", "There was just one problem-- after a while, rubber would rot.", "That dilemma was solved a century later by one charles goodyear, who developed a curing process to keep rubber from rotting.", "A lot of ingredients go into making a simple pink eraser-- carefully measured fillers, accelerators, curing agents, oils, coloring, and the main ingredient-- synthetic rubber.", "They start by putting a batch of rubber into a mill.", "The rubber passes repeatedly between large heated rollers.", "They throw in any defective erasers from the last production run, recycling them into this new batch.", "Then they add sulfur as a curing agent, accelerators to help the sulfur do its job, and red coloring.", "They blend everything for 5 to 10 minutes until the mixture is the consistency of heavy dough.", "Next, vulcanized vegetable oil-- that's vegetable oil treated with sulfur.", "Then regular vegetable oil.", "Then calcium carbonate as a filler.", "When the color and thickness are just right, workers remove the rubber, which, by now, is hot and soft as a result of all that milling.", "They leave it to cool and harden at room temperature for about half a day.", "When the rubber's ready, they cut out large squares, each weighing between 11 and 18 pounds, depending on the thickness of eraser the client has ordered.", "The squares go into a steam-heated press to cure for about 20 minutes at 325 degrees fahrenheit.", "The pressure compacts the rubber, while the intense heat hardens it.", "They trim off the excess then submerge the hot rubber squares in cold water to stop the curing process.", "To make erasers that erase both lead and ink, they cut beveled strips from two batches of rubber, one pink and one blue.", "The blue contains pumice, which gives it extra abrasiveness to erase ink.", "They pair up each pink with a blue to form a two-color strip.", "Then it's into the steam press.", "After 12 minutes, workers remove the trays, trim off the excess, and submerge the strips in cold water to stop the curing process.", "Then an automated machine chops the strips into pieces the size of erasers.", "Now back to the all-pink erasers.", "The rubber squares come out of their cold-water bath and go through a machine that cuts strips with beveled edges...", "Then chops the strips into erasers.", "From there, the erasers drop into a giant barrel.", "Workers throw in some talc to prevent them from sticking together.", "Then they set the barrel spinning for three to five hours.", "As the erasers tumble against each other, the abrasion rounds off their edges.", "The last step is printing.", "A machine stamps each eraser with the company name and the model number.", "It's not the rubber that gives the eraser the ability to erase, but rather the vulcanized vegetable oil that's in it.", "That's what makes the eraser crumble when rubbed on paper, taking away the pencil marks with it." ]

{ "things": [ "Steel Shipping Drums", "Police Whistles", "Miniature Train Wagons", "Glass Blocks" ] }

[ "Today, on \"how it's made\"...", "Steel shipping drums...", "Police whistles...", "Miniature-train cars...", "And glass blocks.", "The steel shipping drum was invented in the late 19th century for the oil industry, which needed an alternative to leaky wooden barrels.", "But those first steel drums also leaked from their soldered seams.", "Welding them proved to be the solution, giving this container an airtight reputation.", "It's a product that really delivers the goods.", "A punch press first cuts and forms the drum's bottoms in one swoop.", "A conveyer shuttles the bottoms down the line to a turntable.", "As a drum bottom rotates on the turntable, a nozzle sprays sealant onto it, coating it completely.", "Then the drum bottoms are stacked up.", "Meanwhile, another punch press shapes steel discs into tops for the drums.", "Rollers turn up the outer edge to a precise measurement.", "Next, steel fittings tumble down a vibratory conveyer to a machine that simultaneously punches threaded openings in the tops and inserts the fittings.", "One hole is for opening and closing the drum.", "The other is a vent.", "At this station, workers check the thickness of sheet steel that will be used for the body of the drum.", "The thickness varies depending on what the container is to hold.", "A machine called a shear slices the the coiled steel into sheets.", "The steel sheets then move on to a forming machine, where rollers curl them into the drum's shell.", "Automated pushers then move each shell through an electric-resistance welder.", "It generates heat to weld the side seam, bonding it from both the inside and the outside so it won't leak.", "The shells roll down to a machine called a flanger.", "The flanger stretches and presses on the outer rims at both ends, creating a lip.", "Then it's over to the beater.", "Its rollers bear down on the shells to make grooves called rolling hoops.", "These rolling hoops add rigidity to the shells.", "The shells now travel down another conveyer and merge with the drum tops.", "Automated pushers deliver a top to the base of a shell.", "The shell rotates in a spinning clamp as rollers curl the edges of the top and shell together.", "This creates an interlocked seam called a chime, which is then flattened by another roller.", "Mechanized arms flip the shells so the bottoms can now be installed.", "To join the bottoms to the shells, rollers form another chime.", "These interlocking seams are comprised of seven layers of steel, making them leakproof.", "That's critical, since the steel drums may be used to transport hazardous goods.", "The steel drums now move forward to a testing station.", "Here, inspectors inject air into each drum and check the seams for leaks.", "The seams have been soaked up, so if bubbles materialize, it signifies a problem.", "The steel drums then go for a whirl under the paint gun.", "It sprays them with enamel paint for a protective sheen.", "Black is the most common color for these shipping containers.", "But custom colors can be ordered, too.", "The steel drums then journey through an oven that bakes the paint to a hard finish.", "The thickness of the paint is gauged with a special tool that makes sure it's thick enough to withstand rusting.", "Workers plug both openings and put a temporary seal on the vent to prevent tampering.", "After that, these steel shipping drums are ready for the long haul.", "Next, get the blow-by-blow at a police-whistle factory.", "It was in the late 19th century that london police started using a special whistle to get attention.", "It was lightweight and had a piercing sound-- a real improvement over the hand rattles they had been using before.", "That same design is still used today.", "They may be a blast from the past, but there's nothing better for blowing the whistle on lawbreakers.", "The average traffic cop blows his whistle thousands of times a day, so the whistles have to resist a lot of spit.", "The whistle's body is made of high-grade brass tubing, in which two slots are punched.", "These are sound holes that will allow the noise to escape.", "Using hydraulic pressure, the brand name is stamped onto the tube.", "Next comes the mouthpiece.", "Rollers sculpt a piece of spinning brass into a shape that's a bit like an hourglass.", "With the mouthpiece complete, a hydraulic punch is used to bend a piece of brass into a part called the slab.", "The slab will be used to create two sound chambers inside the whistle.", "A loop is fitted on to an endcap to make the whistle easier to hang on to.", "A rotating press bends the loop's tab against the inside of the cap to fasten them together permanently.", "Next, an endcap is attached to the slab, and then the slab is forced into the cavity of the whistle, splitting it into two chambers.", "A police whistle actually produces two notes at once, giving it that distinctive timbre.", "These two separate sound chambers will produce two different pitches.", "Now the ends of the whistle are dipped in solder paste and then the looped cap and mouthpiece are hammered onto the pasted the solder paste is a special lead-free compound so the whistle-blower won't be exposed to toxins.", "Solder wires are also inserted in the whistle chambers before capping the ends.", "These solder wires will act in conjunction with the solder paste to seal the whistle in a process that happens next.", "The whistles move through an electromagnetic conduction coil, which heats them to a smoking 425 degrees.", "This causes the solder paste and wires inside to melt and flow into the whistle's seams.", "Each whistle is then dipped in an acid bath, which hardens the solder, sealing the whistle's seams.", "Next, the whistles are lowered into a nickel bath, where positively charged nickel ions migrate to the negatively charged whistles.", "Now it's time to make some noise.", "Each whistle is tested with compressed air.", "The tiniest pinhole will cause a whistle to fail, and that happens in 3% of them.", "Failure is a crushing experience.", "The rejects get flattened and sent to a company that reclaims the metal.", "On both land and sea, whistles are the sound of authority.", "Here, workers assemble a boatswain's pipe, used by naval officers to issue commands and salute dignitaries.", "There's a tiny hole in the ball at the end of this pipe.", "The player opens and closes that hole with his hands to change the whistle's pitch.", "And with that, production at this whistle factory comes to a screeching halt.", "Up next, all aboard.", "You're about to see how raw plastic is transformed into a miniature train car.", "Making miniature train cars is all about the details.", "Every feature is scaled-down to a fraction of the real thing, and nothing is too small to replicate.", "The miniature train car is more than just a toy.", "It's a work of art and a collectible.", "On a miniature train track, the past comes full circle with replicas of trains from days gone by.", "Craftsmen start with historical photos and drawings of actual train cars and scale them down to 1/48th size.", "They feed polystyrene pellets like these into an injection-molding machine.", "It melts the pellets into a thick paste.", "The four sections of the mold close and nozzles pump in the plastic.", "It oozes into all the grooves and hardens almost instantly into the shape of a train car.", "Then the excess plastic gets clipped off.", "Here's a view of how the four parts of the mold come together to shape melted plastic into a boxcar.", "They even create holes in the boxcar to attach accessories and they impress details like ridging that mimics the steel ribs of the life-size train car.", "More molds are used to replicate door rails, brake wheels, and other accessories.", "The assembler clips the parts off the framework and files down the rough sections.", "That is the brake wheel she's snapping onto the end of the model.", "Using a hobby knife, she trims excess plastic from the train car's step.", "She then glues a steel weight to the bottom of the train car to make it 1/48th the weight of the real thing.", "Making something to scale is a bit of a balancing act.", "Finally, she attaches air-brake tanks to the underframe of the car, and it's time to spray-paint the model train car vivid orange.", "It's a color that would have been used on an actual boxcar, combined with white.", "For that two-toned look, the model is held in a paint shield, which protects the orange sections as they spray on the white.", "This technique ensures the paint job has clean lines.", "The car is left to dry overnight.", "Not all paint jobs are so flashy.", "This car is basic black, the perfect canvas for white lettering.", "A pad picks up the ink from letter engravings on a printed plate and transfers the image to the car.", "Metal wheels now roll off a revolving conveyer.", "They funnel into mechanisms that press-fit them onto each end of metal axles.", "The wheel-and-axle assemblies drop into a bin below.", "Two sets of wheels are now installed on a plastic framework.", "The framework is then attached to a coupler, the device that links train cars.", "The wheels-and-coupler assembly are screwed on to one end of the car.", "Then the process is repeated on the other end.", "The couplers are snapped together to connect two train cars.", "In the world of train models, a little grime is just fine.", "A misting of paint makes the cars look dusty and aged on purpose.", "The painter layers colors to get just the right effect.", "This technique adds the element of realism to the model train car.", "It's all a matter of preference.", "Some hobbyists prefer this weathered look, while others like their model trains shiny and new.", "The model train cars have now rolled off the assembly line, and they're ready to hit the tracks for a whistle-stop tour of another era.", "Coming up, the hot scoop on one of the world's favorite building blocks.", "When it comes to building materials, glass blocks are clearly a classic.", "In the 1920s and '30s, they were a cornerstone of the art-deco style of architecture.", "Today, glass blocks are still popular for creating walls, windows, and stunning design features, a stylish way to build a privacy barrier that still lets in light.", "Glass blocks aren't just decorative.", "They insulate from heat, cold, and noise.", "Production begins with just four ingredients-- recycled glass pieces called cullet, sand, soda ash, and limestone.", "A computerized system portions out each one and feeds them into a melter.", "This giant furnace heats the batch of ingredients to a fiery 2,700 degrees, transforming them into molten glass.", "The melter pumps out enough molten glass to make one half block at a time.", "Automated shears slice just the right amount.", "The gob of glass then slides into a waiting mold.", "A plunger pushes the gob down, spreading glass throughout the mold cavity.", "Its waffled surface imprints that pattern into the glass.", "A blast of ambient air cools down the molten glass drastically, from 1,800 degrees to 1,100 in just a few seconds.", "This way they don't lose their shape when a retractable arm extracts them from the mold and lays them on a conveyer belt, leading into a sealing machine.", "This is where two half blocks join together to form a full block.", "Entering the machine, each piece passes over a series of burners that keep the glass temperature constant.", "Sudden cooling could crack or shatter the glass.", "The machine then slowly reheats the half blocks until their edges start melting.", "Next, they enter the part of the machine called the squeeze station.", "Here, an automated press forces a top half and bottom half together.", "Their melted edges fuse, forming a single block.", "The blocks now travel into a leer, an oven that cools the glass at regulated temperatures over several hours.", "This annealing process prevents cracking and allows the glass time to set properly.", "The glass goes in at about 1,800 degrees.", "Coming out, it's down to 175.", "The blocks are now ready for inspection.", "Workers use digital-alignment gauges to make sure both halves are flush.", "Then they run a straight piece of steel along the block's surface to check for any distortion.", "Every block must meet precise standards for both size and shape-- a 71/2-inch square that's 4 inches thick.", "Building with glass blocks is similar to building with bricks-- you use mortar to stick them together.", "To prep the blocks for mortaring, workers now place each one onto a separate station.", "As it spins, nozzles spray the edges with liquid vinyl.", "This coating will help the mortar stick to the glass surface.", "Just one last step.", "An ink-jet printer applies the product code along with the manufacturing date and time.", "The quality-control department runs samples through an impact test.", "A worker drops a weight through a tube onto the side of the block.", "This verifies the strength of the sidewall and the seal between the two halves.", "Finally, the glass blocks are ready for shipping.", "Workers pack them into cardboard boxes that have block-sized sections to keep them safe during transport.", "Glass blocks come in so many shapes, sizes, and patterns that the design possibilities are endless.", "Both practical and beautiful, it's no wonder they're so popular with builders and decorators alike." ]

{ "things": [ "Mosquito Coils", "Solar" ] }

[ "being eaten alive by mosquitos is no picnic...", "Well, except to the mosquitos.", "Not only are the bugs annoying, but just one bite from an infected mosquito can transmit potentially debilitating or fatal diseases such as the west nile virus, malaria, and dengue fever.", "One way to ward off mosquitos is to light a coil that releases mosquito-repelling vapors.", "These coils, manufactured in thailand, contain three natural ingredients traditionally used in this country to keep those biting bugs at bay-- eucalyptus, citronella, and turmeric.", "The first step is to mix them with certain nonactive natural ingredients which form the coil-- coconut shell powder, sawdust, tapioca starch, and joss powder, an adhesive made from the bark and leaves of the litsea glutinosa tree.", "After blending all these powdered ingredients for 10 to 15 minutes, workers bag the mix in an empty ingredient sack, then empty the contents in a kneading tank.", "They add fragrance and dye.", "The coil comes in four varieties.", "This batch of coils will be pink and cherry blossom scented.", "Then, they add the coil's only chemical active ingredient, metofluthrin.", "Its vapors are toxic to mosquitos' nervous systems, yet harmless to humans in low doses.", "Metofluthrin makes up less than 1% of the mosquito coil.", "After about 10 to 15 minutes of kneading, the mix exits the tank as a formable paste.", "A conveyer belt transports it to an extruder, which squeezes the paste through a slot-shaped die, producing sheets approximately 4 millimeters thick.", "A stamping machine then punches out seven coils per sheet.", "The leftover paste travels back to the extruder to be reformed into fresh sheets ready for stamping while the stamping machine ejects the paste coils onto a mesh tray.", "Workers conduct a visual inspection and remove any coils which are misshapen.", "Then they stack the trays onto trolleys.", "They roll the trolleys into the drying chamber, which they heat to a temperature of 131 degrees fahrenheit.", "After 5 1/2 hours, the coils come out of the drying chamber hard and sturdy.", "After conducting another visual inspection, workers transfer the dried coil to the automated packing line.", "The machine's first station stacks the coils in piles of five.", "Workers place a metal coil stand on each stack.", "Then, the machine's next station packages each stack in clear plastic film.", "The package holds the five coils tightly together so they don't rattle against each other and get damaged.", "It also prevents the scent from dissipating before use.", "At the next station, a high-speed robotic arm grabs and opens the retail boxes, aligning them opposite the arriving packages of coils.", "The machine inserts a package of coils into each box...", "Then closes the box.", "Before packaging the mosquito coils, the company lab tests randomly selected samples from the batch.", "The chemist lights a piece of coils and places it in the center of a sealed test chamber.", "Five minutes after the coil has completely burned, she releases mosquitos into the chamber and clocks how much time elapses until they're debilitated.", "The lab also conducts a burn performance test.", "This verifies that the coils take between 7 and 8 hours to burn completely.", "These mosquito coils also come in lavender, rosemary, and herbal blend scents.", "Provided they're kept sealed in their plastic package and stored away from moisture, the active ingredients remain effective for at least 10 years.", "The solar-assist tricycle takes urban commuting in a whole new direction.", "It's part tricycle and part motorized vehicle.", "The motor runs on a lithium-ion battery that gets its juice from the solar panel on the roof.", "And it can also be plugged into an electrical outlet for a charge.", "The solar-assist tricycle is a vehicle for change.", "Propelled by both pedal power and solar energy, it's an alternative way to get around town.", "Making a solar-assist tricycle starts with the side panels for the cab.", "They've been thermoformed from rugged plastic.", "An employee cuts open doorways in the panels using a router.", "A fender was molded into the cutout to minimize waste.", "He cuts a hole in the panel to assemble that fender.", "Another employee then peels off the plastic film that has protected the panel during the cutting process.", "She attaches led signal lights and headlights to the tricycle body.", "She connects the lights to the wiring harness.", "The molded fender completes the tricycle side panel.", "She hangs it on a rack to await the next stage of production and writes the order number on it in order to keep track of it.", "They build the frame from tempered aircraft-grade aluminum.", "An employee mounts crank arms and chain rings to the front and then attaches pedals.", "The crankset transmits human pedal power to the drivetrain.", "Next up is the antlers, an assembly of metal tubes that includes the suspension mechanisms and steering linkage.", "They install steering arms at the ends of the antlers, then mount an aluminum dashboard support to the antlers.", "He inserts the steer tube for the handlebars into the slot in the dashboard support.", "He connects the steering linkage to the antlers using swiveling joints for precise handling.", "He inserts the handlebar into the steer tube.", "The team then secures two rugged bicycle wheels to the axle using cap bolts.", "They position the 1-horsepower motor and transmission between the tricycle's parallel spines and attach them with brackets and bolts.", "They loop a roller chain from the crank to the transmission and another one from the transmission to the rear drive wheel.", "They also link the motor to the rear wheel with a roller chain.", "They equip all three wheels with disc brakes.", "They install aluminum casing over part of the rear wheel and driveline.", "This protects these components and also provides structural support.", "A computerized tool now carves into corrugated polypropylene to create a box for the vehicle battery.", "An assembler then rivets the battery box to the front of the solar-assist tricycle.", "The team attaches metal struts to serve as supports for the vehicle body.", "They're now ready to assemble the body parts to the chassis.", "They align each panel to the frame and bolt it in nine locations.", "The fenders frame the wheels to keep road spray down.", "They fasten side mirrors to the vehicle, drilling the bolts through the body to the dashboard support.", "The employee then applies decals that identify the product.", "He protects the motor and transmission with a rugged plastic bonnet.", "And he screws the adjustable seat to the tricycle's aluminum spine.", "The team curves the flexible solar panel to the top.", "They attach the windshield to the front using high-strength double-sided tape.", "The windshield is made of polycarbonate that's optically clear and shatterproof.", "After the installation, he peels off the protective liner.", "The next worker inserts the battery in its compartment.", "He clips it shut, and the solar-assist tricycle is ready for the road.", "With its egg-shaped cab, it's certainly unusual-looking.", "And that's fitting because this hybrid vehicle is something entirely different.", "Most people use palm oil daily and don't realize it because it just blends in.", "It's a component of half of packaged food products.", "And it's also used in cosmetics, detergents, and even biofuels.", "It has a smooth texture, a natural taste.", "And it's a natural preservative.", "Brought to southeast asia from africa a century ago, oil palms have thrived here.", "Today, this region generates 85% of the world's palm oil supply.", "At the heart of this palm oil boom are breeding programs that ensure high yields.", "Technicians start by dissecting the fruit bunches.", "They analyze the quality of the fruit fibers, kernels, and nuts.", "They also assess their oil content.", "This identifies the most productive palms, as well as the trees best suited to particular growing environments.", "Next, the research team climbs the selected mother palms and pollinates the female flowers with pollen from high-quality male palms.", "They cover the flowers with thick fabric that allow light in but shields them from accidental pollination by insects and from other flowers.", "This ensures that hybrid seed will be the product of the selected parents only.", "It takes 6 months for the new hybrid seeds to be produced.", "Then it's into a heat chamber for 3 months to break the seeds' dormancy.", "They soak the awakened seeds in water.", "Along with the heat treatment, this rehydrating accelerates germination-- a process that takes many years in nature.", "They place the seeds in drawers and regularly mist them with water.", "After a few days, the seeds begin to sprout.", "Skilled staff sort through the sprouted seeds.", "They reject any that haven't germinated completely or that have crooked shoots.", "The seed on the left is the ideal specimen.", "They plant the selected seeds in small bags of soil outside.", "They shade them during this initial period of growth, protecting them from harsh sunlight.", "After 3 months, the seedlings develop roots and leaves.", "They transfer them to larger bags of soil, and 6 to 9 months later, they're 3 feet tall and ready for planting in farmers' fields.", "After 3 years of growth, the young palms bear fruit.", "The time is now ripe to tap into the oil-generating potential of these huge fruit bunches.", "The farmer loads the oil palm fruit onto a tractor cart.", "And it's on its way to the palm oil factory.", "Here, fruit from many farms accumulates in the receiving area.", "When the factory is ready to process the next batch, they open a gate.", "The fruit spills onto a conveyer.", "And it delivers it to giant pressure cookers.", "Cooking the fruit sterilizes it.", "It stops enzyme activity that would degrade the quality of the oil that's to be extracted.", "It also loosens the fruit from the stalks, and some break away.", "A spiraling blade moves them onto a grid screen that sorts the fruit from the stalks.", "The loose fruit drops into a bin below.", "And the stalks with remaining fruit go for further separating.", "Next, presses crush the fruit to squeeze out the crude palm oil.", "The oil flows into a vat.", "Impurities will now be spun out in a centrifuge and also filtered out.", "Meanwhile, the fibers and palm nuts toss in a drum.", "This knocks off fibers that are stuck to the nuts.", "A fan sucks up the lighter fibers, which will be used as factory fuel.", "They crack the nuts, and then a vibrating system separates the shells from the actual kernels.", "The shells will also be used as factory fuel.", "And the kernels will be crushed into palm kernel oil.", "In the lab, they now test samples to determine the oil extraction rate and confirm that the yield is good.", "They also analyze the oil's purity and the amount of free fatty acids.", "They confirm that the batch is of good quality.", "This crude palm oil has gone through many stages of purification.", "And although tests confirm it, the difference is also plain to see.", "Today, everything from boats to outdoor furniture to shower stalls are molded out of fiberglass-reinforced plastic resin.", "This wouldn't be possible without a tool called a chopper gun.", "It shreds the fiberglass into thin, loose fibers and impregnates them with resin while shooting them into the mold.", "A fiberglass chopper gun has a chopper that shreds and shoots the fibers, a nozzle that sprays those fibers with resin, and a catalyst to harden it, an air cylinder that drives the entire system, and separate pumps for the resin and catalyst.", "The make the resin pump, they first cut a stainless steel tube to a length of about 10 inches.", "All the pump's key components are made of stainless steel, which is very durable and doesn't rust.", "This tube will become the cylinder for the resin pump.", "They turn it on a computer-guided lathe.", "The first machining tool reduces the tube to the required diameter.", "The second machining tool cuts a groove in the cylinder for an assembly pin.", "They manually file the edges of the cylinder smooth, then polish the entire surface with sandpaper to remove marks left by the machining.", "Once all the components are ready, they begin assembling the resin pump.", "It has a ball valve at the top and another at the bottom, which open with suction and close with pressure to enable or block the flow of resin.", "Workers fit a rubber o-ring seal around the seat for the bottom ball, then insert the seat into the bottom of the pump.", "This retaining clip holds the seat in position.", "They fit another o-ring seal on top, then place the ball, about 10 inches in diameter, in the seat.", "This spring retainer limits how high the ball can rise when it's lifting to open the valve.", "Next, they attach the pump cylinder.", "They take a preassembled upper ball valve, attach a thermoplastic piston seal, then a retainer that holds the seal in position as the pump's piston, which they now screw on, moves up and down with the pumping action.", "They insert the piston into the cylinder.", "The tight fit creates a vacuum when the piston moves upward, drawing resin into the pump and pressure when the piston moves downward, pushing the resin out.", "Next, they add the top of the pump, then assemble the top seal, which contains a guide held in place by a retaining clip that aligns the vertical movement of the piston.", "They screw the top seal to the pump top.", "They secure the top by inserting a pin into the cylinder groove.", "The chopper's main components are the cutting head, the anvil sleeve, and a hard rubber roller, which the chopper's air-driven motor spins, rotating the cutting head at 4,000 revolutions per minute.", "This bearing pulls the woven fiberglass yarn, called roving, into the cutting head, which has slots for up to eight supersharp stainless steel blades.", "The more blades you use, the shorter the chopped fibers.", "This safety cover prevents fingers from accidentally getting chopped in the process.", "They mount the chopper to this spray gun.", "The lines from the resin and catalyst pumps connect to the back of the gun.", "At the front of the gun, dual nozzles simultaneously spray these chemicals onto the fibers right after they exit the chopper.", "Workers mount the resin pump on a stand along with a filter that prevents the nozzle from clogging.", "They install the air cylinder, then mount the catalyst pump and hook up lines from both pumps to the spray gun.", "To operate the machine, you hook up an air compressor to the machine's air input, connect the pumps to the resin and catalyst reservoirs, and set how much catalyst to deliver.", "Then you insert a strand of fiberglass roving into the chopper and let her rip.", "No resin and catalyst in this demonstration, but normally, they hit the fibers about 4 inches in front of the chopper gun, which shoots a stream of fiberglass-reinforced resin into your mold." ]

{ "things": [ "Plastic Bottles and Jars", "Mail", "Eggs", "Handcrafted Wooden Pens" ] }

[ "Today on \"how it's made\"...", "Plastic bottles and jars...", "Mail...", "Eggs...", "And handcrafted wooden pens.", "Whether you're buying apple juice or peanut butter, you've probably noticed that fewer products come in glass containers these days.", "Plastic packaging is becoming more common.", "Plastic bottles and jars are lighter to carry and leave no shards of glass to clean up if you drop your grocery bag.", "Many transparent bottles and jars are made from a type of plastic called polyethylene terephthalate, or p.e.t. an automated mixer combines p.e.t. pellets with flakes of recycled p.e.t. reprocessed plastic loses some of its physical properties, so the recycled content can't exceed 10%.", "The p.e.t. drops from the mixer into a plastic injection machine that heats it to a piping 600 degrees fahrenheit.", "The dry raw material melts into thick and gooey liquid plastic.", "The machine then shoots it at high pressure into a mold.", "This plastic injection molding process casts pieces of plastic called preforms, starter shapes that subsequent machines will transform into bottles or jars.", "The molded preforms harden almost instantly, thanks to a built-in cooling system.", "These preforms are now on their way to becoming single-serving juice bottles.", "This is another plastic injection molding machine.", "It uses the same method to make preforms for a different model-- 1 1/2- to 2-liter bottles.", "The preform's next stop is a machine called a reheat stretch-blow molder.", "In a matter of seconds, it heats each preform just enough to make the plastic malleable, then inserts a rod to stretch the preform lengthwise while at the same time blowing in air at extremely high pressure.", "This forces the preform into a bottle-shaped mold.", "Cold water circulates within the mold to cool and set the plastic almost instantly.", "This lightning-fast machine churns out 10,600 bottles per hour.", "No wonder we've had to show it to you in slow motion.", "A conveyor belt transports the finished bottles to the packaging area.", "Before blow molding, the preforms for certain models first pass through an oven.", "A technician sets the heat level of each infrared oven lamp individually, applying more or less heat at various points to influence the thickness and shaping of the plastic.", "From the oven, the preforms go into another reheat stretch-blow molder that transforms them into peanut jars.", "It's the same process for this peanut butter jar.", "After molding, the machine instantly cools the plastic, locking in the shape.", "The factory pulls samples off the line at regular intervals for quality-control testing.", "Technicians measure the thickness of the plastic and perform a compression test to gauge its strength.", "They verify the sample's dimensions and capacity.", "They also evaluate resistance to vacuum pressure because containers are often vacuum sealed after filling.", "Some models must also be strong enough to resist the pressure of their contents-- carbonated soft drinks, for instance.", "The recycled material used in making these bottles and jars doesn't come from used plastic containers.", "For hygienic reasons, the factory recycles only new plastic left over from its manufacturing process.", "The finished containers, of course, are fully recyclable.", "They're typically reprocessed into other plastic products or into products that contain some plastic.", "What do the letters \"f,\" \"d,\" \"i,\" \"o,\" and \"u\" have in common?", "They're all part of postal codes used in abbreviations for state names.", "These letters and numbers are read by high-tech machines that sort our mail.", "The trucks unload the containers picked up from postal outlets...", "And bags of mail that were collected from public mailboxes.", "The containers go straight to automated sorting.", "Their contents have already been classified by size.", "Not so for the bags.", "Postal workers empty them and put standard-size envelopes on a conveyor belt leading to one sorting machine...", "And large envelopes into a bin destined for another.", "The standard-sized letters travel to a high-speed, high-tech machine that checks for postage.", "Stamps contain an invisible fluorescent material that illuminates under ultraviolet light.", "The machine's u.v. sensor scans both sides of every envelope.", "No glow, no go.", "Letters with postage are canceled with a postmark so the stamps can't be reused.", "The postal mark contains the date, the state, and the sorting plant's postal code.", "Next stop, a machine called the multiline optical character reader...", "An impressive piece of equipment that processes up to 30,000 letters per hour.", "It reads and digitally photographs each destination address, matching it to the computer's address database.", "Then it prints the postal code in barcode format on the front of the envelope.", "A scanner now reads the barcodes and does a preliminary sorting.", "Local and regional mail stays here and moves on to the next sorting machine for a more detailed breakdown.", "Letters addressed to other regions go to the postal plants there, where a thorough sorting will take place.", "But what happens when all this sophisticated technology just can't make out the address due to, say, sloppy handwriting or smudged ink?", "The optical character reader machine puts the letter on hold and sends the address photo to the video encoding system.", "A postal worker deciphers the writing and types in the postal code, sending the letter back into the sorting system.", "Now the local and regional mail goes through what's called the bcs-- the barcode sorter.", "This performs a more detailed sorting by postal route.", "The machine scans the barcodes at a rate of 30,000 letters per hour, sending the mail to the corresponding letter carrier's bin.", "A worker preps the mail for each route, grouping and labeling it by sector.", "Meanwhile, the large envelopes go through what's called the flat sorting machine.", "It does what three machines did for the standard-sized letters-- postmarks the stamp, reads the address, applies a barcode sticker, reads the barcode, sorts the mail, and drops it into the corresponding letter carrier's bin.", "If the machine can't make out an address, the envelope goes for manual sorting.", "In manual sorting, postal workers handle more than just illegible addresses.", "They also hand sort mail going out of country and envelopes that are too thick or bulky to go through the automated machines.", "At all stages of mail processing and delivery, workers are on the lookout for envelopes bearing insufficient postage.", "Those letters are returned to sender.", "Letter carriers sort the mail for the routes by street and house number.", "If they have a walking route, they load up their first bagful and head off.", "A truck delivers the rest to a locked box along the route called a relay box.", "Carriers pick up the rest of their mail when they pass by it.", "Some letter carriers have what's called a motorized route.", "They deliver all their customers' mail by truck, which sure beats walking door-to-door in a blizzard.", "Hens don't have to mate to lay eggs, and as long as there's no rooster in the vicinity, the eggs will remain unfertilized and edible.", "The color of the shell is determined by the breed of hen, but there's no pecking order when it comes to shell color.", "White or brown, all eggs are the same inside.", "The action begins in the hen house, where female chickens start laying eggs when they're 19 weeks old.", "The building is well-ventilated, and the temperature and humidity are strictly controlled.", "To stimulate laying, fluorescent lighting simulates 15 hours of daylight.", "The hens eat a measured amount of food three times a day.", "Their feed is made up of various grains mixed with soybeans for protein.", "It's fortified with vitamins and minerals and contain calcium to strengthen the eggshells.", "The hens drink water from nipple-ended tubes attached to their cages.", "All these carefully monitored conditions are designed to maximize the yield.", "The average hen lays about 300 eggs a year.", "The cage floor is sloped so the eggs automatically roll onto a conveyor belt.", "Then it's onto a larger conveyor belt, which transports the eggs to the packing room.", "The hens' manure drops through the bottom of their cages onto a conveyor below.", "Even so, some eggs get dirty.", "They'll be thoroughly cleaned and disinfected later on.", "Automated equipment transfers the eggs onto plastic flats.", "It places them wide-end up to keep the yolks properly centered.", "The flats go into a cold room until a refrigerated truck ships them to the grading station, whose job is to classify the eggs by quality.", "The best, grade \"a,\" end up on supermarket shelves.", "Lesser grades go to processing plants to be turned into ingredients used in foods, pharmaceuticals, and products such as shampoos.", "This automated station is high-tech and high-speed, processing 144,000 eggs per hour.", "First, a suction machine lifts the eggs off the flats and transfers them onto a moving track leading to the cleaning station.", "There, a washer gently scrubs the eggs with soap and disinfectant.", "The water is just over 100 degrees fahrenheit.", "Anything hotter would cook the eggs.", "Then, it's into a dryer for five seconds, where a fan sucks up the moisture.", "The eggs then pass over a bright light, which highlights the condition of the shells.", "Workers do a preliminary visual inspection, removing any that are cracked.", "A grading camera above assesses the condition and quality of the shell's exterior.", "Further down the line, other cameras will inspect the interior for blood.", "To check the strength of the eggshells, acoustic sensors tap on the eggs.", "They detect brittle shells by the different sound of the tap.", "The inspection machines mark and reject any egg that doesn't make the grade-- grade \"a,\" that is.", "The approved eggs move on to electronic scales, which register their weight class from peewee to jumbo.", "Pressure-controlled claws then transport them to the corresponding packaging line.", "On the way, every egg gets stamped with a lot number for quality-control tracking.", "The packing machine stamps the egg cartons with a \"best before\" date.", "The eggs have a shelf life of 35 days.", "As for the hens, their expiration date comes at 72 weeks, when the eggs they lay are no longer consumption-quality.", "For all their hard work, they win an all-expenses-paid trip to the slaughterhouse.", "A pen set is a classic gift for any occasion, be it a birthday, graduation, or promotion.", "We're not talking pens of the inexpensive, ball-point variety...", "But rather those cadillac models in sleek metal or sumptuous wood.", "The quill dates back to about 700 a.d. made from a bird feather, it's tip had to be repeatedly dipped in ink.", "Messy and inefficient, the quill remained the norm for more than 1,000 years.", "In 1884, an american invented the fountain pen, with its built-in refillable ink barrel.", "But the true revolution came with the no-fuss ball-point pen patented by two hungarian brothers in 1938.", "Handcrafted wooden pens can be made from just one type of wood or from a combination of woods.", "This artisan uses some 50 different kinds, ranging from domestic maple and oak to imported rosewood, ebony, olive wood, and purpleheart.", "When using just one type of wood, he runs the block through a band saw, cutting a strip 6/10 of an inch wide.", "Then, with a radial saw, he cuts that strip into two pieces, each about two inches long.", "These will become the pen's top and bottom casings.", "Using a tool called a drill press, he bores a hole roughly 3/10 of an inch in diameter right through each piece.", "Making a pen from a combination of woods takes a little more work.", "Instead of using a block of solid wood, he constructs a block by gluing together thin planks of contrasting woods.", "Once the glue dries, he uses a wood planer to remove the excess and smooth out the sides.", "Then, just as he did for the single-wood pen, he cuts the block into strips 6/10 of an inch wide.", "This time, he slices diagonally so that each strip showcases the multiple woods.", "Again, he cuts pieces for the top and bottom casings, then drills a hole through them.", "From this point on, whether he's using one or more woods, the process is the same.", "He coats two brass tubes with glue and inserts one in each casing.", "A few drops of water are added to expand the adhesive into any gaps between the tube and surrounding wood.", "These brass tubes will house the pen's mechanism.", "The glue takes about an hour to dry.", "Then he uses what's called a hand mill to square all the angles and remove the excess glue.", "Now for the artistic part.", "He turns the casings on a lathe to shape them.", "First, he rounds them out.", "Then, using a series of tools, he gives each casing unique detailing.", "He highlights the grooves by using the heat that friction generates to burn them dark.", "When the design work's done, he runs sanding cord inside the grooves.", "Then he sands the surface three times with progressively finer sandpaper.", "To protect the wood, he varnishes the casings with four coats of hardwood-floor varnish, sanding between each application.", "When the last coat dries, he can assemble the pen, starting with the tip.", "He glues it to the bottom casing, tapping it with a mallet to ensure it's fully inserted.", "The tip is made of titanium, a very resilient metal.", "Next comes the clip, also made of titanium.", "He glues it into the top casing.", "Finally, using a vise, he forces in the pen's mechanism.", "The mechanism houses a replaceable ink cartridge.", "A titanium ring joins the two casings.", "As an added touch, the pen can be personalized with an engraved clip.", "And the gift box can bear the recipient's name or a corporate logo." ]

{ "things": [ "Vibrating Mining Screens", "Whoopie Pies", "Wood Utility Poles", "Roller Conveyors" ] }

[ "Mines and quarries use crushers to break down raw material.", "Those raw materials go through a vibrating screen to separate the particles by size.", "The vibrations cause the smaller pieces to fall through the screen while the larger pieces remain on top.", "This limestone quarry uses a vibrating screen with three decks.", "The top deck filters out the largest stones, which will be used to make concrete.", "The second deck collects half-inch rocks.", "They'll be used to make asphalt.", "The final deck gathers the smallest materials to product limestone sand.", "The screen mesh is made from steel wire.", "This steel contains carbon, making it more durable than regular steel.", "A pair of wheel dyes crimp it into a wave pattern.", "The diameter of the wire and crimp pattern determine the shape and size of the screen mesh openings.", "Workers can change the dyes to crimp different patterns.", "The machine cuts the crimped wire to a specific length.", "Then, workers take the pieces over to a loom.", "It weaves screens the same way a textile loom weaves cloth.", "They lay the crimped wires vertically, playing one in between each of the loom's heddles.", "They line up the crimped wire so that the bottom of one crimp faces the top of the next.", "Then they weave a straight wire horizontally across the vertically crimped wires.", "They continue to feed straight wires across.", "Then use the loom to secure each one in position.", "The vertical and horizontal wires interlock to form the mesh.", "Once they've woven a section to the required length, a sheer cuts it off the loom.", "Another sheet cuts the section to the customer's requested dimensions.", "This is the final size of the screen mesh section.", "Next, workers insert one set of the screen into an electromagnetic induction heater.", "The device evenly generates heat inside the steel.", "This is critical because heating unevenly can weaken the steel.", "They inset the heated edge in a steel strip mounted in a press.", "The press clamps the strip over the edge then vents it into a hook strip.", "They repeat the process on the opposite site side.", "The two hook strips attach the mesh section to the vibrating screen.", "The loom can weave many different types of screen mesh.", "This one is made of finer wire that's crimped in a different pattern.", "The openings of the screen mesh are larger and more rectangular.", "It's designed for a less precise sorting process.", "For both screens, the weaving and cutting processes are the same.", "They even use the same technique to attach the hook strips.", "The only thing that changes is the crimping pattern.", "Next, they connect the hook strips to the vibrating screen.", "Installers lay the sections end-to-end on each of the machine's decks.", "Then they fashion the hook strips to the machine with tension rails and secure those rails with large bolts.", "When the mine or quarry needs to change the screening parameters, they simply replace these screens with different ones.", "Whoopie pies are not pies at all.", "This all-american treat is made of vanilla cream frosting sandwiched between two pieces of round chocolate cake.", "The whoopie pie was invented in new england.", "And today, it is the official state treat of maine.", "This company adds a modern twist to the classic whoopie pie recipe.", "In addition to traditional chocolate and vanilla, the company makes four other all-natural flavors.", "The ingredients are certified vegan, non-gmo, gluten-free, kosher and free of many common food allergens.", "Workers begin by making the chocolate cakes.", "The first ingredient is water followed by apple cider vinegar.", "Then, they add either canola or sunflower oil.", "They mix the liquid ingredients in a large bowl.", "Then they add the dry ingredients, starting with tapioca starch, bean flour, and sorghum, a gluten-free grain.", "Next, they mix in cocoa powder, granulated cane sugar, and light brown sugar.", "They run the mixer at a very high speed to incorporate air in the batter.", "This will make the cake lighter and fluffier.", "After about 4 minutes of mixing, the batter is ready.", "They test a sample using a viscometer, a device that measures the thickness.", "If the batter is the right consistency, they pump it through a hopper into a multi-head depositer.", "Each of its five nozzles shoot one ounce of batter onto a moving baking sheet.", "A finished sheet contains seven rows of batter.", "Workers load multiple sheets of batter into an oven.", "The sheets rotate for 15 minutes at 75 degree fahrenheit, evenly baking the cakes.", "The precise combination of ingredients allows the acids in the apple cider vinegar to react with the cocoa powder.", "The result is a perfect little chocolate cake that's rich in flavor and moist in texture.", "The main ingredient for the filling is shortening.", "It's made from sustainable palm oil.", "This means the palm tress were responsibly harvested.", "They mix the shortening well, incorporating enough air to make it light and fluffy.", "Then they add powdered cane sugar and organic rice milk as a dairy-free substitute.", "The rice milk makes the frosting creamy.", "For vanilla frosting, they simply add pure vanilla extract.", "This is a batch of raspberry frosting, so they add pure raspberry extract and beet juice for color.", "When they make mint frosting, they use pure mint extract and alfalfa extract for green color.", "Lemon frosting is made from pure lemon extract and turmeric for color.", "They check the shade against a color chart to ensure the correct flavor.", "The multi-head depositer drops frosting on the baking sheets in the same configuration as the batter.", "Then they assemble the final pie.", "Workers start by placing a piece of cake on top of the frosting.", "They press down hard enough to spread the frosting just shy of the cake's edge.", "They cover the top with a sheet of parchment paper then place a baking sheet on top and flip it over.", "They remove the top baking sheet and the parchment paper.", "Then, they carefully place the second cake onto the frosting.", "Workers roll the trays of whoopie pies into a cooler where the desserts chill for about 15 minutes.", "This hardens them so they won't get squished during packaging.", "Workers place the whoopie pies on a conveyer belt that leads to an automated wrapping machine.", "It wraps double-printed packaging around each pie and seals them underneath.", "Then the machine cuts the film between each pie.", "The next machine packages four sealed whoopie pies per retail box.", "There are zero preservatives in these whoopie pies.", "They're shipped frozen to the grocery store and sold in the freezer section.", "When it's time for a treat, simply let them thaw to room temperature and enjoy.", "Wooden utility poles are a constant presence in our lives.", "They were originally built in the mid-19th century to suspend telegraph lines.", "Now, they hold up power and phone lines as well as fiber-optic and coaxial cables for television and computer networking.", "Builders use many different types of pine or fir trees to make utility poles.", "In the us, southern yellow pine is the most popular choice.", "Foresters select trees that are 10 to 20 inches in diameter and at least 30 feet high.", "They look for a straight, healthy trunk with few limbs.", "The foresters mark the selected tress with spray paint.", "Then, the tree harvester saws them down at the base.", "After the loggers saw off the limbs and cut the trees to a specified length, a log truck delivers the poles to the mill.", "There, a truck scale weighs the load.", "Then, workers ticket it with a tracking number.", "The truck enters the yard and the poles are unloaded into piles.", "A loader feeds the poles to a debarking machine.", "The machine's razor-sharp cutters shave of the bark and the layer of tissue beneath the bark called the cambium.", "Next, a saw trims one inch off the bottom of the log to make it square.", "At the same time, nozzles spray lines of red food coloring at set intervals along the pole.", "These mark indicate different lengths.", "Another worker inspects the quality and measures the circumference.", "This assessment determines the wood's class.", "He marks the length and class on the bottom of the pole.", "The bark and shavings removed from the poles don't go to waste-- a grinding mill reduces them to small fibers.", "The factory uses those fibers to power the boiler.", "The fire in the boiler will product heat, which dries the poles.", "After the poles have been sorted by length and class, loaders stack them on large trams.", "They place spacer sticks in between each pole to allow air to flow around them.", "Then, the loaders push the trams into a large kiln.", "The steam from the boiler flows through the trams, heating the inside of the kiln to 200 degree fahrenheit.", "Large fans blow the hot air around the poles for 3 days until the wood is dry.", "When the poles come out of the kiln, workers brand them with product information.", "Next, they cut a flat surface on one side of the pole.", "Then, they drill holes to attach a crossarm.", "After they drill the holes, they stack the poles in another tram.", "This one takes them to a 125-foot-long treatment cylinder.", "They lock the door and vacuum all the air out of the cylinder.", "They fill the cylinder with a liquid that's 98% water and 2% chemical preservative.", "The preservative is a mixture of chrome, copper and arsenic.", "Once the cylinder is full, the pumps start running to pressurize the liquid, infusing the wood with the chemical solution.", "The 2-hour process leaves the wood resistant to rot, fungus and termites.", "Next, inspectors bore 3-inch holes into each pole to collect a sample.", "The inspectors check to make sure the preservative saturated the wood to the target depth.", "Then, they send the samples to the on-site laboratory, where they're dried in a microwave oven and ground up.", "They also put the sample in an x-ray machine to analyze the chrome, copper and arsenic levels.", "These quality control steps ensure that every utility pole contains the right amount of chemical preservatives.", "These finished poles will assist for at least 45 to 60 years.", "Humans have been using roller conveyors for thousands of years.", "The ancient egyptians used wood rollers to move the large stones needed to build the pyramids.", "Today's conveyors are more complex.", "But the basic concept is still the same.", "Many factories use roller conveyors to transfer materials from one station to another during assembly.", "They can move heavy loads up to 65 feet in a minute.", "To make the conveyer rollers, this factory starts with hollow steel tubes.", "They deliver to the factory in batches.", "After they arrive, a band saw cuts the tubes to length.", "The diameter can vary from batch to batch.", "So an employee obtains the exact measurements.", "He inputs the measurements into a computer that controls this laser.", "The laser etches the company logo onto a sheet of thick steel and cuts out support disks for the roller axles.", "The support disks fit perfectly into the hollow rollers.", "An employee feeds a flat sheet of steel to a computerized break press.", "It bends the sheet into a vertical rail for the conveyer frame.", "Here's the steel before and after bending.", "A worker joins two vertical rails with steel supports called crossmembers.", "He welds them where they meet.", "This creates the frame for the roller conveyer.", "Then, they paint the frame.", "The paint isn't just for decoration.", "It also protects against rust.", "Next, they install the chain-driven axle that will spin the roller.", "An employee measures it and confirms its dimensions.", "Another worker slides three support disks on to the axle.", "He welds the disks in place.", "The disks on the end fit snugly to the roller rims.", "This is why premeasuring is so important.", "He welds the disks to the ends of the tubes.", "He slides roller chain sprockets onto the end of the axle and welds them in place.", "He uses a dial indicator to measure the circumference of the roller and confirm that it's sufficiently round.", "Using a forklift, the team lifts the motor and places it in the conveyer frame.", "They slide the motor's threaded rods into holes drilled in the frame.", "An employee places metal washers on the threaded rods.", "Then he screws nuts to them, securing the motor to the frame.", "He installs a bearing on the end of the roller axle.", "Next, workers arrange the rollers on the conveyer frame.", "They place the bearings on the flange of one of the vertical rails.", "They attach the bearings to the rail with socket screws.", "One of the workers attaches the welded steel chain to the teeth of sprocket wheels.", "He joins the sections of the roller chain with links.", "Then he drops the ends of the chains down to the motor.", "The worker loops the chains around the motor sprockets...", "And connects the ends with the joiner plate and retaining clip.", "Now, they're ready to put this roller conveyer to the test.", "An employee measures the rotational speed of the rollers with an instrument called a tachometer.", "He also tests the conveyor's ability to move heavy objects.", "Once approved, the roller conveyer will be shipped to another factory, where it will be an important part of the manufacturing process." ]

{ "things": [ "Metal Detectors", "Rum", "Tiffany Reproductions", "Aircraft Engines" ] }

[ "Today on \"how it's made\"...", "Metal detectors...", "Rum...", "Tiffany reproductions...", "And aircraft engines.", "Airports use handheld metal detectors to safeguard flights.", "Treasure hunters use hobby metal detectors to find buried loot.", "Vastly different purposes.", "Yet the technology behind them is identical-- a principle called magnetic induction.", "It all hinges on tiny electrical currents creating magnetic fields.", "A tiny electrical current runs through a wire coil inside the detector, creating a magnetic field.", "When the detector passes over a metal object, the field is disturbed, producing a small voltage variation that triggers the alarm.", "To make the coil, they use copper wire that's coated with nylon insulation.", "They wind it around the two ends of a plastic bobbin a specific number of times.", "Polyester tape keeps it from unraveling.", "Security metal detectors need pure iron glued into the bobbin to increase the magnetic-field strength the coil produces.", "Without it, the coil would have to be several times larger and wouldn't fit inside a handheld wand.", "The next step is to solder the coil leads to a circuit board, then solder a vibrator motor to enable the detector to vibrate as well as beep when it finds metal.", "The board contains a microprocessor, the detector's alarm, and other components that react to the signals coming from the coil.", "The coil and circuit board now go into the wand's plastic housing.", "A retaining clip holds the vibrator motor in place.", "They temporarily hook up power to the battery compartment and push a button on the circuit board.", "This calibrates the board to the coil.", "They install a sliding cap on the detector's on-off switch.", "Now they can close her up and stick on the manufacturer's label.", "The last step is to install the 9-volt battery.", "No metal detector leaves the factory before undergoing extensive quality-control testing.", "Metal detectors for treasure hunting have larger coils so they don't need iron inserts to boost the magnetic field.", "In fact, hobby detectors have two coils-- one to transmit and one to receive.", "This configuration lets you set the device to detect only the types of metal you want to find.", "Like before, polyester tape prevents the wound wire from unraveling.", "The leads go into a device called a stripper, which bares the copper wire inside.", "A testing machine ensures the coil meet the engineering specifications.", "Next, they place a circuit board in the coil housing.", "A cable runs from this housing to the detector head, where components interpret the coil's signals.", "After installing the coils, they solder the coil leads to the board.", "They immobilize everything with hot glue, then seal the components inside the housing with epoxy.", "Next, they install a circuit board inside the metal detector's control pad.", "They plug the cable coming from the coils into the board and power up.", "This calibrates the coils to the circuit board.", "Now they test the calibration with three different types of material the metal detector might find in the ground-- iron, silver, and nickel.", "If everything works perfectly, assembly continues.", "They install a small speaker for the alarm.", "Then they attach the control pad to the head and apply the decals.", "They attach a handle and arm support, then a long stem.", "The cable from the coil winds upward around the stem and plugs into the detector head.", "Signals from the coil travel up the cable to the electronics in the head.", "A small computer analyzes these signals to determine whether the detector has found metal.", "If it has, the computer activates a circuit to set off the alarm and display a message.", "But the ground's by no means the limit.", "There are even metal detectors designed for scuba diving that are completely submersible.", "Rum comes from by-products of the sugar industry, like molasses.", "The caribbean and latin america produce much of the world's rum.", "Light rums are the base for cocktails like the minty mojito.", "Amber rums are medium-bodied and aged for flavor.", "They're often drunk straight, as is dark rum, the strongest-tasting of all.", "This fine amber rum is the product of a long and complex process that begins with the harvest of mature sugarcane plants.", "The cut cane goes to a sugar mill where they wash it then crush it to extract its sweet juice.", "They boil it down.", "This produces a kind of molasses that then goes on to a centrifuge machine that draws out excess moisture.", "Rum making really beings here in these distillation towers.", "This is where ferment made from molasses distills into raw rum.", "To make ferment, molasses mixed with water and yeast heats in open tanks for about 30 hours.", "This converts sugar into alcohol.", "Here's a sample straight from one of these tanks.", "Notice that foamy top layer?", "That's fermentation in action.", "Before distilling the contents of the tank, technicians first test a sample.", "In this glass still, steam heats the ferment and releases alcohol vapors that condense at the top of the column.", "As they travel down the still's spiral, the vapors cool and condense even more.", "The liquid that collects in the beaker is 80% alcohol.", "It's the same process inside the distillation towers on a much larger scale.", "The ferment must reach 176 degrees fahrenheit to distill into raw rum.", "Then it's stored in these 13,000-gallon containers until they test it for quality.", "These gas-powered boilers provide the steam heat for the distillation towers.", "Workers monitor the distilling towers day and night.", "This facility can produce more than 10,000 gallons of raw rum a day, all stored in these gigantic silos.", "From there, the raw rum goes into charred oak barrels.", "It's mixed with water and left to age anywhere from 1 to 12 years.", "The charred wood produces asters that give the rum color, flavor, and aroma.", "The longer it ages, the more intense the flavor.", "Technicians perform tests on a sample at the distillery's laboratory, closely monitoring the aging process.", "First, using a hydrometer, they measure the amount of alcohol in the samples to make sure it's in the standard 50% range.", "Next, they smell each sample to make sure the aromas are in balance.", "They keep a journal of all their observations.", "Quality control is the key to producing a consistent, flavorful product.", "Once it has aged, the rum is bottled.", "It's a fully automated process.", "First, they sterilize new bottles in a sodium-carbonate solution.", "Then a conveyer moves them to a filling station that can process 150 bottles a minute.", "Rotating wheels deliver the bottles to a lever system that raises them up to the nozzles on pneumatic pumps.", "They fill up with rum-- more than 72,000 of them each day.", "Next, aluminum bottle caps come down a chute right onto the bottle tops.", "A piston valve pushes down on the caps and tightly seals each bottle.", "Next stop-- labeling.", "First, a spinning roller applies glue to panels set on a rotating wheel.", "The panels pass a dispenser, and a label glues onto them.", "Another rotating wheel grabs the labels from the panel and transfers them onto the bottles.", "Sponges press them neatly into place.", "As the bottles convey out of the labeling station, brushes smooth out each label.", "Finally, the bottles lower into boxes 12 at a time to ship to customers all over the world.", "Tiffany lamps were invented and produced by designer louis comfort tiffany starting in the late 19th century.", "They were renowned for their elaborate stained-glass shades, crafted entirely by hand.", "The term tiffany has come to be used as a generic term for any lamp or hanging light fixture with a stained-glass shade.", "This lighting company produces original stained-glass lamps, as well as reproductions of renown tiffany designs.", "There's nothing machine-made here.", "Each and every creation is meticulously handcrafted.", "The lamp designer first draws a pencil sketch of the shade, then prepares a color rendition.", "He produces a pattern in the lamp's actual size and assigns a number to each pattern piece, then records by code number the specific glass they'll use for each piece.", "Next, they cut out the numbered pattern pieces, lay them on the corresponding glass, and trace them with a marker.", "Using a glass cutter, they score the trace lines and snap them.", "When a piece is too small to get enough snapping leverage, they grip the glass with special pliers called groziers.", "Next, they sand-smooth the rough edges of the cut pieces so they won't puncture the adhesive copper foil that goes on next.", "After wrapping each piece, they crimp the foil tightly, first with their fingers, then with a flat object.", "This design, like many, incorporates glass jewels.", "These come from glass suppliers ready-made.", "The next step is to coat the foil with flux, a chemical that enables solder to stick.", "Now with a soldering iron, they melt tin and lead solder onto the copper foil.", "Initially, they just tack all the pieces together, completing one section of the shade at a time.", "Then they lay the sections side by side in a curved plaster mold.", "This bends them to the correct shape.", "More flux.", "Then with a soldering iron, they tack the sections to each other, then solder the whole interior.", "Once that's done, they remove the shape from the mold and solder the whole exterior.", "Now they top the shade with a brass cap and solder that on.", "This lampshade design features dragonflies with brass filigree wings.", "After soldering the wings in place, it's time for what's called the final beading-- a final soldering over the existing solder lines to make them even and rounded.", "Now they wash the shade in an antiquing solution, which dulls the shine of both the solder and the brass cap, giving the lampshade an aged look.", "In another department, they install what's called the light cluster, a rod with light sockets and a pull chain, into a lamp base.", "They fish the power cord up the base and out the top, then connect the cord to the wires coming from the sockets.", "They tuck in the wiring...", "Apply thread-locking solution...", "Then screw the base closed.", "For the time being, they attach the finial that goes on top of the shade.", "And now a light-bulb moment.", "If everything works perfectly, the tags go on and the base gets its shade.", "The bases of the original tiffanies were made of bronze.", "These, both for tabletop lamps and hanging fixtures, are cast from zinc-- the same look at a fraction of the price.", "For safety reasons, aircraft engines have built-in redundancy features, like dual spark plugs and dual ignition systems so that vital components have a backup.", "Rising gas prices and eco awareness are compelling manufacturers to build aircraft engines that are more efficient and less polluting.", "Aircraft engines are remarkable pieces of engineering.", "To build a four-cylinder engine, a worker wraps abrasive tape around what's called a bearing journal on a crankshaft.", "Using a polishing jack, he polishes the journal to the correct diameter, which he verifies with a digital snap gage.", "An operator then oils the journal and attaches a connecting rod.", "These link the pistons to the crankshaft, which turns to generate power.", "Then he applies gasket sealant on the edge of the crankcase and silk thread that acts like a gasket so when the two halves of the crankcase are joined, the engine won't leak oil.", "He places a camshaft into one side of the crankcase and measures the clearance to make sure it's a tight fit.", "Then he oils it to ensure there is no friction.", "They place the crankshaft and rod assembly into the crankcase, then join the two halves together.", "To prevent the connecting rods from hitting the sides of the housing, they put on what are called torque plates.", "He adds a little sealant to hold a gasket in place then attaches an accessory housing, which holds all the gears and hoses that are mounted on the back of the engine.", "He installs the sump that holds the oil supply, then attaches a piston to each connecting rod.", "Now he mounts a cylinder onto a piston and connects the parts to the engine.", "He'll mount and secure all four cylinders this way.", "He inserts hydraulic tappets and then shroud tubes.", "He attaches them to the cylinder using a retainer.", "He inserts a pushrod into each tube and fits a rocker arm onto each rod, completing the cylinder-and-valve-action assembly.", "He steam-cleans the engine.", "Then he paints it with rustproofing enamel paint.", "Next come the spark plugs-- one on the top and one on the bottom of each cylinder.", "He grounds and then installs two magnetos.", "These devices generate the electricity for the spark plugs, which ignite the fuel in the cylinder.", "He attaches the spark-plug wires from the magneto to the spark plugs, then verifies the engine timing.", "Next come the heat shields...", "The intake pipes...", "All the spark-plug connections and drain tubes, and finally, a fuel injector.", "An operator then attaches a testing propeller to the engine to keep it cool during testing.", "He runs the engine using controls like a pilot would use and certifies everything from engine speed and temperature to fuel pressure and airflow.", "Hours later, he checks the oil filter for signs of foreign material or contamination.", "And this engine passes the test.", "A worker then puts preservative oil into the cylinders.", "This special oil safeguards the engine en route to the customer, whether they be general aviation manufacturers or individual owners.", "Once installed in the airplane and after the standard preflight checks are done, the four-cylinder engine allows the pilot to take to the clear-blue skies in total confidence." ]

{ "things": [ "Horse Bits", "Oat Cereal", "Turquoise Jewellery", "Electric Scooters" ] }

[ "For thousands of years, riders have communicated with horses by inserting a bit in the sensitive area of the animal's mouth and manipulating it to steer him in the desired direction.", "The first bits were made of rope, wood, and even bone.", "Over time, bits have become far more elaborate.", "With silver and gold embellishments, these western-style bits are definitely an extravagance.", "But serious riders don't mind putting their money where their horse's mouth is.", "To make a bit, the maker first pounds his name onto a curved steel piece.", "This is the part of the bit that the reins attach to.", "He stamps one letter at a time to make the lettering fit the curvature of this part.", "He aims a torch at the center of a steel bar to soften it so it can be bent entirely by hand.", "He bends the steel around fixtures to shape it into the bit mouthpiece.", "The mouthpiece will rest on the horse's tongue and the toothless sections of the mouth between the front and back teeth.", "The size and contours must be exact in order for it to sit properly in the horse's mouth.", "He pounds the part that will lie on the tongue to give it a downward curve.", "He trims and shapes the mouthpiece a little more and polishes it until it gleams.", "He inserts steel balls in both ends and tack-welds them to the mouthpiece.", "The balls are part of a hinge mechanism.", "He now permanently welds the balls to the mouthpiece.", "Next, he installs a copper roller on the mouthpiece.", "The roller will act as a kind of soother, providing an outlet for nervous tongue action.", "He sands the end of a curved steel rod to bevel the edge.", "It will be part of one of the bit's shanks.", "He places the top part of the bit shank in a fixture, followed by three curved rods and a ring for the reins.", "Now, perfectly aligned, he welds all the parts together.", "This bit shank is now ready for some decorative touches.", "He welds tiny beads of stainless steel to the shank, making it look like a row of pearls.", "He gives the bit's second shank the same beaded look.", "He assembles the shank to the two ends of the mouthpiece.", "The two shanks are ornamental, yet functional, connecting the bit mouthpiece to the bridle and reins.", "He welds the hinge pins to the shanks.", "Next, an engraver cuts decorative shapes in sterling silver, wriggling the tool for a zigzag effect around the edges.", "He carves swirls onto it.", "It takes years of practice to perfect this artistry.", "One false move and he'd ruin the part.", "Once the engraving is complete, he brushes an acid cleaning solution on the back.", "He then melts a tin-and-silver alloy and applies it to the back of the engraved piece, spreading it for maximum coverage.", "This molten metal will serve as a solder to fuse the engraved part to the shank.", "To prepare the shank, he heats it from the bottom and cleans it with more of the acid solution.", "He applies more solder and transfers the engraved silver to the bit shank.", "He reheats the shank to ensure the solder is completely molten before cooling and fusing the parts together.", "The engraving is now one with the shank, and he washes it with clear tap water.", "After he solders more engravings to the bit, he polishes the silver until it gleams.", "Now, the bit just needs the headstall.", "That's the leather harness that holds the bit in the horse's mouth.", "He slips the headstall tabs into rings on the bit's shanks and screws the ends of each tab very tightly together.", "Crafted entirely by hand, it takes a couple of days to make one of these bits.", "After that, it's time to take it for a test trot.", "Breakfast cereal is most commonly made from such grains as wheat, corn, rice, and oats.", "Oats are a popular choice for health reasons.", "They contain a soluble fiber called beta-glucan, which, when consumed regularly, helps maintain normal blood cholesterol levels.", "These tasty little oat \"o\"s come ready to eat in a bowl with milk or dry as an easy and portable crunchy snack.", "At the cereal factory, production begins with the bulk ingredients, mainly oat flour and wheat starch.", "After the mixer blends these ingredients thoroughly, an air-driven tubular conveyer transfers them to the next station, which blends in the lesser-quantity ingredients, primarily salt and fortifying minerals such as calcium.", "The entire dry mix is sifted, then transferred to the next station, which adds water to transform it into dough.", "Then the machine cooks the dough by heating it with steam for approximately a minute.", "An extrusion machine now compresses the dough and forces it through a stainless-steel forming die.", "The forming die is a large disc with hundreds of little \"o\"-shaped holes.", "The dough exits the die holes as long \"o\"-shaped tubes, which knives then cut into individual \"o\"s.", "At this point, the cereal's moisture content is about 30%.", "In order for the \"o\"s to be crunchy, that has to be reduced to about 3%.", "So the next station spreads them out on a conveyer, which travels through a warm-air drying tunnel for about an hour.", "When the cereal exits the dryer, the moisture content is down to about 11%.", "The next operation is so top-secret, the company won't let us show it.", "It's called expansion.", "A heating process turns the moisture in the \"o\"s to steam.", "This expanding steam puffs the \"o\"s much the way hot air pops popcorn.", "This is what the \"o\"s look like prior to expansion...", "And after.", "They lighten in color due to the air inside.", "Next, the cereal travels over screens.", "The mesh is just the right size to let the \"o\"s remain on top, and any smaller, broken pieces fall through.", "Now the cereal enters the coating station.", "The coating is a combination of sugar and water, with water boiled out to reduce the mixture to a concentrated syrup.", "The cereal enters a coating drum.", "Inside, two nozzles spray the syrup on the \"o\"s.", "Continual rotation ensures the application is thorough and even.", "To dry the coating and further dry the cereal, the \"o\"s now travel on a belt through another warm-air dryer for about 20 minutes.", "This reduces the cereal's moisture content to the target level of 3%.", "For quality control, the factory regularly tests samples of the finished product.", "First measuring the moisture content...", "Then checking the density, which is calculated by weighing a specific quantity of cereal.", "Assuming everything checks out, the cereal proceeds to packaging.", "The packaging machine feeds plastic film around a fill tube, which drops in 20 ounces of cereal.", "Heat seals the top of the bag as well as the bottom of what will be the next bag, then cuts the filled bag loose to the conveyer belt below.", "It passes the bags through a metal detector to ensure no foreign object fell in accidentally during production.", "The next machine slides each bag into a cereal carton, stamps on the eight-month \"best before\" date, then seals the carton flap shut with food-grade hot glue.", "As each box of cereal exits the production line, it passes over what's called a check weigher, a scale which ensures the package contains the correct quantity of oat cereal.", "Turquois jewelry has adorned the human form for thousands of years.", "Worn by egyptian pharaohs and aztec kings, turquois was one of the first gemstones to be crafted into jewelry.", "Fast forward to today and turquois hasn't lost its luster.", "In the american southwest, native people have long mined the earth for a stone that is as blue as the sky.", "Turning it into jewelry is a tribal tradition.", "There are many shades of turquois, and some are more greenish than blue.", "The artist rinses off the dirt and debris to reveal the true color of each stone.", "He evaluates them and selects one.", "He cuts it with a circular saw.", "As he cuts, he lubricates the stone with water to keep it cool, because too much heat could cause discoloration.", "He cuts the stone thinner again, with an eye to fitting the turquois in a silver pendant setting.", "He sands the surface flat and smooth so it will sit well in the setting.", "He selects coordinating pieces for a mosaic work and sands them to create an equally flat surface.", "He now etches a line on a sheet of silver and then saws along this line to produce a silver strip.", "This silver strip will now be used to make the pendant setting.", "He wraps it around a steel mandrel to shape it into a loop.", "Then, using a leather mallet, he gently pounds the silver to the mandrel to perfect the shape.", "He pinches the ends with pliers to close the loop.", "Next, he saws a silver square.", "He stamps the maker's insignia onto it, as well as the hallmark indicating the silver's purity.", "He seals the silver loop with solder.", "He places the loop on the front of the silver square that he's covered with a flux.", "This paste facilitates the soldering process as he now joins the loop to the square.", "He cuts the square to round it to the loop using metal shears.", "The pendant setting has now taken shape.", "Using a fine abrasive file, he gets rid of the excess silver around the rim, and he smoothes the edges.", "He solders a loop for the chain to the pendant setting.", "The chain loop is known as the bail.", "The artist is now ready to create a turquois mosaic in this setting.", "The initial cuts were just approximate, so the stones don't exactly fit together in the setting.", "He grinds each one a little at a time until they do.", "He's careful to not grind too much.", "That would leave gaps in the mosaic.", "Each stone must sit snugly against the next in the silver setting.", "He handles the turquois gently because it's a soft stone and breaks easily.", "In the event of a fracture, he improvises and treats it as an artistic opportunity.", "He cuts a tiny bit of another stone to complete the mosaic.", "It serves as an accent piece, enhancing this stone mosaic pattern.", "The turquois stones now all fit together like pieces of a puzzle.", "He removes the stones from the setting and mixes a two-part epoxy.", "He applies a generous amount to the setting.", "He places the turquois stones back in the pendant in their original configuration.", "The epoxy dries quickly and the stones bond to the silver in minutes.", "The turquois mosaic now undergoes an intensive sanding, beginning with a rough-grit sandpaper and ending with a fine one.", "The sanding makes the seams almost disappear.", "He applies a sapphire grit and water solution to a leather buffing wheel and polishes the pendant until it takes on a nice patina.", "Crafted using techniques handed down through the generations, native turquois jewelry still makes a statement.", "That's why it never seems to go out of style.", "An electric scooter is a motorized version of the traditional foot-powered kick scooter.", "While the kick scooter is designed primarily for children, the battery-powered electric scooter is decidedly an adult vehicle, popular with urban commuters looking for a simple and inexpensive set of wheels.", "This isn't your kid's scooter.", "Lightweight, battery-powered, and foldable, it reaches speeds of up to 20 miles per hour and can carry a passenger weighing up to a hefty 250 pounds.", "Most of the components, like this sprocket, which goes on the rear wheel, are made of aircraft-grade aluminum-- a high-strength, yet lightweight metal.", "After cutting the shape, the computer-guided milling machine cuts decorative holes that further lighten the weight.", "A punch press cuts the shape of the brake disc, made of aircraft-grade stainless steel, also a strong, yet lightweight metal.", "The scooter chassis is made of high-strength steel.", "To one end, they weld on a bushing for the real axle.", "To the other end, a large tube to house the scooter's electric motor.", "To that support tube, they weld the front part of the chassis to which they'll later connect the handlebar.", "They also weld on a support for the rear wheel.", "They paint the chassis with what's known in the industry as powder coat-- dry paint particles applied with an electrostatic charge, an application technique which ensures full, even coverage.", "The chassis goes through an oven for about five minutes at 403° fahrenheit to bake on the finish.", "The brake disc, meanwhile, has gone through a heat-treatment process for strengthening, and has acquired aluminum spacers to properly position the first magnesium wheel rim, which goes on next, followed by the rubber tire, then the second wheel rim.", "To hold this front wheel assembly together, they thread a lug nut into the bolt protruding from each spacer.", "These lug nuts are self-locking, meaning their threads are shaped in such a way that they won't loosen during normal use.", "This is an important safety feature.", "Next, workers insert the battery-powered electric motor into the support tube on the chassis.", "After securing the motor in place with screws, they install the drive-chain adjuster.", "The drive chain links the motor to the rear wheel.", "This adjuster maintains the appropriate chain tension under all conditions.", "Now they mount the rear axle and rear wheel with its large sprocket.", "They install a small sprocket on the drive shaft, which protrudes from the motor.", "Then they take the drive chain, made of high-strength steel, and hook it around the two sprockets.", "They mount the rear fender and chain guard, both made of high-strength plastic, then tighten the axle to hold everything together securely.", "Now for the scooter's handlebar.", "An automated welding machine fuses two aluminum tubes into a \"t\".", "After chemically treating the handlebar to prevent corrosion and wear, they install a catch that holds the handle to the base when the scooter's folded.", "Next, the lever for the disc brake on the front wheel and the control for the motor.", "Last but not least, rubber handlebar grips, embossed with a snazzy design.", "The motor control has a push-button ignition, a thumb throttle for regulating speed, and a battery-life indicator.", "With the motor control and brake lines taped in their proper position, workers mount the handlebar on the chassis with the hinge pin, enabling it to fold down onto the base.", "They mount the front wheel with its disc brake.", "When you activate the handlebar brake lever, this caliper and pad grab the disc, which stops the rotating wheel.", "An aluminum pan in the base holds the battery, battery charger, and all the electronics.", "They cover it with a birchwood platform on which the rider stands.", "The wood has a weatherproof coating and features the company logo in nonskid material to prevent the rider's feet from slipping.", "The mechanics are simple.", "The motor turns the drive shaft, which turns the small sprocket, which turns the chain, which turns the large sprocket mounted on the rear wheel, propelling the scooter." ]

{ "things": [ "Photographs", "Fur Tanning", "Welding Electrodes", "Electric Violins" ] }

[ "Today on \"how it's made\"...", "Photographs...", "Fur tanning...", "Welding electrodes...", "And electric violins.", "In the 1830s, the first photographers used light-sensitive chemicals to capture images on paper.", "Today, machines do much the same but with amazing speed, accuracy, and versatility.", "It's a tried and true method many people still prefer to make their memories into pictures.", "The photo lab receives envelopes containing rolls of film for developing.", "Processing will turn each exposure into a negative image and then a positive.", "That positive is what we know as a photograph.", "A scanner takes a digital photo of the order detail specified on the packages.", "It tracks things such as print size and finish and the number of copies you ordered.", "A conveyer then sorts the envelopes into bins, grouping them with similar orders.", "Next, a machine extracts the film rolls from the metal capsules in total darkness.", "Exposing the film to light would ruin the photos.", "The envelopes go into bundles so they can later be re-matched with the right pictures and negatives.", "Here's what the machine looks like inside.", "A blade cuts open the metal capsule, and another slices off the leader.", "The machine unravels and lines up as many as 60 films end-to-end.", "The films are just over three feet long.", "A sticker joins the ends and identifies each film with a bar code.", "The machine measures the assembled strip, then winds it onto a reel inside a metal box.", "Another machine unwinds the reel and runs it under a nondamaging infrared light so that a technician can check for tears.", "Just one tiny tear could jam the machine and ruin all the photos.", "If the tech does find a tear, he repairs it by hand.", "He puts his arms in the machine's little dark room so as not to expose the film to regular light.", "First, he applies tape to reattach the area.", "Blades then cut the tape evenly on both sides.", "The worker is able to see what he's doing on a tv monitor hooked up to an infrared camera inside.", "Developing the exposures requires four chemical baths still in the dark.", "In the first, sulfates make the image appear as a negative.", "The second includes acetic acid to halt the effect of the sulfates.", "The last two baths preserve the image and rinse away chemical traces.", "To print the pictures, workers load the negatives into yet another machine.", "This one contains light-sensitive paper.", "All it takes is a flash to transfer the image.", "But that light is powerful, almost as bright as the sun.", "A sensor instantly adjusts the intensity to correct any improper exposure by the photographer.", "To develop the prints, the paper goes through four chemical baths similar to those used for the negatives.", "One bath reveals the image, another stops that process, and two more preserve the image and rinse off the chemicals.", "What's different this time is that the paper then heads into an oven to dry for two minutes at 160 degrees fahrenheit.", "Now a technician marks the pictures that are too bright, too dim, or out of focus, and then removes them for redevelopment.", "Next, a machine unwinds the strip, scans the bar codes, and cuts out the pictures that belong together.", "It also cuts the negatives into numbered strips of four.", "A worker now slips the proper photos and negatives into an envelope.", "The computer shows her what to include, and a machine provides the original package the film came in.", "When you get your photos, you can check them against your original order.", "That way, you can ensure that everything's picture-perfect.", "Fur has been in style since prehistoric times.", "Talk about a fashion original.", "In those early days, fur garments were pretty basic.", "Their main purpose was to keep people warm, a primary need.", "These days, fur is often a fashion choice, but it still provides old-fashioned warmth.", "At the tanning plant, a worker sorts through raw beaver pelts purchased at auction.", "He inspects the quality of the hair, then determines the type of garment they're suitable for.", "He hammers a lot number into the underside of the pelt.", "It perforates the skin.", "This technique is used so that the number stays on the pelt during processing.", "Using a pneumatic punch, he cuts out the ear cartilage.", "It's a crucial step.", "They need to get rid of the cartilage early on so the pelts can go through certain machines during tanning.", "The pelts are a bit dried out because of preservation techniques used before they were delivered to the tanning plant.", "To rehydrate them, they put them through various chemical washes.", "The final bath contains tanning chemicals.", "They convert the underside of the animal skins to leather.", "The supple leather texture will allow the pelts to eventually be shaped into garments.", "Between each wash, the furs go into a ringer.", "It spins out the excess liquid.", "All that moisture has caused the pelt to thicken, so they thin it down with a spinning blade called a flesher's knife.", "You need to be an expert to wield this tool.", "One false move, and you'll cut into the follicles and lose fur.", "Next, a worker shovels sawdust into a big drum.", "He gathers up the pelts and places them in the drum along with the sawdust and adds a mineral solution.", "The drum turns, tossing it all for about half an hour.", "This cleans and conditions the leather side of the pelts.", "The furs emerge still damp, so they hang them over wooden dowels leather side up.", "The rest of the sawdust will fall away in subsequent operations.", "Now a worker scrapes off the pelt's long hair to expose the downy undercoat.", "This undercoat has a more desirable look and texture.", "He rubs a generous amount of oil into the leather of the pelt to lubricate it.", "Then he tosses the pelts into a kicker box, so named for the automated kickers.", "The kicking action causes the oils to penetrate the skin.", "Next, a spinning metal wheel tugs at the pelt to stretch it.", "A worker cuts away the edges...", "And it's into the hot-press.", "This irons and adds luster to the fur.", "After a quick brush, the pelts get one more press.", "Then a shearing machine cuts the hairs to an even length.", "Finally, they bundle up the pelts for a trip to the garment factory, where they'll be great design material.", "More than a century ago, welders first fused two metal surfaces by melting a metal stick over them using an electric current.", "That stick is now called a welding electrode.", "It's the simplest and most popular way to weld.", "Farmers and mechanics often use this tool to repair heavy machinery.", "This company's electrodes are coated with powdered metals and minerals.", "During welding, the metals melt, and the minerals protect the area from oxygen, which would weaken the bond.", "The electrode transmits an electric current that heats and melts both the electrode and the metal surfaces, welding them together.", "Thin metal wire forms the electrode's core.", "The kind of wire depends on what the electrode is designed to weld.", "But most often, the core's made of carbon or stainless steel.", "A machine simultaneously spins and bends it, evenly reshaping the wire until it's completely straight.", "Four metal rollers then push and guide the wire into a guillotine.", "The blade chops the wire into segments that will become the electrode cores.", "These segments range from 10 to 17 1/2 inches long.", "The factory puts a variety of metals and minerals in the coating.", "The metals are often nickel, manganese...", "And iron.", "The minerals-- alumina, magnesia, and limestone.", "They also add a colorant to differentiate the models.", "Workers mix the ingredients with a bit of glue until they turn to the consistency of wet sand.", "A worker then packs the mix into a machine that forms it into slugs with a hole down the middle.", "He adds a plastic cap.", "Then a metal cover slides on, and the machine takes over.", "It takes only a minute for the machine's piston to compress the powder into a solid.", "Now to put the powder coating on the core wires.", "A worker loads four slugs into an extrusion press.", "It will apply 120 tons of pressure on the slugs to shoot the powder through nozzles that will coat the wires as they pass through the slug's hole.", "To load the wires into the press, they first stack them in this feeder.", "The opening at the bottom is adjustable for different diameters because core wires range from spaghetti-thin to pencil-thick.", "These rollers pass them through the press one at a time.", "Four wheels then pull the wires from the feeder into the extrusion press for coating at a rate of up to 1,000 electrodes a minute.", "When the coated electrodes emerge, they hit a metal wheel that positions them on a conveyer.", "A sander removes up to 2 1/2 inches of coating from the bottom where you grip the electrode, and it bevels the tip so it conducts electricity even better.", "A worker now checks for uneven coating and to see if the wire's well centered.", "The coating dries at room temperature for up to 72 hours.", "To cure the coating, workers put the electrodes in an oven heated to 905 degrees fahrenheit for up to 5 hours.", "Once they've cooled, the electrodes head into a printing press.", "An ink wheel first prints the model and type of current that's required.", "Another ink wheel then applies a color to the gripping end.", "It's another way to differentiate the model in case the lettering on the side rubs off in storage.", "From there, it's off to packaging.", "An optical scanner counts the electrodes.", "Then a stacking machine separates them into 7.7- to 11-pound bundles.", "Finally, a worker inserts them into cardboard canisters.", "He adds a piece of cardboard to compress them tightly for the trip.", "A sticker marks the contents, and tape keeps the package tightly sealed.", "The invention of the electric violin was all about turning up the volume.", "It was back in the big-band era, and the sound of the traditional violin was overpowered by the horns and drums.", "Amplifying the violin changed everything.", "Suddenly, the violin wasn't just a background sound.", "It was part of the show.", "The wired violin comes in different shapes because it doesn't rely on the body to resonate sound.", "This craftsman builds his electric violins one piece at a time, starting with the neck.", "He traces the shape onto a piece of maple.", "Then, he outlines the top plate.", "He uses walnut for the lower bout, or bottom part, as well as for the backbone of the violin.", "Next, he cuts out the shapes using a band saw.", "His goal here is to be very precise because the closer he gets to the outline, the less sanding he'll have to do later.", "The dimensions for the top and neck are exactly the same as a traditional violin, so there won't be any difference in the reference points the violinist relies on.", "The lower bout is very stylized...", "And the head is more streamlined than a traditional violin.", "There's no decorative scroll.", "Next, he chisels out a cavity in the head of the violin to create the pegbox.", "He carves parallel grooves onto the back to give it a snazzy look.", "Using a rasp, he shaves the wood to the correct thickness.", "He drills holes for the tuning pegs into the side of the pegbox, one for each of the four strings.", "He files down the grooves on the back a little more.", "Then he scrapes the rest of the neck to give it a final finish.", "Using a reamer, he tapers the peg holes.", "The ebony pegs have matching tapers, so they fit snugly into the holes.", "He checks to make sure everything measures up.", "Now he brushes wood glue onto the next section and presses the ebony fingerboard onto it.", "He wraps them with surgical tubing to hold them together while the glue dries.", "He drills two assembly holes in the top piece and makes corresponding holes in the other parts.", "He smoothes the edges of the backbone with an oscillating sander.", "Then, using a high-speed router, he bevels the lower bout piece to give it a clean edge.", "He rubs teal-colored stain into the wood because loud colors seem appropriate for these high-volume instruments.", "A crystal has been glued into the violin's wooden bridge to generate electricity from the string's vibrations and create sound.", "He pulls the wire from the bridge through the backbone...", "And then mounts the bout to the backbone.", "He bolts an ebony chin rest on top.", "Next, he attaches the neck to the rest of the assembly.", "He loops on the ebony tailpiece.", "He pulls a string from the tailpiece to a peg.", "The act of tightening the first string raises the bridge, which will be held in place only by tension.", "Now it's time to hook up the violin to the amplifier and let the music tell the rest of the story." ]

{ "things": [ "Electric Stand" ] }

[ "In the 21st century, there's more than one way to chase down a perpetrator.", "The electric stand-up vehicle goes where traditional police and security cars can't-- sidewalks, parks, shopping malls, even airports.", "The officer stands for better visibility.", "For a suspect, there may be nowhere to run.", "This electric three-wheeler is the latest thing on the police beat.", "Not only can it travel in areas that are inaccessible to cars, but its environmental footprint is lighter than a regular police cruiser.", "It's energy efficient and it generates no local pollutants.", "Production starts with the vehicle's frame.", "An employee assembles the tube steel parts and welds them together.", "The next worker attaches the vehicle's control-board panel to the welded frame.", "He inserts the steering shaft into the column and slides a plastic collar onto the bottom of the shaft.", "He secures the collar with screws and tightens the adjustment mechanism.", "He installs the second collar on the upper part of the steering shaft.", "The two collars will stabilize the shaft to keep the front wheel of the vehicle straight.", "He plugs the electric motor cable into the control panel.", "Next, another member of the team sprays a uniform layer of a gel coat onto a two-part mold of the vehicle chassis.", "The gel will act as a release agent for the finished chassis.", "They make the chassis from fiberglass.", "He sprays it evenly into the crevices of the molds.", "He presses out air bubbles using a rubber roller.", "The fiberglass dries and solidifies, taking the shape of the mold.", "The surface is smooth, but there are some ragged bits around the edges.", "Those are sanded.", "He cuts out a slot in the upper part of the chassis for a police warning light.", "Finally, the chassis gets a coat of automotive-grade white paint.", "He paints the wheel wells black, and with that, the outer chassis is complete.", "There's an interior panel and it's made of fiberglass, too.", "A member of the team mounts it to the inside of the steel-frame assembly.", "He then secures the outer panel to the vehicle frame.", "This electric three-wheel vehicle is ready for the rear-wheel hubs and brake rotors.", "He clamps brake calipers to the rotors.", "The wheels are next.", "The rear ones are motorcycle wheels.", "For the front, they use a golf-cart wheel.", "He equips the wheel with a pulley system to transfer energy from the motor.", "He installs the 1-horsepower motor and attaches the pulley to it.", "The motor is the size of a lunch bucket, but can pull up to 450 pounds and reach 20 miles per hour.", "He hooks up the front wheel to testing equipment and powers up.", "It evaluates the motor speed and noise.", "It also detects any undue strain or wheel wobbling.", "Satisfied with the front-wheel assembly, he installs it on the vehicle.", "He wires, and then attaches the throttle and brake control to the handlebar.", "They carpet the floor with non-slip rubberized foam and then slide the two rechargeable batteries into their respective compartments.", "The charge time is three to four hours.", "Next, this grab handle gives the driver something extra to hang on to.", "They equip the vehicle with warning lights and a high-beam headlight.", "This electric patrol vehicle has been six hours in the making, and it's now ready for a spin.", "Nowadays, you don't have to wait for your favorite fruit to be in season.", "You can buy it year-round in the freezer section of your local supermarket.", "Frozen fruit is useful to have on hand for baking, for making fruit salads or smoothies, to use as a topping, or to eat as a healthy snack.", "Timing is everything.", "For example, strawberries, when sold fresh, are picked well before they're ripe so they won't spoil before reaching store shelves as much as a week later.", "But if the berries are for the freezer section, they're harvested when fully ripe.", "That state of perfection will be frozen in time within 36 hours.", "Farm workers pick the berries by hand and trim them right in the field with one swipe over a sharp stainless-steel blade.", "Within 90 minutes of harvesting, the strawberries are on their way by refrigerated truck to the nearby processing plant for cleaning, sorting, and quick freezing.", "First stop on the processing line, a bath in fresh water to remove field dirt.", "This wheel gently submerges every last strawberry.", "Then, a shower of clean rinse water.", "Followed by a spray rinse with highly-chlorinated water to sanitize the berries.", "Next, eagle-eyed workers pick out and discard any bruised or under-ripe berries.", "The rest receive a final rinse en route to the freezing tunnel.", "Temperature-- -34 degrees fahrenheit.", "The cooling coils contain liquid ammonia-- a refrigerant commonly used for industrial-scale freezing.", "Inside the tunnel, where the frigid air circulates at high speed, the berries freeze in about 20 minutes.", "Upon exiting, they ride through a sorting machine.", "The smaller berries drop through narrower gaps between the rollers near the top, the medium-size ones through wider gaps partway down, while the larger ones continue to the bottom.", "These peaches, also handpicked when ripe, go through the same cleaning process as the strawberries.", "First a bath, then a shower.", "Then a sanitizing rinse with chlorinated water.", "After workers pick out leaves, twigs, and any less-than-perfect fruit, a sorting machine sorts the peaches by size-- small, medium, and large-- sending each size to a separate conveyor belt.", "Each belt leads to a different line of stainless-steel pitting machines, adjusted for the size of the incoming fruit.", "First, the machine places the peaches stem-down.", "Next, a knife cuts the peach in half along its natural line.", "Then mechanical jaws grab the stone inside and dislodge it by twisting the two halves of the peach in opposite directions.", "Each machine can pit 90 peaches per minute, so the only way to see that action is in slow motion.", "All the peach halves and stones coming out of the pitters tumble onto a vibrating conveyor.", "The stones fall through the holes while the peaches, larger than the holes, continue on.", "A conveyor flips them cut-side up so that workers can inspect and remove any stone fragments.", "The next conveyor gradually lines them up in single file to enter the slicing machines.", "The slicer blades cut each half into four to six pieces, depending on what format the customer ordered.", "Then the slices go into the freezing tunnel.", "Peach slices take slightly longer than strawberries to freeze-- about 25 minutes.", "To prevent the frozen fruit from defrosting, the air temperature in the packaging area is a frigid 39 degrees fahrenheit.", "An automated scales weighs out the per-package quantity, then drops the berries into a retail bag.", "The machine then heat seals the bag and deposits it on the final conveyor, which goes to the pre-shipping freezer.", "Only 15 minutes have passed since the fruit was frozen, and just 24 hours since it was field picked.", "Liquid refreshment can leave its mark on the table.", "Coasters come between the glass and that.", "But two centuries ago, coasters were mainly placed on the rim of the glass to keep out flies.", "Made of felt, they unfortunately spread germs, so the cardboard coaster was invented to improve hygiene on the pub scene.", "Beverage coasters protect the table and are also a marketing tool.", "Raise the glass, and you'll see advertising catchphrases and promotional graphics.", "In fact, some bar hoppers consider coasters pub art and accumulate vast collections.", "Production at this facility in germany starts with spruce wood.", "In this case, it's from the black forest nearby.", "They spray the wood with water to moisten the bark.", "Then it's into a tumbler that tosses the wood logs.", "As they knock against each other, the bark peels off.", "The de-barked wood exits onto a conveyor with slots to correctly orient it for entry into a massive grinder.", "Inside, chains press the wood logs against the grinding stone, shredding them into chips.", "Water flows over the grinding stone to cool it and carry away the chips, which are then mixed into a mash that has a porridge-like consistency.", "It's pure wood pulp.", "They now add leftover product from previous beer-coaster production to the pulp.", "This will be used to make the middle layer of the beer coasters.", "Finally, they mix residual paper from the manufacturer of magazines and envelopes with water.", "This creates a lighter-colored pulp.", "It will be used for the printable surfaces of the beer coaster.", "They spray the pulp onto a mesh that drains water from it.", "The fibrous wood core goes between the layers of the lighter pulp.", "Spigots apply a mix of wheat starch and water that acts as a glue between the layers.", "Off the mesh conveyors now, the pulp board travels between cylinders that squeeze out the moisture.", "More heated cylinders dry it.", "Knives now cut the board into large rectangles sized for the coaster-printing and cutting machinery.", "This specialty cardboard is known as wood-pulp board.", "It's lightweight yet highly absorbent.", "Next it's over to the printing department to put the beer-coaster artwork on the wood-pulp board.", "They use offset printing-- a process that involves more revolving cylinders.", "Color cylinders pick up ink and transfer it to the printing cylinders.", "From there, the image goes to a rubber-wrapped cylinder that then prints it onto the sheets.", "A print specialist scrutinizes the print job close up with a magnifying glass.", "He checks the color and clarity of the images and confirms that they're correctly positioned on the sheet.", "The borders of the images must line up with the grid of blades on the die-cutting machinery.", "If the alignment is even slightly off, every coaster on the sheet would be ruined as the die cutter punches out the coasters, dozens of them in one swoop.", "The coasters end up over little chutes, and pushers give them a nudge.", "They fall down the chutes and land neatly on a pallet below.", "The coasters stack up, and when there are 100 or so in each pile, they're ready for packaging.", "Machinery shrink wraps the stacks, and they're ready for the thirsty masses.", "This factory can produce and package 10 million offset-printed beer coasters every day, so there should be no shortage at cocktail hour.", "They also print coasters using a centuries-old technology known as letterpress.", "Blank coasters drop down into the machine.", "A rolling wheel presses each coaster against an ink plate.", "It's a system that both prints the image and embosses it on the cardboard.", "It's a difference you can both see and feel.", "Letterpress production is lower volume than offset, generating 100,000 coasters per day.", "For coasters, the design possibilities are endless.", "Just raise a glass and enjoy.", "A door handle is a decorative detail that delivers tremendous bang for the buck.", "It's quite inexpensive, yet through its design, material, and finish, contributes immensely to defining the style of a space, from traditional to ultra modern.", "These hand-forged iron handles open the door to a rustic english country decor.", "While the handle itself is iron, the backplate behind it is steel.", "A computer-guided water machine cuts the backplate out of a 3-millimeter-thick steel sheet.", "The machine slices through the steel not with a blade or saw, but with a concentrated high-pressure jet of water.", "The water contains a tiny amount of a super-fine abrasive and cuts through the steel with 2,000 times the pressure of a car tire.", "The jet cuts the contour of the backplate, then holes for the key, the mechanism, and the screws, which affix the plate to the door.", "Next, with a beveling machine, they cut a neat angle on all four sides of the backplate.", "This smooths the sharp edges and gives the backplate a finished look.", "Meanwhile, on a computer-guided lave, a knife progressively shapes a round steel bar into the main component of the door-handle mechanism-- the inner barrel.", "The next tool bores a hole in it to receive the spindle-- a bolt that runs through the door, connecting the handles on either side.", "To make the handle, a blacksmith heats up an iron bar in the 1,600-degree heat of a forge and hammers it to a tapered point.", "Then he repeatedly reheats and works the iron, hammering it some more and bending it against a steel forming jig.", "With each bend, the handle comes closer to the final shape.", "Once the blacksmith has completed his work and the iron handle has cooled, they drill a hole to receive the mechanism.", "Then with another tool, they angle the edges of the hole.", "This increases the surface area to which they now weld the mechanism's inner barrel.", "The larger the welded area, the stronger the weld.", "The welder places both components in a positioning jig to get the proper alignment, then welds them together.", "He removes the assembly from the jig, flips it, and welds from the other side.", "They grind the weld lines flat, rendering them unnoticeable.", "If the handle is supposed to have a hammered finish, this is when they create that texture with, you guessed it, a hammer.", "Now they heat the handle assembly and the steel backplate in the forge, then dip them in a vat of beeswax.", "This protects against rust when used indoors.", "With the main components now ready, final assembly can begin, starting with the mechanism.", "They slip a nylon washer, then a steel spring over the inner barrel.", "Next, they grease the outer barrel made of forged iron and place it over the inner barrel.", "The washer in between the barrels eliminates friction when they move against each other.", "This prevents the barrel from wearing out and squeaking.", "They install a tab washer made of nickel-plated steel.", "This tab restricts the barrel's rotation so that it doesn't simply spin around and around.", "This high-strength steel locking clip holds the inner and outer barrels and that important tab washer in place.", "Now that the handle and mechanism are complete, all that remains is to align backplate to handle and secure it in position with screws.", "Each retail package contains two handles and two backplates-- one for each side of the door.", "Also in the box, the steel spindle that goes through the door, connecting the barrels so that the handles turn in unison to retract the latch and open the door.", "While their mechanics are hidden from view, these hand-forged handles are certainly a sight to be seen." ]

{ "things": [ "Cars", "Grocery Carts", "Rapid Tooling and Prototyping", "Collectible Coins" ] }

[ "Today on \"how it's made\"...", "Cars...", "Grocery carts...", "Rapid tooling and prototyping...", "And collectible coins.", "The automotive industry has seen a lot of changes in recent years.", "More and more robots are replacing workers on the assembly line, and it isn't just cars and trucks coming off the line anymore.", "Today's hot wheels are sport-utility vehicles and vans.", "In the plant's body shop, they begin by putting together the front structure of the van.", "It's made up of the radiator support, two side rails, and clips on the front of those side rails for the bumper structure.", "Then they put this front structure onto the automated production line.", "Meanwhile, robots weld what's known as the ladder assembly.", "It's the backbone that supports the floor and sides of the van.", "It contains, among other things, the pockets that will hold the seats.", "Now the robots take the front-end structure and the ladder assembly and weld them together.", "Elsewhere, robots work on the body panel for the passenger side of the van.", "The entire panel is made of one piece of galvanized steel.", "The robots weld reinforcements onto the panel so they can later attach interior finishing and other components.", "A transfer device swoops down and transfers the panel to the next station.", "The driver's side body panel, coming off another welding line, is headed there, too.", "At the next station, robots have already installed an underbody with a floor panel on top of the ladder-assembly unit we saw earlier.", "Now the robots weld the body side panels to the underbody.", "They also weld inner wheel wells to the body's side panels.", "Then they weld on a roof.", "The van then rolls into the area of the body shop called closures.", "That's where they install the lift gate, the hood, and the doors.", "An inspector checks the gaps around the hood, looks for dents and dings in the body, and makes sure the doors are flush with the side panels.", "He marks any areas that need repair or adjustments with removable ink.", "The engines arrive at the plant already assembled.", "Workers just have to install and adjust a few components.", "Meanwhile, the van is off at the paint shop, followed by the trim shop for glass, handles, and interior components.", "In the chassis department, the engine, transmission, rear suspension, and brake assembly are installed from underneath.", "This part of the assembly line has two tiers.", "The van goes on top, the components on the bottom.", "The machines that install the components have long pins that fit into holes in the van's underbody.", "This positions the components with precision.", "Workers hook up the gas tank manually.", "The seats arrive ready-made from a nearby factory.", "They simply clamp into place in the seat pockets that were welded onto the ladder assembly earlier.", "An automated machine attaches the tire to the wheel rim.", "Then it inflates and balances the tire.", "Workers mount the tires, starting the nuts by hand, then tightening them with tools.", "Now the van comes off the carrier and goes full weight on its wheels for the first time.", "Workers start up the ignition and run the van through a series of tests.", "It's taken the plant about 24 hours to produce this vehicle, which will soon be on its way to a car dealership.", "Geomatics is a high-tech science whose objective is to gather geographic information, then study and use it.", "The tools of geomatics range from cartography to remote sensing to satellite imaging.", "We wouldn't be able to study the environment or monitor and develop our natural resources without geomatic data.", "An oklahoma grocer invented the first shopping cart back in 1937.", "He noticed his customers stopped shopping once their hand baskets became too heavy to carry.", "His basket on wheels became a rollaway success.", "This factory makes about 50 different models of shopping carts.", "They're built with heavy-duty steel and carbon wire.", "A single cart is made up of more than 150 wire pieces of various lengths and diameters.", "Automated machines bend the wires to form the carts' numerous components.", "To make the cart's basket, a worker uses a guide called a jig loader to line up the wires in a mesh formation.", "Then a machine automatically spot-welds them together.", "The next machine applies 20 tons of pressure to bend the wires into a basket shape.", "A robot welds the sides of the basket.", "A worker then trims off the excess wire.", "An automated machine bends a piece of wire to form the handle of the shopping cart.", "They make the frame for the base of the cart, called the chassis, out of one thick tube that's 13 feet long.", "A robot welds the chassis using wire melted by an electrical current.", "This creates a very strong joint.", "A die machine punches out casters that'll hold the wheels.", "They're made of thick steel for extra strength and durability.", "They spot-weld the casters to the chassis.", "They clean the cart's metal components in a bath of soap and acid.", "They electroplate the metal with nickel, then with chrome as a finishing coat.", "It's finally time for the cart to take shape.", "They rivet the wheels to the chassis...", "Then install the bottom rack.", "The basket comes next.", "They print the warnings on the plastic panel for the collapsible baby seat.", "Then the seat goes on along with the plastic corner bumpers.", "They print the store's name on the handle inserts.", "The handle goes on last.", "After some final adjustments and a quality control check, the newly minted shopping cart is ready to roll.", "Every machine, from your vacuum cleaner to your car, is made up of a series of parts.", "Those parts are designed by specialized companies.", "They first build a prototype, then make the molds or tools needed to manufacture the parts.", "They design the part in 3-d on a computer.", "The computer then guides the machines that construct the prototype.", "One method divides the 3-d drawing into cross-sectional layers just a few thousandths of an inch thick.", "It feeds this information to a laser that's directed at a tray filled with a light-sensitive liquid resin.", "The laser's light hardens the resin in the shape of the part layer by layer, eventually constructing the prototype.", "They rotate the prototype under ultraviolet light for a few hours to cure the resin.", "Then they polish or paint the prototype according to the requirements of the design.", "Another prototyping method works much the same way but uses a fine, powdered plastic instead of resin.", "The computer guides the laser to melt the powder in the shape of the part, again layer by layer.", "They extract the hardened prototype from the unmelted powder.", "A third method of prototyping doesn't use a laser at all.", "The computer simply guides machinery to carve the prototype out of a hard material such as a wood composite.", "Once a prototype is ready, they use it to construct a model of the part out of a very durable resin.", "They'll use that model to make a mold, then they'll use that mold to cast the part out of metal.", "The resin model dries at room temperature in 24 hours.", "Its surface must be smooth or else the mold will have defects.", "They attach channels that will guide the molten metal into the mold.", "Next, they fill the model with a mix of sand and a binding agent.", "They smooth out the surface, then number it for tracking purposes.", "The sand mix takes about 15 minutes to harden into a mold.", "Now they can finally cast the part.", "They carefully pour in the molten medal, in this case, magnesium, heat it to about 1,300-degrees fahrenheit.", "They block the hole with sand to prevent the metal from reacting to the air.", "The metal takes about 10 to 20 minutes to harden, depending on the size of the mold.", "They crack the mold open on a vibrating conveyer.", "They use a plaster mold to cast parts that require a better surface finish.", "Workers position a box around the prototype to contain the plaster.", "The mold goes into an oven at about 570-degrees fahrenheit.", "It takes 48 to 72 hours to cure, but it's not ready for casting just yet.", "Workers first have to pierce some holes in it to let all the air escape or the metal won't flow into all the crevices.", "And they have to put in filters to keep out impurities.", "They strap the two halves of the plaster mold together, securing them with metal screws.", "Workers carefully pour in molten magnesium, using a special gas to prevent the metal from catching fire.", "Again, they seal the opening with sand.", "It takes the metal anywhere from 20 minutes to an hour to cool.", "Then they break open the plaster to remove the metal part.", "They cut off the channels through which they poured in the metal and polish the part using grinders and sanders.", "Then they paint it using special spray paint that adheres to magnesium.", "The part is finally finished.", "It takes several weeks to prototype and tool metal machine parts.", "When you think about it, even the machine that make these parts are made of parts that were created with this method.", "The first people to make coins were the lydians in asia minor in 640 b.c. about 40 years later, the concept spread to ancient greece, where coins often featured an owl-- the symbol of the goddess athena.", "Around 500 b.c., the chinese invented coins made of cheap metals like copper, instead of gold and silver.", "Today's currency coins are still made of copper, nickel, and other inexpensive materials.", "The mint manufactures collector coins using sterling silver as well as sterling scraps left over from making other coins.", "The silver goes into a casting furnace at 2,100 degrees fahrenheit.", "The melted silver is cast into a continuous bar about 1 1/2 inches high by 5 inches wide.", "A machine cuts the continuous bar into individual bars about 30 inches long.", "Each bar goes into what's called the roughing mill.", "The mill's two rollers squash the bar flat, using up to 9 tons of force.", "It takes up to a dozen passes to flatten the bar into a strip just half an inch thick.", "A machine called the finishing mill thins the strip out even more to what will be the final thickness of the coin, anywhere from 3/100ths of an inch to 2/10ths of an inch, depending on the denomination.", "Next, the blanking machine stamps out blank coins.", "The silver that's left over, called sisel, goes back into the casting furnace, where it's melted down into fresh bars of silver.", "The next stop for the blanks is the rimming machine, whose spinning wheel presses a raised edge, or rim, on each one.", "The blanks then go into a tub filled with water, cleaning solutions, and steel beads.", "The beads act as an abrasive agent, smoothing and polishing the blanks.", "After a 20-minute cycle, they empty the tub's contents into a sifter to separate the blanks from the beads.", "Workers then towel dry the blanks by hand.", "This ensures there will be no water stains on the coins.", "Throughout the coin-making process, as the silver is worked, it becomes brittle-- so brittle that it could easily break when struck.", "That's why at several stages the metal goes through an oven called an annealing furnace.", "The coin design comprises artwork or a photograph or a combination of both.", "This coin will feature a photograph of queen elizabeth provided by buckingham palace.", "The artist uses a computer program to design a collage of various elements.", "Once mint officials approve the final design, the process of engraving can begin.", "They take a plaster disk that's 10 1/2 inches in diameter.", "The computer guides the engraving machine to turn the one-dimensional computer design into a three-dimensional version in rough detail.", "This creates a plaster model of the design in the negative.", "They now use this negative to cast a plaster positive.", "An artist then enhances the detail by hand.", "Once that's done, they cast a negative plaster mold.", "From that, they then cast a positive mold, this time in rubber.", "From the rubber, they cast a negative mold out of hard, black epoxy.", "They mount the epoxy model on a machine called a pantograph, which is essentially a reducing machine.", "It traces the model and cuts a version 1 1/2 times smaller in brass.", "This reduction process takes 36 hours.", "Then an engraver takes the brass model and fine-tunes the design under a microscope.", "At this stage, the engraver also adds the lettering, noting the year, the denomination, and the country of issue.", "Then comes another 36-hour reduction process.", "They reduce this brass model to 1 1/2 half times its size to create what's called a matrix-- a negative model made of high-grade steel that's the final size of the coin.", "Then they strike the matrix onto a block of steel which creates a positive called a punch.", "Then they strike the punch onto another steel block to create a negative called a die.", "The coins are made one at a time in the coin press.", "There are two dies per coin, one for each side, positioned above and below the blank.", "They strike simultaneously, not once but twice, to create a high-quality impression.", "In contrast, circulation coins are struck just once on high-speed machines that make several hundred coins per minute." ]

{ "things": [ "Bicycle Helmets", "Aluminum", "Car Brakes", "Lithium Batteries" ] }

[ "Today on \"how it's made\"...", "Bicycle helmets-- letting safety go to your head...", "Aluminum-- probably the most versatile metal around...", "Car brakes-- we bring you breaking news about how they're manufactured...", "And lithium batteries-- you'll get a charge out of this one.", "If you're serious about bike-riding, you should also be serious about safety, and it all starts with your head.", "Today's bike helmets meet all the required safety standards and come in a wide range of colors and styles, which means you can protect your head and look great doing it.", "A bicycle helmet is constructed of an exterior shell and an interior one of polystyrene foam designed to absorb shocks.", "Some designs for bicycle helmets are drawn by hand and with computer-aided graphics.", "The design has to take into account that it is not on a flat surface, but on a rounded one.", "This creates optical deformities that have to be corrected.", "Fabrication begins with the exterior shell.", "This polymer sheet is heated in a heat former at a temperature of 65 degrees centigrade.", "The mold lifts the sheet and suctions it to fill all the cavities of the mold.", "This operation lasts about one minute and produces four shells.", "Then, when cooled down and hardened, the four shells are cut by hand.", "Ventilation openings are cut with a heated wire apparatus.", "These openings have been preformed during molding of the shell.", "The heated wire easily and neatly cuts the polymer.", "Next up, trimming the helmet to eliminate excess polymer.", "The circumference is manually cut using a router.", "The edges are then sanded to even them.", "It is also possible to cut the circumference of the shell with a heated wire.", "This operation takes more time, but is more precise because of the resulting cleaner cut.", "Now they're going to fabricate the foam interior that will be placed inside the shell.", "It's made of polystyrene beads that will expand and bond together.", "This expander increases the volume of the granules that fall into it.", "Steam and an agitator let the polystyrene beads expand uniformly.", "The granules are now ready.", "The contents of this bin will be able to produce about 20 foam pieces, which will take shape on these molds.", "The press closes up for the six minutes that it takes to mold four foam pieces.", "The particles fuse with steam before being cooled with water.", "The foam is removed from the mold.", "Forms are produced for different helmets.", "Fusing of the particles has welded the granules to one another.", "Depending on the helmet model, openings have to be made with this heat iron to allow for installation of an air-vent accessory.", "All that remains is to make the adjustment pads, cut with this press-powered stamper.", "The adjustment pads are held in with velcro to allow easy adjustment of the helmet.", "This allows the cyclist to change the foam pads for greater comfort.", "Inserting the straps calls for good manual dexterity and takes only a minute.", "The shell and the polystyrene foam liner have to be joined.", "They're adjusted one inside the other, then solidly secured with adhesive tape.", "The helmet is now completed.", "And now it's ready for packaging.", "The safety helmets have to be certified, guaranteeing their safety, and conformity tests are done.", "At least one helmet in 500 will undergo this destructive test.", "Here, it drops vertically onto a piece of steel.", "This facility can produce up to 4,000 helmets daily in hundreds of models and over 500 variations.", "Take a look around, and you'll find this wonder metal everywhere, in everything from screen doors to jet planes.", "Aluminum has so many applications because it's light and strong, and it's corrosion- and crack-resistant.", "Producing aluminum is costly, but it saves money over time.", "Aluminum-- so widely used today, and the world's most abundant metallic element, does not occur in a natural state.", "The most available source of aluminum is actually bauxite.", "Bauxite is mainly mined in tropical countries.", "The aluminum atom in bauxite is bonded to oxygen molecules.", "These bonds have to be broken by electrolysis to produce pure aluminum.", "Bauxite is carried by rail to the plant, where it will be crushed.", "Then, through a chemical transformation called the bayer process, alumina is extracted.", "This is then roasted in calciners to eliminate all moisture.", "This is the reduction facility.", "This plant has 432 pots through which a powerful electric current will be passed to produce electrolysis.", "An overhead crane dumps alumina into the pots.", "Then the electric current from the anode passes through the alumina that we see here at the bottom of the pot.", "Via the process of alumina reduction at 1,742 degrees, the anodes lose volume and will have to be replaced.", "It's a continuous operation.", "Each anode has a life-span of about 20 days.", "Spent anodes are recovered from the pot with this overhead crane and carried off to be recycled.", "They clean the aluminum rods, which will then be reused.", "Here we see the crust formed atop the anode.", "When the anodes are replaced, the accumulated impurities have to be recovered from the top of the pots.", "This is accomplished with these pincers.", "Then a new anode is inserted into the alumina, and electrolysis continues.", "The electric current breaks the molecular bonds.", "The heavier aluminum collects at the bottom of the pot, while the oxygen bound to fluorine is released as a gas, which is drawn off and treated.", "The liquefied aluminum remains at the bottom of the pot.", "It has to be recovered in this huge crucible with a tube.", "The tube is dipped into the bottom of the pot, and a vacuum system draws the molten aluminum from the crucible.", "The aluminum is recovered in a short time.", "Air is vacuumed from the crucible by a flexible pipe held by an operator.", "The tube is finally withdrawn, and the overhead crane dumps another quantity of alumina into the pot.", "Thus, the aluminum-fabrication process continues uninterrupted.", "The crucibles filled with molten aluminum are transported to the casting house.", "Their contents are poured into holding furnaces, that have a capacity of 60 tons.", "In these very hot furnaces, the molten aluminum is stored to await casting.", "Finally, casting begins.", "The aluminum can be semicontinuously vertically cast, producing ingots, sheets, or billets, or it can be directly cast into semifinished products.", "The cooling of aluminum pieces is accelerated by water sprays.", "The large, rectangular ingots, which can weigh up to 25 tons, will head for hot-rolling, and eventually will be fabricated into products like aluminum foil.", "From four to five tons of bauxite have produced two tons of alumina, which in turn produces one ton of aluminum.", "This particular plant produces 200,000 tons of aluminum annually.", "Some other facilities can turn out as much as 400,000 tons.", "If you've ever had to stop suddenly while driving at high speed, you know that once you hit the brakes, they can easily lock up, making you skid.", "But with the sophisticated computer technology behind today's antilock brakes, skidding is becoming a thing of the past.", "Brakes are absolutely essential equipment for every vehicle to slow down and stop.", "And brakes have remained practically unchanged for the past 40 years.", "Conventional disk brakes have pads that press against the brake disk attached to the wheel.", "These pads grip the disk on only 15 to 30 degrees of its circumference.", "This develops high heat, wheel skidding, and results in premature wear.", "The new floating disk brakes have two pads of friction material on 360 degrees of the disk.", "When the brake is applied, hydraulic pressure activates the diaphragm, which applies pressure on the inboard pad, which is then pressed against the disk.", "In this animation, the diaphragm movement is exaggerated.", "However simple, the design of this brake calls for some complex development steps.", "It all starts on the monitor screen with computer-aided design.", "This powerful software creates objects in three dimensions, which can be virtually manipulated.", "They then proceed to digital analysis.", "Here, digital models are submitted to repeated braking to verify that the parts conform to design objectives.", "The software verifies changes in heat, the effects of vibration, and resistance to breakage.", "The right choice of materials is critical.", "The electrical components also have to be created.", "Here, we see the delicate construction of tiny sensors, that measure the force exerted by the braking system.", "The sensor is the main component of the intelligent a.b.s. braking system, which functions more efficiently than traditional antiskid systems and reduces braking distance.", "Next, it's the fabrication stage of prototype parts, which will be tested.", "The machining of these parts must take into account the requirements of mass production.", "This high-precision, robotized machining is done by computer-controlled digital machines.", "A liquid sprinkled on the machine part cools it during the process.", "The finished parts are precisely measured, then fitted and assembled to form the total braking system, which will be first tested in the laboratory.", "Brakes in full contact have a friction surface six times superior to traditional brakes.", "The use of aluminum and composite materials allow for a weight savings of 5.5 pounds per wheel.", "This affects roadholding and reduces fuel consumption by .", "05 gallons per 100 miles.", "They proceed to power and endurance tests on this dynamometer, in which a brake and wheel assembly act against a large rotating drum.", "These lab tests are critical, since they can detect any defect in a braking system before it's installed on an actual vehicle.", "In order to evaluate the power and endurance of the brakes in full application under extreme conditions, they were installed on this porsche 911 turbo entered in the motorola cup.", "They proved completely satisfactory, and the porsche went on to record many wins.", "Once all validation tests are done, we move on to the next step.", "Brakes are installed on a production-model vehicle.", "With data systems, engineers can observe the performance of brakes under all conditions thousands of times a second.", "Finally, engineers proceed with actual braking trials with test vehicles.", "All that remains is to produce brakes on a large scale to supply auto manufacturers' production lines.", "And that's the story of brakes, from original idea to final product.", "There's nothing like the sound of a car engine starting, especially when it's 15 below on a winter morning.", "Today's automotive batteries are smaller, more powerful, and more efficient, even at extreme temperatures.", "It's all thanks to the power of lithium-ion-cell technology.", "While dissecting a frog in 1786, the italian researcher galvani noted that when his scalpel touched a leg muscle, it contracted from an electric current produced.", "Later, volta believed the current was produced by the metal instruments, the animal being only a conductor.", "To prove it, he stacked disks of zinc and copper connected by conductors and fabric impregnated with an acid solution.", "And so, in 1800, the electric battery was born.", "Batteries power all kinds of electric motors.", "A new lithium-metal-polymer battery pack such as this one could soon power an electric automobile, as well as a hybrid vehicle.", "This battery will be made up of four components.", "It all starts with this lithium ingot, which weighs about 11 pounds.", "It's transformed into a thin sheet by this extrusion press that applies 440 tons of pressure.", "The press creates a sheet that's only about 1/100 of an inch thick.", "The whole extrusion sequence is closely computer-controlled.", "Extrusion is now completed.", "The metallic lithium sheet is the required 1/100 inch in thickness, or 1/4 of a millimeter.", "The sheet has to be further thinned.", "Placed on a roller, it is carried to the laminator.", "At room temperature, it's thinned once again.", "In just 20 minutes, the 11-pound ingot will have been transformed into a thin sheet .", "01 inches wide and some 655 feet in length.", "This laminator completes the thinning of the sheet.", "The resulting 1 1/4 mile-long sheet will allow for the fabrication of 210 battery units.", "Lithium is a soft, sticky metal.", "For this reason, a polypropylene film has to be fixed onto the lithium sheet.", "Without this protection, the sheet would adhere to itself and become unusable.", "The sheet will be used to make individual battery cells.", "Then these cells will be assembled, in series and in parallel, and inserted into modules of different shapes.", "To make an individual battery cell, the sheet has to be rolled up.", "This automated spooling machine winds up the lithium film in 26 revolutions.", "The wound-up sheet is put into a vacuum oven, where the various layers adhere firmly to one another.", "This step lasts for about 90 minutes at 176 degrees.", "Here, a test is made.", "Using a voltmeter, the battery is checked to see that it produces the required 3.56 volts.", "Any problem can be detected here and corrected.", "A final quality check is made with this caliper.", "It precisely measures the thickness of the battery cell.", "The battery cells are then stored.", "Metallic plates are placed between them for the entire storage period.", "One more step remains, and that's the metallizing of the contacts.", "The battery cells are sent off to a fabrication facility in this container.", "The container is robotically handled.", "First, it's put into a protective tank.", "Then the metallizing of the contacts is done by spraying on molten metal.", "This takes just a few seconds, since the metal cools very quickly.", "The battery is now finished.", "It comprises four elements-- lithium, which acts as the anode, a metallic oxide cathode, a dry solid polymer electrolyte, and a metallic current collector.", "All that remains to be done is the assembling of the individual battery cells into a module.", "It begins with the placing of individual cells onto one another and isolating them with foam so that they do not touch each other.", "These red sheets are actually heating elements, since the lithium-metal-polymer cells function at temperatures of between 104 and 176 degrees.", "Here, we see these modules of a battery pack for a hybrid vehicle, an automobile that works with a gasoline-powered motor and an electric motor.", "This prototype battery was created for a totally electric vehicle.", "It surpasses heavy traditional lead-acid batteries that can't develop the same amount of electrical energy and have much shorter life-spans." ]

{ "things": [ "Rawhide Lampshades", "Chocolate Chip Cookies", "MRI Scanners" ] }

[ "You doesn't need to have antlers over the fireplace to bring a touch of wildlife to your decor.", "A more subtle approach can be a lamp with a shade made of rawhide.", "Rawhide is untanned animal skin.", "The hide typically comes from livestock, so you get the decorative \"bang\" without firing a shot.", "You typically see rawhide lampshades in rustic settings, but they've also been known to add an eclectic twist to a modern decor.", "This company has been using the same techniques to hand-craft rawhide lampshades since 1929.", "The first step is to construct the shade's frame out of 3-millimeter-thick steel wire.", "They begin by cutting the various lengths of wire to make the component's first shade of a particular size.", "Every frame has one top ring, one bottom ring, and several vertical ribs connecting the two.", "After clamping the wires alongside a measuring gauge, they position the blade where required and cut.", "They curve the pieces for the rings with crank-operated rollers, which apply pressure to bend the wire.", "It takes a few passes to work the steel wire into a full circle.", "Then they spot-weld the ends together to complete each ring.", "They cool the hot weld in cold water.", "Now it's time to assemble the frame.", "They use a jig to correctly position all the parts.", "This one is for a slanted shade with an 18-inch bottom diameter.", "After laying in the bottom ring, they position one rib at a time and spot-weld it to the ring.", "They assemble the spider-- the inner structure of the top ring.", "They take a brass washer with four holes in it and insert a steel wire arm into each one.", "A single strike of a 1-ton press locks each arm in the washer.", "They spot-weld the spider to the top ring...", "Then the ring to each rib of the frame.", "The frame is now fully constructed and ready to be coated with baked-on paint.", "This not only makes the frame more attractive, it prevents the steel from rusting as it comes in contact with the wet rawhide.", "The freshly-washed sheepskin is the highest grade of hide available, so the color is an even butterscotch-- rarely any color variations or spots.", "They center the frame upside-down on the skin, then work their way around, folding the skin upward and over, clamping it in place with clothespins.", "Then, they flip the shade right side up and slit the skin at the top with a razor blade to release some tension.", "Now they sew the skin to the top and bottom of the frame with rawhide lace.", "However, this rawhide is cow skin.", "Once the sewing is complete, they cut off the excess skin.", "The rawhide is still quite wet, so they dry the lampshade in a heated closet for about five hours.", "When it comes out, they bathe the rawhide in a moisturizing agent then a finishing solution, the specifics of which are a closely-guarded company secret.", "These treatments bring out the butterscotch color and seal the hide to prevent it from drying out and cracking.", "The lampshade then goes back into the heated closet for 24 hours.", "Lampshades are often hands-painted before this, in which case the finishing solution seals the oil paint as well as the hide.", "Each design is original and signed by the artist-- a unique work of art designed to light up a room.", "Legend has it that chocolate-chip cookies were invented in 1930 by an american innkeeper who ran out of baker's chocolate.", "She improved by breaking a semi-sweet chocolate bar into small pieces.", "Instead of melting, the chocolate merely softened, dotting the cookie with chocolate chips.", "They look homemade, and they taste homemade, but this home is a factory.", "Each ingredient goes into an industrial-size mixer, starting with white sugar.", "Then brown sugar.", "Then butter.", "The mixer thoroughly blends these first ingredients until the butter becomes soft and creamy and the sugars are evenly dispersed.", "Then it's time for the headliner-- chocolate chips.", "They're semi-sweet, which is a mixture of bitter and sweet chocolate.", "Next, flour, followed by baking soda to make the dough rise and salt to add flavor.", "The final ingredients are whole eggs, beaten, combined with vanilla, made from beans harvested in madagascar, africa.", "Mixing resume until everything's well-blended, which usually takes about five minutes.", "The company closely guards recipe specifics, but if you're curious, you could probably figure them out by multiplying the ingredients of a home recipe to the yield of a production batch.", "Workers transfer the cookie dough to a machine called the former.", "It pushes the dough through round dies, producing row upon row of round pieces weighing 1.4 ounces each, one of several sizes the factory produces.", "The factory then flash-freezes the dough rounds for sale to food-service customers such as restaurants and hotels, which bake the cookies in their own kitchens.", "The freeze tunnel uses liquid nitrogen to create the frigid temperature.", "The passing dough rounds solidify in approximately five minutes.", "Exiting the freeze tunnel, the dough rounds pass under a metal detector to ensure they don't contain any metal particles.", "This safety measure is standard practice in the food industry.", "The packaging system is entirely automated.", "The first station erects the box.", "The second station lines it with plastic.", "A conveyer belt, meanwhile, feeds the frozen, unbaked cookies onto automated scales.", "Once a scale hits the per-box weight, feeding pauses.", "The bottom swings open, and the cookies drop into the box awaiting directly underneath.", "The next stations seal and label the boxes, which workers then load onto pallets.", "The pallets go into a storage freezer, where they stay until it's time to ship them out, by freezer truck, to the customer.", "This company also sells gift tins of cookies online and by catalog.", "For that market, they bake the cookies in-house.", "Workers lay out the dough rounds 2 inches apart on trays lined with parchment paper.", "This prevents sticking, making it easy to remove the baked cookies without breaking them.", "The dough rounds are nearly 1½ inches wide by 1 inch high.", "As they bake, they flatten out and double in diameter.", "The trays remain in the oven for seven minutes at 300 degrees fahrenheit.", "A turntable inside rotates them so that the cookies bake evenly throughout the tray.", "A few cookies per batch go to the quality control tester, who, unfortunately, doesn't get to conduct the assessment by eating the samples.", "Rather, the tester measures the diameter and height to ensure consistency in size and chip content.", "In the online and catalogue order assembly area, workers line the bottom part of the gift tin with a decorative cellophane bag.", "Then, they carefully layer the correct number of fresh cookies inside in a staggered configuration.", "This not only creates a nice presentation, it also prevents damage in transit.", "They close the bag with a gold twist tie to seal in the freshness...", "Close up the tin, then pack it for shipping.", "This is how to give a gift of homemade chocolate chip cookies without ever setting foot in the kitchen.", "The mri scanner was invented in 1977, and it has revolutionized medical diagnostics.", "Short for magnetic resonance imaging, an mri offers an inside look at the human body without surgery or x-rays.", "When investigation health problems, it's a great way to get the picture.", "Using magnetic fields and radio-wave pulses, an mri can look right through you to determine what's going on under the skin.", "The magnet is incredibly powerful.", "It's up to 30,000 times stronger than the earth's magnetic field.", "To make an mri scanner, they weld aluminum casing around the magnet, creating a tunnel in the center for the patient.", "The seams must be extremely tight because the tube will also contain the super-cold liquid helium which will make the magnet so incredibly powerful.", "Once the welds are complete, they cap the magnet and transfer it to a test chamber.", "They pump helium gas into the tube and activate a vacuum system that sucks out the air in the chamber.", "A sensor confirms there are no leaks and the welds are tight.", "They now construct a second aluminum tube around the magnet.", "This will act as an insulating shield.", "They wrap and aluminized mylar blanket tightly around the magnet.", "Aluminized mylar was first developed as an insulating material for space suits.", "In this case, it will be used to deflect heat to keep the magnet cold.", "They now insert the magnet into a steel shell.", "This is know as the vacuum vessel.", "The air will be pulled from the space between it and the magnet, creating a vacuum which will serve as another insulator.", "They mask the mri tunnel with plastic and spray paint the exterior white.", "The paint will protect the steel from rust.", "Next, they install a refrigeration unit knows as the cold head.", "The cold head will maintain the helium around the mri's primary magnet at the incredibly chilly temperature of -452 degrees fahrenheit.", "This will keep the helium in a liquid state.", "Without the cold head, significant amounts would vaporize and be lost.", "They now pump the liquid helium into the magnet.", "It's one of the coldest things on the planet, and the fill nozzles turn frosty.", "Exposed to this extreme cold, the magnet loses all electrical resistance and becomes a super conductor, generating intense magnetic fields.", "With the mri magnet complete, they move on to the gradient coil, which will control the orientation of the image with electrical pulses.", "It starts with a fiberglass epoxy tube cut to the correct length.", "A worker carves grooves in the tube and fills those grooves with epoxy.", "He then winds copper wire into the epoxy-filled grooves, and it adheres, forming the gradient coil.", "The team slathers epoxy onto the entire tube.", "The epoxy seals the wire, preventing vibrations of the coil when it's in operation.", "They layer etched copper plates onto the epoxy, and they adhere.", "They wrap the coil tightly with teflon cloth.", "A worker pours epoxy resin onto the fabric.", "He then winds tubing around the gradient coil, which adheres to the epoxy-coated cloth.", "These are cooling lines.", "They'll disperse heat generated by the gradient coil.", "Another worker now preps the next fiberglass tube.", "This one is for the mri's radio-frequency coil.", "There's much more to come before this mri scanner is ready to provide an inside look at the human body, so stay tuned.", "An mri scanner produces detailed images of bones, organs, and other structures inside the human body.", "It does this by generating a strong magnetic field that causes the body's hydrogen atoms to align and send a signal.", "The result is a picture that could lead to a diagnosis.", "Work on the mri's radio-frequency coil is under way.", "A technician attaches plastic risers and pads to the fiberglass core.", "The risers and pads will hold the circuitry parts at a uniform level.", "She applies adhesive-backed strips of copper from one band of risers to the other.", "These copper strips are the antenna.", "They'll send and receive signals from the body and relay them to a computer to produce the mri image.", "She presses the copper with round-tipped tool for better adhesion to the core.", "She then dabs epoxy glue into the riser compartments.", "She inserts capacitors into the glue-filled compartments.", "These little capacitors will store energy and change the frequency of the coil to match the magnets.", "The technician solders the ends of the capacitors to the copper antenna as she builds the circuitry.", "She transfers numerous high-voltage inductor boards to the pads and screws them in place.", "Next up are cable-splitter units.", "Another technician installs one near an inductor board.", "She routes some of the cables from the splitter to the several of the inductors.", "And she solders the cables to the inductors.", "She places a plastic cable track on the side of the radio-frequency coil and snakes the main power cable through it.", "She solders the cable to the antenna.", "The technician stiffens the copper antenna with composite boards to dampen vibrations when the mri is in operation.", "She applies epoxy around all the cables.", "The epoxy secures the cables to keep them from moving around and making noise.", "The mri's radio-frequency coil is complete and ready to be put to the test.", "The next worker caps the ends with metal domes and bolts them tightly together.", "She pumps highly pressurized air into the capped radio-frequency coil.", "She spray soapy water over the exterior of the coil and looks for air bubbles.", "Bubbles in the soapy residue would indicate a leak, which would disrupt airflow in the mri.", "With the radio-frequency coil leak-free, they now slide it into the gradient coil, which has gained an outer fiberglass shell since we last saw it.", "The worker connects exterior tubing to the network of cooling lines inside the gradient coil.", "With those connections made, they're ready to assemble the coils to the magnet.", "The worker slides the assembly off the cart and into the mri magnet.", "He installs a bracket that centers the coils, maintaining a small gap between them and the magnet.", "He equips the mri with microphones and speakers, to communicate with the patient.", "There's also a signaling system here for the patient to activate in the event of an emergency.", "Now for the ultimate test.", "They energize the magnet and send standard test objects into the mri.", "They scan the objects and confirm the picture is clear.", "They add a metal and plastic outer casing.", "This mri scanner is now ready to focus on diagnosis.", "The next picture it takes could be a life saver." ]

{ "things": [ "Windshields", "English Saddles", "Butter", "Post Clocks" ] }

[ "Today on \"how it's made\"...", "Fiberglass insulation...", "Wooden ducks...", "Gumball machines...", "And exhaust systems.", "It's pink and fluffy, and it keeps us warm.", "Fiberglass insulation is a great way to prevent heat loss from our buildings.", "It has a woolly texture, but it is, as the name suggests, made of very fine threads of glass.", "That's why it's sometimes referred to as glass wool.", "Fiberglass insulation will reduce energy consumption, but it also reduces waste because it's made from at least 35% recycled glass.", "The recipe also includes what's called the batch-- a lot of sand and smaller portions of soda ash, limestone, and other minerals.", "The glass, called cullet, used to be bottles and windows.", "This will be its second recycling.", "The cullet and batch ingredients spill onto a conveyer-belt system, which transports it all to an electric furnace.", "The conveyer moves back and forth to evenly distribute the cullet and batch ingredients.", "They seep down and melt into a previous mix, which is now a pool of glass at the bottom of the furnace.", "The glass liquid now flows out of the furnace and into sloped channels.", "Inside these channels, the temperature is kept red-hot by natural-gas burners.", "This keeps the glass mix in a liquid form, as it oozes out of the holes in the bottoms of the channels.", "The melted glass falls about 3 feet into a spinning bowl.", "It's called a fiberizer.", "The spinning action flings the glass through thousands of holes in the bowl, creating thousands of feathery glass fibers.", "Gas and compressed air pull the fibers, stretching them thinner.", "The process is a lot like making cotton candy, and the spun glass even has a similar texture.", "But the fibers will soon become even more like cotton candy.", "Nozzles spray them with a polymer glue tinted pink.", "The now-pink and sticky fibers drop into a hole in the ground and amass.", "Then a conveyer belt takes the mounds of sticky glass to an oven.", "Steel plates compress the pack as it enters the oven that's heated to 500 degrees fahrenheit.", "Hot air blows through it, setting the glue.", "As the pack exits the oven, circular saws cut through it, making 15- to 24-inch-wide strips that are called lanes.", "The lanes pass by a series of poles that push them apart.", "Next, an ink jet brands each lane with a number that conveys the \"r\" value.", "\"r\" stands for \"resistance to heat flow\".", "It's a measure of how well the insulation will stop heat from going through the roof and your energy bill along with it.", "A chopper with big steel teeth now cuts the lanes, making chunks that could easily be installed in an attic or wall.", "After chopping, the conveyer belt accelerates, transporting the fiberglass batts to the next station.", "A few at a time, the batts plunge down a chute, to a mechanical arm which slides the batts into a compression chamber.", "There, a hydraulic ram squishes the batts down, reducing their bulk 5 to 10 times.", "This compaction will make them easier to transport.", "Now another ram comes from the side and pushes the stack of compressed batts forward into a spout.", "The spout is a hollow batt-shaped frame.", "A worker pulls a plastic bag over it.", "Then the ram pushes the fiberglass-insulation batt into the plastic bag, and the process begins again.", "A conveyer belt transports the batt-filled bags to a machine that heat-seals them.", "Then they're sent off to be installed.", "For centuries, hunters have used wooden ducks to lure live ones to within shooting range.", "Stringing together decoys and floating them in the water, hunters trick the birds down from the sky with duck calls.", "Nowadays, hunters generally prefer cheaper, plastic decoys.", "Wooden ducks are mostly decorative items for the home.", "This company's flock includes males, females, and androgynous models like this one.", "This more elaborate male is inspired by another aquatic bird, the loon.", "To make them, these craftsmen use eastern white pine because it's easy to carve and has a nice grain.", "First, a machine shapes a 2-inch-thick slab.", "They cut the slab lengthwise.", "They'll use four to six of these smaller pieces to make most of the duck's body.", "The birds range in size from baby ducks just 4 inches long to geese at more than 19 inches long.", "A craftsman now applies a generous amount of carpenter's glue to one side of the wood.", "Using a lot ensures a strong bond and prevents splitting later on.", "The pieces then go into what's called a wood clamp.", "He tightens a vice, squeezing them together.", "It takes about two hours for the pieces to bond properly.", "Then he'll shave away the excess glue and even up the surfaces.", "Once that's done, they run the block over what's called a joiner.", "A roller with 3 blades shaves about 3/4 of an inch from what will become the top and bottom of the duck.", "Each model has three wooden patterns for the top, the bottom, and the profile.", "Here, a worker traces the outline of the bird's profile in pencil on the wood.", "Since this is a small model, he'll make two birds with one block.", "Using a band saw, he trims along the trace line.", "This company recycles the cutoffs into fireplace kindling and shavings for farm stables.", "Next, he uses another pattern to create the top of the bird.", "These patterns provide only the general shape of a particular model.", "The craftsman will later carve the details using smaller electric tools and by hand.", "Now he sands the wood with a pneumatic drum sander-- a tube of pressurized air with sandpaper stretched over it.", "He uses higher pressure for sharper curves, lower pressure for softer edges.", "To sculpt the bird's plumage, the craftsman uses this band sander whose rounded edge presses sandpaper into the wood.", "Here, he makes three long grooves-- one on top, and one on each side of the duck.", "The head's made from a different piece of wood than the body.", "Here, he sands down the piece to smooth out the curves.", "Using various shaping tools and the band sander, he sculpts the bird's head and bill area, then the underside and rear end of this waddling duck.", "He also carves depressions for eye sockets to come later.", "Here, he puts glue on the neck to attach it to the rest of the body.", "Using a nail gun, he reinforces the area with two nails on each side.", "To hide the nails and smooth out the neck, the craftsman uses wood putty.", "Once it dries, he'll sand it smooth.", "Next, he tints the duck bill using an orange wood stain...", "Then a forest-green stain to tint the head and neck areas.", "Males have colorful feathers to better attract mates.", "Females have more neutral colors to blend into their surroundings and protect their ducklings.", "The craftsman covers the duck's lower body with a clear wood stain.", "This way, the natural grain of the wood shows through.", "The front gets a clear but darker stain to mark the chest.", "And darker stain also highlights the plumage in the long grooves.", "Then, some green accents for the feathers on the sides in the back.", "Next, two coats of white paint to mark the duck's collar.", "Then he glues plastic eyes in the eye sockets.", "The irises are black, brown, or red, depending on the model.", "He then sprays on a protective, water-based varnish, and elevates the duck on nails so that the underside will dry along with the rest.", "Finally, the craftsman rubs the entire carving in wood wax.", "This makes the varnish appear uneven in places, giving the duck a worn, antique finish, like he's been around the pond a few times.", "The prices of wooden ducks vary according to size and detail.", "$500 will buy you this magnificent canada goose with wings stretched and ready for a graceful landing.", "For a century, there have been machines to give us gumballs.", "Vending machines that dispensed gumballs were introduced in 1907 on a new york city subway platform.", "Today's machines are more modern versions of the originals, but they still perform, basically, the same function.", "The gumball machine is all about instant gratification.", "Insert a coin, turn a handle, and out comes the merchandise.", "To make a gumball machine, a designer first sketches out the exact proportions.", "Then, a worker ladles molten zinc into a holding furnace, where a steel plunger pushes the metal through a die that forms a gumball machine base.", "A mechanical claw removes the newly shaped base from the die and places it on a conveyor belt to cool.", "A similar die shapes the coin mechanism handle and drive gears.", "A worker places a braided hose with a natural-gas flame under a mold that will shape the gumball-dispensing chute.", "He pours piping-hot liquid aluminum into the mold.", "The flame below warms the mold enough to prevent condensation, which would ruin the shape.", "But the mold is still cooler than the aluminum, and that allows it to solidify into a chute shape in seconds.", "Now, using a punch press, a worker trims the waste away from the lid for the gumball machine.", "They also trim the front plate of the coin mechanism, using a similar press.", "A computerized cutter mills out a hole in the top of the globe that will hold the gumballs.", "The globe is made of shatterproof plastic.", "At another station, they press the base of the gumball machine against a cloth-covered buffing wheel to give it a shine.", "A worker now assembles the coin mechanism, layering the front plate, the coin carrier, the back plate, and ending with a cam, the part that ensures the coin mechanism moves clockwise.", "She screws it tightly together, then inserts the handle on the front plate.", "The handle will turn the coins that pay for the gumballs.", "She places a little spacer and drive gear on the handle stem that protrudes through the back of the assembly and then screws the drive gear onto the handle stem.", "Now it's time to put the money up front.", "They insert a coin in the slot and turn the handle to make sure the system works.", "People in many countries like gumballs, and so these coin mechanisms can be made to accept currencies from around the world.", "They can also be used in other types of vending machines.", "Now they spray powder paint onto the lids, giving them a coating that's almost 1/16 of an inch thick.", "They bake the paint onto the lids at 400 degrees fahrenheit for 25 minutes.", "Now it's time to put all the pieces together.", "They place the dispensing wheels in hoppers, then cover them with a part that stops free gumballs from spilling out.", "The next part is the adaptor ring, and the plastic globes fit on top of them.", "They place aluminum rings on top of the globes.", "Then they slide two side rods through the top rings, down into the bottom of the globes.", "They screw them down very tightly, and then they set the assembly aside.", "Now they place plastic bodies on bases and install the chute doors on the front.", "They place the chute covers in the plastic body...", "And mount the coin mechanism just above the chute.", "Next, they slide the globe assemblies over center rods and onto the plastic foundations.", "They put a lid on every globe...", "And then lock them on.", "And now we're at the vending part of the story.", "Gumball, anyone?", "The job it does is exhausting.", "The exhaust system on your vehicle gets rid of harmful gases that could damage the engine.", "It also cleans up the gases a bit before venting them into the air.", "A properly functioning exhaust system does another big job-- muffling the airborne noise of the engine.", "It's a system of metal tubes and plates we only seem to notice when it breaks down.", "And when it does, everyone can hear it.", "To make an exhaust system, a mechanical puller draws a stainless-steel strip up into a punch press, shuffling it back and forth to allow for a precise cut with little waste.", "The press brings 60 tons of force to bear as it pushes the steel into a die.", "It punches out a baffle shape with holes in it, which will form the skeleton for the muffler box.", "The finished baffles fall onto a conveyor and go into a storage cage.", "Now a long steel tube tumbles to automated blades which score the tube crosswise to prevent denting and then cut it to produce smaller tubes that go inside a muffler.", "A circular saw descends on another tube to make a tail pipe.", "Its length depends on the type of muffler being made.", "A louver machine spins and punctures one of the inside tubes.", "The holes will regulate airflow in the muffler.", "A cnc bending machine grips and bends a pipe in several spots.", "This is how they make inlet, intermediate, and outlet tubes.", "These tubes run the length of the exhaust system.", "Then they place a tube in a circular hydraulic vice, which pinches the end down to a prescribed diameter to allow for further assembly.", "A worker now places two baffles in a jig.", "He fits the tubes through the holes in the baffles so that the tubes connect the baffles.", "Three mandrels slide into the tubes.", "The mandrels expand, locking the tubes to the baffles.", "Then they contract and slide out.", "Now the baffles and tubes are one piece.", "Next, a robotic arm picks up metal sheets, which will become the outer skin of the muffler box.", "It pushes them under an oval mold.", "Another arm with numerous rollers on it moves up and wraps the steel around the oval form.", "Then a metal block moves over the ends, double-folding them.", "This locks them together, and it completes the assembly of the muffler's outside skin.", "Magnets pick up the new skin, and, sliding on rails, they relay it to a mechanical claw which, in turn, feeds it to a flanger.", "The flanger bends the edges, creating a lip on either end of the muffler skin.", "A carousel turns, and a mechanical claw transfers the newly flanged muffler skin to the stuffing position.", "Hydraulic pushers press the pre-assembled baffles and tubes inside the skin.", "After the muffler is stuffed, the robotic claw transfers it to a conveyor belt.", "Next, a worker presses each end of the muffler against a set of steel expansion fingers.", "The fingers move forward into holes in the muffler.", "They expand and lock the baffles and tubes inside to form one solid, internal unit.", "Grippers place the muffler on a spinning machine that will fasten the caps on.", "Rollers press against the flared edges of the revolving muffler, tightly locking the end cap to the rest of the body.", "Here, you see the rolling in slow motion.", "It takes only a few revolutions to do the job.", "Then the roller backs away, and a mechanical arm grabs the muffler and transfers it to a conveyor belt.", "Now these mufflers are ready to help keep the traffic noise at a minimum." ]

{ "things": [ "Wood Toys", "Retro Toasters", "Laboratory Furnaces", "Aerogel" ] }

[ "a rubber tree's life-span for natural rubber production is limited to about 25 years.", "But making toys out of their wood gives unproductive trees a second life.", "This idea comes from southeastern asia, home to most of the rubber and latex production worldwide.", "This company, based in thailand, manufactures toys such as this series of animal-shaped racers made of locally farmed rubberwood.", "They buy old trees that have exceeded their productive life.", "A worker feeds lumber through a wood-rounding machine.", "The machine drives the log through a mill and turns it into a rod.", "The worker places the rod on a tray alongside other pieces ready for cutting.", "A cutting machine automatically matches the length of the rods while a round saw cuts out blanks, which accumulate in a crate.", "A router removes the sharp edges on the blanks.", "Stacked in a feeder tube, the blanks drop down one by one on the router table.", "An automated feeding mechanism pushes each blank against the router head.", "The router blade bites into the blank and trims off the edge, leaving the pieces ready for sanding.", "At another station, a lathe turns spherical shapes out of the wood.", "Several blades move in sequence to form the piece.", "When a new length of wood comes through, the front blade moves in.", "Once it backs away, another set of blades shapes the piece laterally before a cutter blade separates it from the rod.", "A worker now pours a nontoxic, water-based paint over the sanded blanks.", "He transfers the batch into a tumbling machine.", "The tumbling process will even out the color and drain the extra paint to accelerate drying.", "The worker closes and secures the lid of the tumbler before he starts the machine.", "The facility can simultaneously process 40 batches of painted parts in 30 minutes.", "The painted parts now go to a pad printer.", "An automated arm feeds the parts to the printer, which stamps each piece with a nontoxic paint.", "A worker uses a table saw to groove another set of painted parts.", "The custom-made jig ensures that the cut is straight and even and that the blade makes only a narrow and shallow groove in the wood.", "The worker places the grooved part on a jig and bores a hole into the piece with a drill.", "The machined piece goes to another pad printer.", "The pad picks up paint from a tray and transfers it to the wood.", "This process, called tampography, allows the printer to reproduce a design on an irregular surface, such as this wood piece.", "The printed parts dry at room temperature.", "As a last pad printer paints two dots on the wood, the face of the animal racer slowly takes shape.", "This red-colored powder is processed rubberwood sawdust entirely recycled from the machining operations.", "A worker fills molds with the reprocessed sawdust and prepares them for casting.", "The machine compresses the sawdust in a die and turns it into a solid and compact material called planwood.", "A worker starts assembling the planwood pieces to form the body of the racers.", "She applies a thin coat of nontoxic, formaldehyde-free glue and presses two corresponding planwood pieces together.", "She removes the excess glue with her finger before she hammers a dowel into the assembled planwood body.", "To finish the head of the racer, she inserts a felt piece into the groove machined on top and presses the head into the racer's body using a pneumatic press.", "The worker then drives the axles through holes in the planwood assembly.", "She takes painted and pad-printed wheels and applies a drop of fast-hardening glue inside each wheel hub.", "She then hammers the wheels into the axles and takes the assembled toy to a customized machine designed to press the wheels firmly into the axles.", "This finished chicken racer is one of a wide variety of rubberwood toys manufactured with environment-friendly processes and materials.", "Whether your preferred shade is light, medium, or dark, owning a reliable electric toaster that evenly heats and browns both sides of your bread just the way you like it is one of life's small pleasures.", "And if that toaster adds some style to your kitchen, all the better.", "Making retro-style toasters is this british company's bread and butter.", "While some of its models are new designs in a vintage style, this one is authentically retro, in continuous production since the 1960s.", "The manufacturing equipment, however, is modern.", "A computer-guided laser cutter cuts out many components from sheet steel coated with zinc for corrosion resistance.", "They stamp the company logo and then use the same press to begin forming a rectangular box.", "They bend three sides on this press...", "Then bend the fourth on a machine called a box folder.", "They rivet the body closed, then spray on a thick layer of paint powder known as powder coat.", "Then, they run the body through a tunnel oven for 10 minutes to bake the finish.", "The computer-guided laser cutter also cuts out several toaster tops from a sheet of stainless steel.", "This model is a four-slice toaster, so the machine cuts four slots per top.", "To make the manual bread ejector that pops up the hot toast, they weld steel strips to a round steel bar.", "Moving the toaster's ejector knob lifts this bar, raising the top of the toast out of the slot.", "They bend the strips, creating a cradle to stabilize the bread so that it doesn't wobble and get caught while moving up and down within the slot.", "This machine makes the toaster's guard wires out of copper-coated steel.", "The guard wires are barriers that prevent the bread from touching the toaster's heating elements.", "The machine first welds cut horizontal wires to four continuous vertical ones.", "Then, a blade chops the vertical wires every 12 inches, producing two side-by-side guard wires.", "Workers cut them apart on a guillotine, then, with a hand press, fold over the top of each one.", "This prevents the bread from catching on the top of the guard wires.", "Now they take the toasting compartment and insert the eight guard wires, one for each side of the four bread slots.", "Then, they install the bread ejector.", "Next, the heating elements.", "Being a high-end toaster, the elements are sheets of pure mica, a mineral that's heat-resistant up to 1,800 degrees fahrenheit.", "They connect them with electrically conductive copper links.", "They mount the switch that selects the number of bread slices to toast.", "Then, they install a red neon light that illuminates when you start the toaster and turns off when the toast time has elapsed.", "The timer switch has a bell that sounds when the toast time is up, at which point the switch cuts the current to the elements.", "They attach the dials for the slice selector and timer switches and connect their wires to the main power cord.", "Then, they place the toaster compartment into the body and screw on the toaster's stainless steel top, the protective film now removed.", "They flip the toaster upside down and wire up the elements.", "They install the ejector knob, positioning its spring against the bread ejector.", "When the bell rings, indicating your toast is ready, you move the knob to raise and retrieve your slices.", "A technician tests the toaster thoroughly, ensuring that all of the elements heat to the correct temperature, that only the selected slots heat up, that the timer is accurate, and that the bell rings when the selected time elapses.", "they install the removable crumb tray, then close up the bottom of the toaster with a ventilated base plate.", "Nylon feet elevate the toaster for ventilation and to prevent the screws attaching the base from scratching your kitchen counter.", "The style may be retro, but this 1960s-design toaster was ahead of its time with its energy-saving slice-selector feature that stops the toaster's empty slots from heating up unnecessarily.", "Laboratory furnaces are small but powerful appliances.", "They can reach temperatures of 3,000 degrees fahrenheit or more.", "These incredible furnaces are often used to test the quality of things like fuel oil, greases, coal, and to confirm the strength of structural materials.", "Exposed to the red-hot intensity of a laboratory furnace, this piece of steel should endure and even be strengthened by the exposure.", "It's the ultimate test of the steel's integrity.", "Making a laboratory furnace starts with this laser cutter.", "It carves out steel panels for the lower cabinet.", "A press brake folds the panels with precision to make three-sided pieces of cabinetry.", "A worker stacks them up.", "The next worker applies a powder coat to the metal parts using a compressed-air sprayer.", "When baked on, the powder forms a tough thermoplastic skin.", "At the next station, a worker tucks the end of an iron alloy wire into a lathe.", "As the lathe spins, it winds the wire around a mandrel, producing a tight coil.", "This coiled wire will serve as one of the furnace's two heating elements.", "After stretching the coil to widen the gaps and bending it to create parallel rows, the technician attaches electrical clips.", "He flips a switch.", "And electricity surges through the coil.", "This relieves stresses in the metal caused by the winding and bending.", "He now inserts two coils into the ridges of the mold.", "He transfers it to a vat filled with a ceramic fiber mixture.", "A powerful vacuum pump pulls the mixture into the mold, filling all the crevices.", "The vacuum then draws out the moisture.", "The coils are now embedded in a ceramic cake.", "This cake bakes in an oven overnight and solidifies, encasing and insulating the heating coils.", "A worker cuts the solid ceramic-fiber block in two, creating two separate heating modules.", "He trims them so they fit neatly in the furnace chamber.", "A computerized router cuts out other insulation pieces to fit the rest of the furnace chamber.", "This ceramic brick is a threshold insulator.", "This piece is a surround for the furnace door.", "A team now puts all the ceramic fiber pieces together in a metal framework.", "The heating element blocks form the sides of the furnace chamber.", "They thread the wires from the coils through the back panel.", "They insert the side and back panels in the framework.", "They assemble the other ceramic fiber parts to form an insulated chamber.", "They screw the framework tight, and this nestles the ceramic-fiber walls more closely together.", "They tuck the threshold insulator into place, completing the laboratory furnace's heated chamber.", "A technician now places the furnace's electric heating control panel in the lower cabinet.", "He fastens it to the metal cabinet with screws.", "He wires the temperature-control board to a touch screen and connects the power supply for the touch screen.", "He installs a stainless steel shelf on top, towards the front.", "He screws the front panel that houses the touch screen to the cabinet.", "He adds the top panel that the furnace chamber will sit on.", "He assembles the metal surround for the furnace chamber to the control cabinet, then slides the furnace chamber into place.", "Moving to the open back, he wires the heating elements for power and inserts a temperature sensor into a hole in the center of the chamber.", "He assembles a connector block, which will relay the sensor signal to the controller.", "He encloses the back with another metal panel.", "The next technician hinges the door to the metal surround.", "The door is a metal structure that's filled with many layers of ceramic-fiber insulation.", "He lowers and raises the door to confirm that it operates smoothly.", "This metal cover is the finishing touch.", "He snaps it onto the door and secures it with screws.", "The laboratory furnace's thick, insulated chamber is ready to contain the extreme heat and maintain it.", "And these torrid conditions are ideal for quality-control testing.", "Aerogels are the lightest solid materials on earth.", "They have nanosized pores that make it difficult for cold or hot air to penetrate.", "Used to insulate the electronics of the mars rovers and to capture comet dust, aerogels are among the most fascinating materials.", "Aerogels in shaped forms look almost like holograms.", "Yet they feel like hard foam.", "It's why they are often called frozen smoke or solid smoke.", "Making them starts with four ingredients-- a chemical called tmos, methanol, concentrated ammonia, and water.", "The technician adds measured amounts of tmos and methanol to a beaker that has a magnetic stir bead at the bottom.", "He transfers the beaker to a device that generates a rotating magnetic field.", "This causes the bead in the bottle to evenly mix the ingredients.", "He pours the mixture into a larger beaker and adds specific amounts of water, additional methanol, and ammonia hydroxide.", "As the ingredients are blended, a chemical reaction occurs.", "The tmos and water react to form silica.", "The chemical reaction will also cause the mixture to become a gel.", "But before that happens, he quickly prepares the molds.", "He pours pure methanol over a plastic grid and arranges rectangular molds over the grid.", "He injects precise amounts of the silica gel mix into the molds and leaves them to gel.", "During this process, the methanol under the grid evaporates, preventing excessive drying of the gels.", "The mixture coagulates in just minutes, but it takes about a day for the gels to fully strengthen.", "He then soaks the silica gels in methanol baths repeatedly over a period of several days.", "The methanol seeps in the gel's pores to flush out impurities.", "The gel pores are so minuscule they can't be seen with the naked eye.", "The technician decants the used methanol into a container.", "He'll send it to a recycler to remove impurities, and this will allow it to be used again in the aerogel production process.", "After several days of soaking in methanol, the silica gels are purified.", "They're ready for a process known as supercritical drying.", "It's a process that will convert these silica gels into aerogels.", "A technician places the gels in a pressure vessel.", "He locks the heavy steel lid with 12 large bolts and nuts so it will hold tight against a pressure that's 100 times greater than that of the normal atmosphere.", "He connects the hose that delivers liquid and carbon dioxide to the vessel.", "The liquid carbon dioxide replaces the methanol in the gel's pores.", "They then heat and pressurize the gels until the carbon dioxide in them becomes supercritical.", "It's semiliquid, semigas.", "The supercritical carbon dioxide diffuses out without collapsing the gels' solid skeletons.", "This transforms the silica gels into transparent solids that are mostly air.", "To demonstrate the insulating properties of the nanosized pores, they aim a blowtorch under an aerogel with a peanut butter cup on the top.", "It doesn't melt.", "A technician then places the aerogel on a scale to confirm its incredible low density.", "This aerogel weighs less than a nickel.", "Next, using a scoopula, which is a tool with a v-shaped dent, she breaks an aerogel into little pieces.", "She inserts the bits into a glass tube with a bulb at the base.", "She transfers the tube to a machine that measures how much nitrogen gas the aerogel bits take up at different pressures to determine the size of the pores and the surface area.", "Aerogels can have other magical properties.", "To demonstrate, she rubs specially treated aerogel particles on her hands.", "She then plunges her hands into water.", "The aerogel particles act like waterproof gloves and repel the water.", "This water resistance makes aerogels useful for a variety of applications.", "They can be added to paint or other things to make them waterproof and add insulating properties.", "Scientists continue to explore the potential of aerogels.", "A gossamer synthetic material that weighs almost nothing, there's a lot more to them than it may seem." ]

{ "things": [ "Prepared Mustard", "Violins", "Nuts and Bolts", "Toilet Paper" ] }

[ "Today, on \"how it's made\"...", "Prepared mustard...", "Violins...", "Nuts and bolts...", "And toilet paper.", "We eat it on hot dogs and hamburgers, on sausages and sandwiches.", "No condiment cuts the mustard quite like mustard.", "The ancient romans took the mustard seed to what is now france, and by the 9th century, big-time mustard production was under way.", "Yellow mustard and dijon mustard have a few ingredients in common, but that's where the similarity ends.", "Not only are they prepared quite differently-- they're derived from different varieties of mustard seed.", "Yellow mustard is made from the seeds of the white mustard plant.", "Turmeric and paprika provide the yellow color and sharp flavor.", "The other ingredients are salt, water, and white vinegar.", "The powdered ingredients go down a shaft to a mixing tank containing the water and vinegar.", "Yellow mustard's proportions are roughly 60% water, 20% vinegar, 15% seeds, and 5% salt and spices.", "The last ingredient to go in is the mustard seed-- hull, bran, and all.", "The tank's rotating mixers blends the ingredients for about an hour at seed-crushing speeds reaching 165 miles per hour.", "The tank's contents empty into several stainless-steel mills.", "Inside each one, a pair of synthetic stones grinds the seeds, a process known as stone milling.", "That grinding action heats the mixture to about 140 degrees fahrenheit.", "The liquid thickens into creamy, bright yellow mustard.", "Before bottling, they perform what is called a finesse test.", "This ensures the mustard is smooth enough.", "If its particles are larger than 9/1000 of an inch, the factory adjusts the milling stones closer together to produce a finer grind.", "They make dijon mustard from brown mustard seeds, sometimes mixed with other varieties, and they usually use two types of vinegar-- cider and white.", "The ingredients ferment in a tank for 12 hours before mixing.", "That's what gives dijon mustard its strong flavor.", "After mixing, it's the same stone-milling process we saw before.", "Here's what the inside of those mills look like-- a rotating stone rubbing seeds against a stationary stone-- the same principle as an old-fashioned mortar and pestle.", "Dijon is made with twice as many seeds as yellow mustard and 20% less water, which is why it comes out thicker and denser and needs the occasional stir.", "Filters screen out any particles larger than 9/100 of an inch.", "The factory saves these coarse pieces to put into specialty mustards.", "Now the creamy, smooth dijon mustard goes into a stainless-steel tank.", "A slow-speed revolving mixer removes the air, which would otherwise turn it brown and dull its flavor.", "The yellow mustard tanks also have mixers to remove air and to keep the condiment well-blended.", "Both dijon and yellow mustard have to cool overnight before bottling.", "From start to finish, it takes about 20 hours to produce yellow mustard, and about 32 hours for dijon because of its fermentation period.", "Yellow mustard has a 15-month shelf life, while dijon stays fresh for a year.", "Both should be refrigerated after opening to preserve their flavor.", "Mustard is a condiment that even health-conscious eaters can enjoy.", "It packs a lot of flavor in just a few calories.", "Mustard contains a small amount of fat, somewhat more if the manufacturer uses oil in the recipe, but it's still a cholesterol-free food.", "The violin was developed in the 1500s, evolving from a series of guitar-like instruments that musicians played with a bow.", "While the violin is best known for classical and gypsy music, today you hear it in pop, country, bluegrass, even jazz.", "First they cut a piece of maple, then split it in half to expose the grain in mirror image.", "They melt down glue flakes made from animal hide, then bond the pieces together.", "Violin makers only use glue, never nails or screws.", "These pieces of wood will form the back of the violin.", "After four hours, the glue is dry, and they can remove the clamps.", "Using a small plane, they even out the surface.", "Then they trace the violin's shape and cut it out.", "They shave the surface sculpting a downward slope from the middle using an even smaller plane.", "Then they carve a groove along the circumference.", "After dabbing it with glue, they insert what's known as purfling, a reinforcement made from a thin strip of hardwood, usually maple.", "Finally, they carve the reverse side to the right form and thickness.", "Next they make the sides of the violin, known as the ribs.", "First they soak thin strips of maple or sycamore and press them against a heated bending iron to curve them.", "Then they glue the strips around a form, connecting them at the top and bottom, and at the corners with small blocks of wood.", "They clamp everything together and let the glue dry for four hours.", "Next they glue thin strips of wood called counter-ribs onto the edge of the ribs.", "This enlarges the surface so that it's easier to glue the ribs and the back together.", "They make the violin's front, or belly, from a solid piece of spruce.", "To the underside, they glue a spruce support bar called the base bar.", "Sound escapes through the two curved slots called f-holes.", "They cut out and carve the violin's neck and scrolled head from a piece of maple.", "Then they glue it to the body.", "They sculpt the fingerboard from ebony, a hardwood durable enough to withstand centuries of a violinist's fingering.", "Using a tool called a peghole reamer, they make the holes for the ebony or rosewood pegs around which the strings are wound.", "They coat the wood with four or five coats of varnish, depending on the color, then polish it with several coats of oil over several days until the finish is shiny and silky-smooth.", "Next they insert the sound post.", "This little cylinder conducts sounds and supports the belly against bowing pressure, so it's critical to position it in precisely the right spot between the belly and the back.", "It's not glued, but rather wedged into place.", "The bridge isn't glued either.", "It's held in place by the pressure of the four strings, which they feed through the ebony tailpiece and wind onto the pegs.", "The bridge has little notches in which the strings sit.", "The violin is finished.", "They make the bow from horsehair and a high-quality brazilian wood called pernambuco.", "They bind the hairs at one end with strong sewing thread, then burn them and seal them with wax to prevent fraying.", "This end goes into the frog, the wooden box at the bottom, or heel, of the bow.", "They cover the frog with the mother-of-pearl lining, then slip on a ring made of nickel, silver, or gold to prevent the hairs from tangling.", "Next comes the screw that controls the tension of the hairs.", "They comb the hairs to make them parallel, then insert them into the tip of the bow, known as the head.", "They tighten the screw until the hairs are taut.", "Finally they rub on rosin, a sticky pine-tree resin that keeps the bow from slipping off the strings.", "At \"how it's made,\" we pride ourselves in showing you the nuts and bolts of how everyday items are made, so it's about time we visited a real nuts-and-bolts operation.", "We sure couldn't do without these tiny but essential pieces of hardware.", "If only they weren't so darn easy to lose.", "Nuts and bolts are made from what's called steel wire rod.", "After spending up to 30 hours in a furnace to make it pliable, the wire rod goes into a bath of sulfuric acid to remove any rust particles.", "It's rinsed in water then coated with phosphate, a chemical compound.", "This prevents the steel from rusting before the bolt forming begins and lubricates the steel to make forming easier.", "They form the bolts by cold forging, shaping the steel at room temperature by forcing it through various dies at high pressure.", "The forming machine first straightens the wire rod, then cuts it into pieces slightly longer than the bolt length.", "The extra will become the bolt head.", "Each piece goes through a die that makes it perfectly round, then through a series of dies that progressively shape the head of the bolt on one end.", "The machine heads up to 300 bolts per minute.", "Here's what the heading stages look like in slow motion.", "This die creates a slight collar.", "The next one turns it into a round head.", "Then the last one transforms that into a hexagonal head-- the most common shape.", "Next the machine forms the opposite end of the bolt.", "A tool called the pointer shapes the bottom of each bolt, creating what's called the chamfer, the part the nut catches on to.", "Here's the bullet before and after the chamfer.", "The bolt needs threads to enable the nut to screw onto it.", "Once again, they use the cold forging method.", "High-pressure rollers press in the thread pattern...", "As we see here in slow motion.", "This is the actual speed, up to 300 bolts per minute.", "During each production run, they take several samples to verify dimensions.", "They use various measuring devices-- a micrometer to check the bolt's length, calipers to measure the width of the head, and a ring gauge to check the threads.", "To make the nuts, they use a process called hot forging.", "They cut steel bars into small pieces known as slugs, then heat them to 2,200 degrees fahrenheit to make them malleable.", "As we see here in slow motion, hydraulic cameras punch the slugs into hexagons, while a die pierces the hole.", "Then a tool called a tapper drives into the hole to cut the threads.", "That black liquid is a lubricant oil to minimize wear and tear on the tappers.", "The nuts and bolts now go into an oven at 1,600 degrees fahrenheit for about an hour.", "This gives them the required strength.", "Then a rapid cooling in oil for five minutes to solidify the steel's internal structure.", "By now the steel is hard, but brittle, so they heat the nuts and bolts for another hour.", "This removes their brittleness yet maintains their strength.", "The quality-control team pulls samples off the line, measuring how much force it takes to break them.", "If a bolt meets its minimum strength requirement, it passes inspection, provided the break occurred in the threading-- the weakest part.", "Finally packaging-- labeled, among other things, by size and grade.", "Toilet paper is probably the most indispensable item in your home.", "After all, it's not something you want to run out of at the wrong time.", "Most of us probably take our rolls of toilet paper for granted.", "So you may be surprised to learn that bathroom tissue, as it's properly called, is a relatively new invention.", "The vikings used wool.", "The ancient romans employed sponges, and french royalty wiped with lace.", "Then in 1857, an american entrepreneur figured that people had had enough of using leaves, corncobs, newspapers, and mail-order catalogs, so he invented therapeutic paper, as he so tastefully named it.", "Toilet paper only came in piles of pre-cut sheets until 1890.", "That's when one company introduced bathroom tissue on a roll.", "Ever wonder where all that recycled paper goes?", "Well, look no further than your bathroom.", "Many brands of toilet paper begin as recycled paper.", "The bales of paper drop down into the pulper, a giant tank with an agitator, similar to a washing machine.", "It mixes the paper in lukewarm water for about 10 minutes, transforming it into what's known as pulp and screening out all the bits of metal and plastic.", "Now they have to take out the ink.", "The ink-removal system injects the pulp with air.", "Ink particles attach to the air bubbles, which rise to the top.", "The system then skims off the foam, leaving the pulp ink-free.", "Next the pulp passes through a series of rollers, which squeeze out the water.", "This dries out the soggy pulp, enabling it to absorb the chemicals they'll use to bleach it.", "Revolving knives now chop up the pulp to prepare it for the bleaching process, the details of which are a closely guarded trade secret.", "The bleach turns the gray pulp a pure white.", "The company says it does this without using chlorine or other toxic chemicals.", "They spread the wet pulp onto a flat screen that runs through a hot dryer.", "In less than a second, the pulp dries into a delicate paper 4/1000 of an inch thick.", "Each spool holds close to 47 miles of paper.", "That spool now feeds a machine with rollers that emboss a pattern, in this case a waffle print.", "The pattern isn't just aesthetic.", "It also makes the paper thicker and therefore more absorbent.", "Elsewhere in the factory, production is rolling, so to speak, with two strips of cardboard, each 3 inches wide.", "The machine coats the underside of the top strip with glue, then winds the two strips diagonally to create a continuous cardboard tube.", "The machine then cuts the tube in 65-inch lengths.", "The tubes ride an elevator to the toilet paper zone.", "There, two giant spools of paper feed what's called the winding machine.", "The two sheets come together to form a two-ply toilet paper.", "The paper then winds onto a cardboard tube, creating a super-wide roll of toilet paper.", "When the roll is full, a blade automatically cuts the paper, and winding resumes on the next tube.", "The machine automatically seals the end of the roll with glue to prevent unraveling.", "A circular saw slices the super-wide toilet paper roll into 16 standard rolls, 4 inches wide.", "The toilet paper is finished and ready for packaging.", "This batch is for commercial use.", "Each roll is individually wrapped in paper.", "Check out this slow-motion wrapping action.", "Toilet paper destined for residential use gets wrapped in transparent plastic, 4 to 30 rolls per package." ]

{ "things": [ "Heated Skate Blades", "Gliders", "Hand Bells", "Fire Hoses" ] }

[ "Hockey skates are not all created equal.", "That's why professional hockey players are always looking for ways to get that cutting edge.", "They know championships are won or lost in fractions of a second, and that's when heated skate blades can make all the difference.", "With a simple touch, heated skate blades are revolutionizing the game of hockey.", "They give much more control and speed on the ice.", "They do this using a smart board, the brain of these performance-enhancing blades.", "It all starts with custom-made, stainless-steel blades.", "A technician places them inside an injection-molding machine.", "Liquid plastic is injected into a cavity, creating a plastic overmold.", "Once bonded with the overmold, the blades are ready to receive the electronic smart board.", "The smart board fits into the plastic overmold that runs along the top edge of the blade.", "After removing excess plastic from the mold, the technician places the prepared blades onto a mounting tray.", "He uses thermoconductive glue to ensure contact between the heating wire, the temperature-controlling smart board, and the blade overmold.", "After that, the technician inserts insulating material along the entire length of the overmold so the heating wires make perfect contact with the steel.", "Once the smart board is secure, the technical places the blades into a low-density injection machine that encapsulates the smart board with impact- and moisture-resistant resin.", "The smart board is now waterproof.", "Meanwhile, another high-pressure injection-molding machine makes the blade holders that support the finished blades.", "These blade holders will be given an actual power supply-- a high-performance lithium-polymer rechargeable battery that makes heating the blades possible.", "The battery will be cleverly concealed inside the heel of that molded chassis.", "To do this, a technician first attaches rivets into the heels of the blade holders, then mounts the blade holders onto an automatic rivet press.", "This machine pressure-punches the rivets so they will make a proper connection to the battery for recharging.", "A printer heat-presses the brand name and logo on the heel.", "The logo sits over the flexible proximity sensor, or the on-and-off button that a technician wraps around the battery.", "Then she buries the combined unit into the heel of the blade holder to protect it from moisture and impact.", "She then locks it into place.", "Next, the technician attaches a threaded insert bolt to the blade overmold.", "This special bolt hold the blade in place and allows for quick and easy blade changing.", "The technician then connects the blade to the blade holder and presses the blade firmly into the chassis.", "Then she locks all electronic and mechanical components into place.", "A charging unit powers up the battery for testing.", "Then the technician seals off the heel chamber to further protect the battery.", "She turns on the smart board to make sure all systems are go.", "An l.e.d. confirms the blades are heating properly.", "In the meantime, another technician assembles the molded charging unit for the blades.", "The technician hand-trims the motherboard that controls the charger so it will fit flawlessly into the charging unit.", "She inserts the finished motherboard into the back of the unit and checks to make sure it works properly.", "Then she snaps on an airtight cover that seals the unit, fully protecting the motherboard against wetness and shock.", "Finally, she plugs in the charging unit to confirm it works.", "A rechargeable battery, a manual, a convenient charging unit, and a pair of performance-enhancing skate blades complete the kit.", "They heated skate blades are now ready to ship around the world.", "They're quick and easy to mount on the boot, with the built-in smarts to help create the next champion.", "Gliding involves flying unpowered aircraft, though some models are fitted with a small engine and propeller so they have the power to launch into the air on their own.", "No matter what the model, the sport of gliding is all about the joy of using the forces of the atmosphere to fly higher, faster, and longer.", "Gliders, like this model version, have three main parts-- wings, fuselage, and tail.", "Workers build each part of the glider in two pieces, using resin and steel molds.", "They begin with the fuselage mold.", "They lay down strips of kevlar, a strong, heat-resistant material.", "Then they apply epoxy resin to the kevlar fiber to reinforce it.", "They leave the epoxy to dry and the next day apply strips of carbon fiber to reinforce the fuselage.", "The direction in which workers lay down the fiber layers is key.", "In flight, gliders are subject to strong forces that can bend and twist the structure.", "They must be sturdy yet as light as possible.", "The glider's tail boom gets the same treatment, except where the antenna will go, as radio signals don't penetrate the carbon fiber very well.", "Workers apply a thin coat of white gel paint to the 30-foot wing mold.", "Gliders are always white so they don't absorb the sun's rays and overheat.", "They roll a sheet of carbon fiber over the painted mold.", "Then the entire assembly team skillfully applies an even coat of resin.", "They've got to be quick.", "The resin cures in just 30 minutes.", "They add a final layer of carbon fiber to strengthen a portion of the wing that's subject to strong wind currents.", "After laying a white fleece over the layers of carbon fiber, they seal it between two sheets of plastic.", "A vacuum compresses the layers, which draws excess resin to the surface where workers can remove it.", "The two wing parts are glued together using the same epoxy resin that bonds and seals the carbon fibers.", "Mixing in some cotton flakes helps thicken the resin, which they apply to the main spar, the wing's backbone, then to the front, back, and center portions.", "Using a crane, workers carefully fit the two wing molds together.", "The molds' weight forces out any excess glue.", "They tightly clamp the two molds together and leave them to harden overnight in an oven heated to 140 degrees fahrenheit.", "The next day, there's a loud pop when workers separate the two molds.", "They carry the completed wing structure, which weighs only 132 pounds, over to another area to trim the resin overflow and sand down the seams.", "Using a diamond-tip cutter, they cut the wing in two for transport, revealing its inner structure.", "Then they make sure they can easily put it back together before going on to the paint shop where they reassemble it.", "Workers scan the surface and mark the areas they will sand by hand.", "They mount the glider's fuselage on a rotating stand so they can easily access the entire surface.", "They sand it and then polish it to a mirror finish.", "As workers assemble the glider, they inspect every system.", "They check the engine command that lowers the glider's launch propeller and retracts it into the fuselage.", "The landing gear must lower and retract smoothly out of the glider's undercarriage.", "Now they reassemble the wings.", "They check the air brake located in the wing.", "And, finally, they install the canopy.", "The glider is complete.", "Sturdy yet light, this midsize model can reach speeds of nearly 186 miles per hour thanks to its sleek design.", "Hand bells can be seen in church choirs, schools, and ring concerts.", "There, skilled ringers read music similar to a piano score, playing all the notes found on a modern musical keyboard.", "Finely crafted and tuned, hand bells will continue to entertain generations to come.", "hand bells have a long tradition of making beautiful music, from church hymns to the music of beethoven.", "It all starts with a casting mold that a worker encloses in a two-part container, or flask.", "He fills the bottom half of the flask with special, coarse sand that's ideal for making sand molds.", "He compacts the sand, and then he turns the metal flask over.", "He places guide rods onto the bell shapes and fills the top part of the flask with sand.", "He puts a ramming board on again, and he compacts the sand that fills the top part of the flask.", "Now he removes the guide rods.", "Then he removes the top half of the flask and takes out the casting mold.", "He reconnects the top of the flask and then frees it completely from the sand mold.", "A worker places bronze ingots into a crucible to melt them down.", "He places heat-sensitive material onto the sand mold, and then heavy weights to hold the mold together safely.", "When the melted bronze reaches about 2,200 degrees fahrenheit, a worker guides the crucible over to the sand mold and pours the molten metal into the cavity of the mold.", "He stops pouring when he sees the heat-sensitive material smoking.", "This indicates the mold cavity is filled.", "Workers then use a vibrating bed and small hammers to free the finished castings from the sand mold.", "Rotoblasting cleans the dirty castings.", "A worker trims off the excess pieces that feed the molten metal into the bell cavity.", "He sands the sharp edges of the bell and then drills the center hole for the assembly screw.", "The bell casting then goes on a lathe.", "Here, a carbide cutting tool, working with a stylus that follows a template of the bell, removes the coarse casting surface and makes the bell shiny.", "This turning operation also shapes the bell to give it the right tone.", "Another carbide cutting tool shapes the inside of the bell casting, giving it shine and the desired tuning, as well.", "Using a custom-made tracing device, a worker reproduces the outside shape of the bell on paper.", "He then traces the inside of the bell casting until he completes an exact replica of the inside and the outside shape.", "And this must match a master template.", "A worker polishes the bell using fine sandpaper.", "He also puts a jeweler's finish on the inside.", "Then he tests the bell's sound quality using a stroboscopic tuner and the human ear.", "He re-sands the bell to make a slight tonal adjustment.", "Then he tests it again to make sure it strikes the perfect musical note.", "A worker gives the bell that final polish, and another craftsman engraves the bell for the customer.", "Finally, a worker puts the ringer and bell together.", "She puts a washer, a hand disc, and a handle onto the assembly screw and screws it all into place.", "Hand bells make wonderful music in the hands of skilled ringers, whether the musical compositions are performed by an intimate gathering of friends or by a concert bell choir of 13 ringers or more.", "The music made by traditional hand bells is timeless.", "firefighting used to consist of passing water buckets hand to hand.", "The first fire hoses of the 1600s were made of leather.", "But these hoses were heavy, would crack when dry, and often break open under pressure.", "Modern firefighting began with the lightweight, cotton fire hose, lined with rubber to keep the cotton dry and flexible.", "Fire hoses come in a range of sizes to fulfill a range of functions-- from small, lightweight ones for fighting forest fires to large, heavy-duty hoses for industrial fires.", "Production begins with hundreds of bobbins of polyester yarn, feeding automated looms a floor above.", "A series of spring rods keeps the yarns under uniform tension.", "This is essential to create a tight weave.", "The factory programs each loom to weave specific patterns, which incorporate identifier stripes.", "This is a visual guide to help workers assemble the fire hose later on.", "This woven fabric will form the fire hose's exterior called the jacket.", "It's got to weather some nasty conditions, so they soak it in a plastic polymer solution with dye for color.", "The liquid encapsulates the fibers, making them durable and water-resistant.", "At another station, they mix granules of polyurethane, a form of plastic, with white colorant and adhesive pellets.", "This mixture is for making the waterproof tubing that forms the inside of the fire hose.", "When they activate the adhesive in the mixture with heat, this tubing will bond to the hose-jacket fabric.", "The mixer fees the ingredients to an extruder, which melts the mixture and forms it into a hollow tube.", "The tube then passes through a basin of cool water to set the plastic.", "Next, the tube goes to the inspection table where an automated printer prints code numbers on it for tracking purposes.", "To assemble the fire hose, they first pull out an outer hose jacket over a 33-yard-long cable.", "Then with another cable, they feed a second untreated hose jacket inside the first one.", "Finally, they attach a cable to the third and innermost layer, the tube, and pull it along the entire length of the double jacket.", "Once it's all the way through, they trim both ends.", "The three layers-- outer jacket, inner jacket, and tube-- are now ready to become one.", "They begin the fusing process by clamping one end of the assembled hose to a steam nozzle.", "As the clamp holds the hose steady, the nozzle blasts pressurized steam into the tube.", "At the same time, it moves backward, pulling out any kinks.", "The hot steam melts the adhesive in the tube material, and it penetrates the inner jacket around it.", "Once everything's perfectly straight, they pump in cold air to solidify the adhesive.", "This permanently bonds the layers.", "They roll up the finished hose into a coil, controlling the winder with a foot pedal.", "Then they lay the coiled hose on a table to install the couplings.", "Those are the components that attach the hose to the water supply on one end and to the spray nozzle on the other.", "They trim each end and then insert a brass expansion ring and then an aluminum coupling on top.", "An expansion machine does the rest.", "They attack the end securely to the machine's protruding bar.", "Then the bar retracts and expands, pushing the brass ring outward.", "The force wedges the brass into the aluminum coupling permanently.", "This company tests every fire house it produces under high pressure on this table.", "After marking the type of hose with a stencil in indelible ink, they fill the hose with water.", "They check for holes and kinks and verify that the couplings stay in place.", "After the test, they drain the water.", "They insert a giant sponge to get rid of any water left behind.", "And now these new hoses are ready for their baptism by fire." ]

{ "things": [ "3" ] }

[ "In 1895, ogden bolton jr.", "Registered one of the first patents for an electric bicycle in the u.s. a century later, they've become one of the most popular electric vehicles in the world.", "Using electricity to enhance performance, the e-bike is definitely in the current.", "These electric three-wheel trikes combine ergonomic design with cutting-edge mechanical engineering.", "A rechargeable battery powers the electric engine.", "The rider sits comfortably in the ergonomic seat, places his feet on the pedals, releases the parking brake, and takes off.", "The process begins with a water jet cutter.", "It uses ultra-high-pressure water and sand to cut parts out of a thin aluminum sheet.", "The cutter significantly enhances productivity without sacrificing precision.", "It can make several parts out of a single sheet of aluminum.", "Parts that are ready for assembly go to the cnc brake press for folding.", "A stopper positions the piece on the v die, where a punch comes down to fold it.", "A worker inspects the folded part to make sure it's ready for assembly.", "A cnc bender curves aluminum extrusion tubes for the frame.", "This machine has multidirectional bending capabilities and can make multiple bends to a single extrusion tube.", "The trike frame assembly process starts on a jig.", "Once all the tubes are in place, a welder spot-welds the aluminum brackets.", "He welds about 20 spots, bonding the brackets to the tubes.", "The tubes bear most of the load while the brackets keep the frame aligned.", "The worker uses an electric tig-welding torch to complete the welding.", "He welds at a low temperature to avoid heat deformation in the metal.", "A mechanic installs thermoformed recyclable abs plastic over the back frame tubes.", "He assembles the rear wheels, which have a seven-degree negative camber angle for better grip and handling.", "The mechanic mounts brake levers, gear shifters, and handle grips onto the steering bar and tightens the six-point socket nuts with an allen wrench.", "He applies a structural adhesive on the drop-out poles and in slots located on the front frame tubes.", "The adhesive provides the flexibility and strength needed to keep the drop-out poles in position.", "Now, the mechanic assembles the front and back frames together.", "The two frames connect under the seat through an integrated direction pivot and suspension system.", "The mechanic slips the front wheel into the drop-out poles on the frame.", "He uses a calibrated torque wrench to tight the wheel nut.", "He assembles the three-cog front cassette to the bottom bracket, then bolts on the pedal crank arm using a threaded taper pin system.", "Next he installs the derailleur for the nine-gear cassette and bolts it on with a lock-tight bolt.", "The compact drivetrain makes the trike 15% more energy-efficient than regular bicycles or tricycles.", "A mechanic installs the disc brake system on the front wheel electric hub and verifies that it is functioning properly.", "The seats are made of woven synthetic fabric wrapped around the frame and tightened with bungee elastics.", "He locks the removable battery pack in place with a key.", "A console indicates levels of electrical assistance and battery regeneration.", "This trike's wheel base allows it to ride on bike paths.", "When on the road, its width takes up more space.", "The design of this electric trike combines stability and safety for a secure and pleasant ride.", "The easiest way to treat dry skin is to spread on some skin cream.", "It rejuvenates the skin cells and acts as a protective barrier.", "This is particularly important in the winter, when cold outdoor air and indoor heating suck the moisture out of your skin.", "If you have dry skin, it's wise to keep a good supply of skin cream on hand.", "It's not just dry air that makes skin flaky and itchy.", "Cancer treatments can also dry out the skin, along with other medical conditions, like diabetes.", "The first ingredient is stearic acid.", "It's a wax derived from palm tree oil.", "The next ingredient is refined lanolin.", "It's blended with isopropyl myristate, a natural oil that helps soften the stearic acid.", "These ingredients make up what's called the oil-soluble phase of the recipe.", "Workers heat the stearic acid until it liquefies, then add the blend of lanolin and isopropyl myristate and keep heating.", "While the oil phase is heating, they prepare the water-soluble phase of the recipe.", "The first ingredient is glycerin derived from a vegetable source, such as corn.", "They heat and mix it, then add purified water.", "They continue heating the mixture to just below the boiling point, add a floral fragrance, then pump the oil phase into the bottom of the tank.", "It blends in with the water phase while naturally rising to the top.", "They gradually lower the temperature.", "This makes the mixture creamy and bright white.", "After an hour of mixing, the skin cream is ready.", "They pump it out of the mixing tank to supply tanks that feed the filling line.", "This company packages its skin cream in jars for body cream and tubes for hand cream.", "Workers unpack boxes of plastic jars and line them up on a conveyer belt that feeds the labeling machine.", "Each jar passes a photo-eye sensor.", "This sensor triggers the machines to spin the jar at the same speed as the adhesive label coming off the roll.", "Workers place the labeled jars onto a turntable that feeds the filling machine.", "Two single-file lanes each lead to three nozzles.", "The machine fills up to 125 jars per minute, depositing 12 ounces of skin cream into each jar.", "The two lanes of filled jars merge as they approach the capping machine.", "The caps come down a chute to the machine's carousel.", "A device called a timing screw correctly positions each jar to receive a lid.", "The lower part of the machine holds the jar steady as an arm secures the lid in place.", "The next station on the line applies an adhesive label onto the cap.", "The jars of body cream are ready for sale.", "This factory also packages hand cream in a tube that you can keep in your purse or pocket.", "A mechanical arm places the tubes on a turntable, cap side down.", "The bottom of each tube is open and ready for filling.", "A nozzle squirts two ounces of skin cream into the tube.", "Then the machine heats the open end to soften the plastic, clamps it shut, then cools the plastic to a solid state.", "When you rub the cream on your skin, the key ingredients, glycerin and lanolin, pack a one-two punch.", "Glycerin is hydroscopic, meaning it draws water from the air to the skin.", "Lanolin smoothes the skin, forming a protective film to lock in the moisture.", "Patio heaters make it possible to dine outside even when it's cold.", "When this outdoor space heater is turned on, it creates a circle of warmth.", "The heater can take the chill out of a cold summer evening and extend patio season well into the fall.", "It's a chill day, but not on this patio.", "It has its own microclimate, one that's warm and toasty.", "It's all thanks to the infrared heater overhead.", "To make a patio heater, an engineer first maps out the design on a computer.", "He transfers the design to cutting equipment, like this laser.", "It cuts screw holes and vents into steel that's covered by a protective plastic film.", "The laser also cuts a part that will be shaped into the patio heater's housing.", "After removing the plastic film, a worker places the steel between the jaws of a press brake.", "It bends the part to form a rim around the edges.", "Additional bends give the part a rounded profile.", "A laser probe checks that the worker's fingers are not getting too close to the jaws.", "Once all the parts have been cut and shaped, the patio heater is ready to be assembled.", "A worker creates a reflector that will direct heat down and out of the unit.", "Then he attaches an insulator to the reflector.", "It will protect the roof and walls that the heater will be mounted to.", "He inserts the insulator and reflector assembly.", "The legs of the reflector assembly fit into the laser-cut holes in the housing.", "He temporarily places the control box cover at the end of the housing.", "Then he aligns and welds a side panel to the housing.", "He welds a second panel to the other side.", "After covering the assembly with protective plastic again, he grinds down the welded seam.", "This gives the patio heater unit cleaner edges.", "He buffs the seams to a low sheen using a cloth wheel and polishing paste.", "This makes the seams blend in with the steel.", "The burner is next.", "It's made of steel but has a ceramic grill with hundreds of tiny holes.", "This contoured pattern allows heat to radiate in all directions.", "He tucks insulation into the heater body to protect it from the hot burner.", "Then he installs the burner on top of the insulation.", "It fits snugly to the reflector and insulator framework.", "He places a separator at one end of the burner, leaving a space for a control box and gas line.", "He inserts the control box and connects the gas line to the burner.", "He attaches the spark igniter and temperature sensor to the separator.", "He secures the burner to the main assembly with screws.", "He tucks the electronic controls into the control box and connects all of the wiring.", "He seals the control box with a metal plate and rubber gasket.", "This makes the electronics watertight.", "Finally, he adds a vented panel to the top of the controls and a metal grill to the rest of the heater.", "Over at a test station, a technician powers up the heater using a remote-control system.", "He checks for gas leaks or blockages and confirms that the temperature rises in response to the remote control's commands.", "This patio heater has passed all of the tests and is now ready for the outside world, where people are sure to be attracted to its warm glow.", "In the early days of the automobile, wheels had wood spokes and rims.", "But by the 1920s, manufacturers began using more durable materials, like iron and steel.", "Today, wood-spoke wheels are used in classic-car restoration.", "In the early 1900s, cars had wood-spoke wheels.", "When those antique vehicles need new wheels, collectors turn to wheelwrights.", "They can build wood-spoke wheels just as it was done a century ago.", "Production starts with the steel rim that wraps around the wood wheel.", "The steel spins in a lathe as stationary tools cut it to the correct profile and create a lip for gripping the rubber tire.", "A worker measures the rim to confirm it's the same as the original.", "You can see the difference the machining has made.", "Another member of the team measures the moisture content of hickory wood and selects boards that are sufficiently dried.", "He traces a rough pattern of a wheel spoke and cuts along the penciled lines.", "This gives him a basic shape to work with.", "Next he selects a more exact pattern.", "He clamps this pattern in a wood carving duplicator alongside four of the rough spokes.", "He follows the contours of the pattern with a tracing wheel.", "The tracing wheel moves cutting tools that carve the hickory.", "This duplicates the profile of the wheel spoke pattern.", "He sands off marks left by the cutting tools and smoothes the surface of the newly formed spokes.", "Then he secures the spokes one at a time in a jig.", "This steadies the spokes as he cuts the wider ends into a wedge shape.", "Together, two wheelwrights arrange the spokes in a wheel formation.", "The wedges fit together at the center like pieces of a pie.", "They tighten clamps to bring the spokes into perfect alignment.", "One of the wheelwrights inserts a steel hub in the center hole.", "He drills holes into the wood and inserts bolts to secure the steel hub.", "Using a tool that's like a big pencil sharpener, he carves the ends of the spokes, creating dowels.", "Dowels are peg-like fasteners.", "He sands the dowels on an angle to create a gentle slope in each one.", "These slopes make it easier to slide the spokes into the two-part wood rim.", "Using a special tool, the team stretches the rim and pulls the spokes into position.", "Then they insert the doweled ends of the spokes into the holes.", "This process is difficult.", "One wrong move, and they could damage the spokes or rim.", "But thanks to their skill, the wood-spoke wheel comes together.", "All of the parts are intact, and the spokes are firmly secured in the rim.", "A wheelwright measures the circumference of the wood rim and calculates how much will need to be trimmed off.", "He shaves down the wheel, adjusting the circumference to the desired dimension.", "The wheel must be slightly larger than the outer steel rim.", "You'll see why next.", "They place the steel rim over an intense gas flame and cover it with a piece of metal.", "The heat causes the steel rim to expand.", "After about 15 minutes, the wheelwright removes the cover.", "He grips the hot rim with tongs and transfers it to the wood wheel.", "The enlarged steel rim fits loosely around the outside of the wooden wheel.", "They now spray the steel with cold water.", "As the rim cools, it shrinks to the hickory wood, creating a permanent bond.", "The wheelwright shaves the spokes down to make them look more streamlined.", "He sands the wood to enhance the grain.", "It took 16 hours to make this wood-spoke wheel.", "It's brand-new, but looks like a thing of the past." ]

{ "things": [ "Carbon Fibre Car Parts", "Hand Dryers", "Recycled Polyester Yarn", "Fleece" ] }

[ "Carbon-fiber car parts, such as bumpers and spoilers, are nearly as strong as steel ones, and yet they're 1/5 the weight.", "Of course, a car that weighs less accelerates more quickly and burns less gas, so carbon fiber offers style that actually does go that extra mile.", "Custom spoilers, bumpers, and other parts make a vehicle more aerodynamic.", "When the parts are made of carbon fiber, they create this effect without the hindrance of extra weight.", "It's easy to get carried away with all the extras.", "Yes, that is a miniature basketball court in the trunk of this car.", "Carbon-fiber parts are made of fabric that's tightly woven with very fine threads of virtually pure carbon.", "To transform the material into a rigid car part, they begin with paste wax.", "They brush it into the crevices of a fiberglass mold.", "This mold is for a car rocker panel.", "The wax seals the mold and also serves as a nonstick coating.", "They protect the lip of the mold with masking tape.", "Then they spray a second nonstick substance, polyvinyl alcohol, into the fiberglass form.", "Now they're ready for the carbon-fiber material.", "They unroll it and spray it with adhesive.", "Despite the nonstick coatings, they'll want this fabric to stick to the mold for a while.", "The glue will gradually dissolve into the material.", "They press the glued carbon-fiber material onto the lip of mold.", "After all, they don't want any wrinkles in this job.", "This material has yet to gain its steely strength, so they easily trim the excess.", "They layer the fabric seven times, again following the lines of the mold.", "They apply a permeable material called flow media to the carbon-fiber layers.", "They place plastic mesh on top of the flow media and tuck it into the curves of the mold.", "They frame the layers with double-sided tape which sticks because this area was taped off earlier to protect it from the nonstick spray.", "This strong double-sided tape is called butyl tape.", "They drape a plastic bag over the mold and press the edges to the butyl tape for an airtight seal.", "They pleat the bag and close the pleat with more tape.", "The pleats give the plastic bag some slack.", "They push the folds into every crevice of the mold, then turn on a vacuum.", "As the vacuum sucks the air out, the bag compresses the layers in the mold.", "Meanwhile, they activate some plastic resin with a chemical catalyst.", "They place a hose in the resin.", "The other end is attached to the vacuum bag.", "As the vacuum continues to draw air out of the bag, it pulls the resin into it.", "The resin saturates the seven layers of carbon fiber to laminate them into the shape of the car part.", "After the part cures, it's ready to come out of the mold.", "Cleaning it up reveals the solid union of epoxy resin and layers of carbon-fiber fabric.", "Carbon fiber can be molded into almost any vehicle accessory.", "Its versatility is one of its strengths.", "Painted to match the vehicle, the parts blend with the steel, adding some aerodynamic flash to this road show.", "Public washrooms often have electric hand dryers.", "Many prefer them over paper-towel dispensers for environmental reasons-- no trees killed and no waste.", "Hand dryers also require less maintenance because there's no garbage bin to empty and no need to restock the machine with clean paper towels.", "This new-generation model dries hands in 10 seconds and uses 80% less energy than conventional hand dryers.", "A sensor turns the unit on and off automatically.", "A circuit board with a microprocessor runs everything.", "The assembler builds a strip of eight control boards at a time.", "They go into a track that first runs through a chemical cleaning.", "This preps them for soldering.", "The boards then flow through molten solder.", "As it cools and solidifies, it fuses the components in place.", "An inspector scrutinizes every board, then, wherever necessary, does soldering touch-ups by hand.", "Finally, they separate the eight control boards.", "Working a board at a time now, they plug in and test an infrared sensor.", "The sensor shoots a continuous beam to the area below the air outlet.", "The testing machine uses a strip of metal to represent hands.", "When the strip cuts the beam, it triggers the dryer to start.", "When it departs, the beam is restored, triggering the dryer to stop.", "To produce the air flow, a motor spins a blower wheel at a rate of 20,000 revolutions per minute.", "After connecting the blower and motor, they slip them into the unit's plastic inner housing.", "They add a rubber gasket to lessen vibration noise then close up the housing.", "Next comes this electrical heating element.", "Its coils will heat the air as it passes.", "After applying mandatory electrical warning stickers, they install the circuit board on a mounting bracket, then connect the bracket to the housing.", "Then they connect the wires coming from the heating element and the motor to the control board.", "Now they send the unit to the testing area for, quite literally, a dry run.", "They make sure it turns on and off properly.", "They check the blowing force, the air temperature, the voltage.", "Elsewhere in the factory, they work on the hand dryer's outer housing.", "It's cast from zinc.", "After it comes out of the mold, they polish it with a buffing wheel to prep the surface for painting or chrome plating.", "In the plating tank, they run a positive electrical charge to chunks of metal and a negative charge to the zinc cover.", "This draws metal particles through the water like a magnet onto the surface of the cover in a thorough and even layer.", "For this model, they first plate the cover in copper...", "Then nickel...", "Then chrome.", "The underlay metals are required for the chrome to adhere.", "Once the plating's done, they clean the cover...", "Apply an arrow sticker pointing to the air outlet...", "Then glue on a plate with the name of the manufacturer and model.", "The inside unit, attached to a wall plate now, fits right inside.", "They fasten the cover using tamper-proof screws, then shine it up with a few squirts of window cleaner.", "These hand dryers come in a wide range of finishes, letting you dry your hands in style.", "The recycling of plastic bottles is changing the fabric of society because those bottles are being turned into polyester yarn.", "The recycled polyester yarn is woven into material that's used to make socks, fleeces, and other things.", "It puts a whole new spin on polyester.", "Polyester is made from oil, so recycling means we get more mileage from our precious resource.", "They convert polyester manufacturing waste on the left and plastic bottles into chip form.", "Pulses of hot air toss the chips, giving them hard shells.", "They go through a dryer to get rid of moisture that would weaken the final product.", "The shells keep them from sticking together, aiding the drying process.", "A worm screw moves the chips through heated pipes, which melt them into a thick liquid.", "This molten recycled polyester is now ready to be turned into yarn.", "It will be pressed through this die plate that looks as lot like a shower head.", "It's part of a device called the spin pack, which also includes a mesh filter...", "A metal distribution plate...", "And bits of shattered metal for extra filtration.", "It's important to screen out impurities that might compromise the recycled product.", "They screw the cap onto the spin pack and insert a metal connector piece.", "They preheat the pack so the polyester won't harden as it flows through it.", "Then they transfer it to one of the openings from which the liquid polyester flows.", "There are dozens of these openings, all capped by a spin pack.", "68 tiny holes in each disk shape the recycled polyester into filaments.", "They cool and harden as they exit.", "Each one is five times finer than a single human hair.", "Some of it breaks during equipment stops and starts, and that goes into a big box to be recycled again.", "The rest converges and funnels into a guide, which bundles all the strands into one yarn.", "The yarn travels around rollers into a compartment where air buffets the yarn to entangle the filaments.", "This holds them together.", "A spool then racks up the yarn at a speed of 125 miles per hour.", "Next, an autonomous vehicle pulls up, the spools move into position, and a long spindle emerges from the automated vehicle to collect them for more processing.", "They group a sample from every production run with strands of black yarn which allows the lighter yarn to stand out.", "They fray both ends of the yarns with a razor so they'll be easier to examine under a microscope.", "The technician projects the magnified image onto a screen and counts the number of filaments.", "At this point, the yarn is stiff like dental floss, but that's about to change.", "This machinery pulls the polyester yarn over heated rubber rollers.", "The process stretches it and realigns the molecules.", "More equipment twists it, and then it's taken up by automated spools.", "Now this recycled polyester yarn is less like dental floss and more like wool.", "From plastic bottles and manufacturing waste, to polyester yarn, this transformation has taken just a couple of weeks.", "This recycled yarn is now ready for the material world, making consumerism a less wasteful thing.", "The invention of polyester fleece in the 1980s changed the way we dress for the cold.", "Instead of heavy and constricting clothing, we can now layer with lightweight fleece.", "Its texture gives us that warm, fuzzy feeling, and so does the philosophy behind it because it's often woven with recycled yarn.", "From trash to textile, today's fleece offers warmth from waste because it's partly knit with yarn made from soda bottles and other discarded plastic.", "The recycled yarn looks and feels exactly the same as the virgin kind.", "They both unwind into a huge, circular knitting machine.", "It knits a lot faster than grandma, so we've slowed down the video to given you a good look at the knitting action.", "Hundreds of tiny needles grab and stitch the recycled and virgin yarns together to create a perpetual tube of material.", "This machine generates three feet of polyester every two minutes.", "Big metal brackets flatten the knitted tube so it can be taken up by a spool.", "Inspectors check for any major flaws.", "If necessary, they'll halt production until the problem can be fixed.", "Then it's over to the laundry department, where a cylindrical machine washes and dries the material.", "It then dyes the fabric under pressure and adds a water-repellent chemical to the fabric.", "After another wash and dry, equipment funnels the polyester into a holding bin.", "They feed the long polyester tubing through a device that twists it to wring out the rest of the water.", "As the knitted tube exits the twister, a circular cutter slits it, turning it into a sheet.", "The sheet of fabric is thin and not fleecy at all at this point.", "One side is a smooth knit, while the other is rougher.", "It has thousands of tiny loops.", "Cylindrical wire brushes will transform this polyester into fleece in a process called napping.", "Each brush spins at a different speed.", "It's all carefully calculated to break the knitted loops without tearing the fabric.", "The napped side of the material is now fuzzy and fleecy.", "The smooth side of the fabric winds around a second set of spinning brushes.", "They pull fibers through from the fleecy side to evenly distribute them on both sides.", "The double brushing increases the fabric's thickness fivefold and builds air pockets into the fleecy pile for insulation, all this without adding weight.", "A spiraling blade then shears the fibers to a uniform length to prevent pilling, which looks bad and can compromise those insulating air pockets.", "Each production run undergoes a battery of tests, like this one for water repellents.", "If the water doesn't soak into the fleece, it's a pass.", "In another test, they insert scratchy nylon strips in the head of the tool.", "As it spins, it rubs the fabric the wrong way.", "The test simulates wear and tear and determines whether the fleece will resist pilling.", "They try to set fire to a swatch that has flame-resistant fibers woven into it.", "The fleece smolders and then extinguishes the flame.", "Once the fleece has passed all the tests, production resumes.", "Grippers pull it along the edges to stretch it to the desired width.", "Steam rises to heat-set the fabric to its new measurement.", "And now this batch of fleece is ready to sew.", "They fold is for transport to the clothing factory.", "In its various colors and textures, this high-tech fabric will help protect you against the forces of nature.", "And with its recycled content, it also gives nature a bit of a break." ]

{ "things": [ "Scuba Diving Lights", "Interchangeable Sandals", "Race Car Simulators", "Fibreglass Doors" ] }

[ "A dive light is essential when scuba diving at night, but can also be used for daytime dives to explore underwater caves and shipwrecks.", "The deeper you dive, the more water absorbs certain colors in the light spectrum.", "When you use an artificial light, you can see the underwater world in true color.", "The dive light is waterproof to a depth of 295 feet.", "It's brighter than a car headlight, with six outer l.e.d. lights for floodlighting and three inner l.e.d.s for alternate spotlighting.", "The dive light begins as a conceptual drawing.", "The mechanical designer sketches out its basic features and a few proposed shapes.", "Then the company creates foam models.", "Scuba divers test these models and provide feedback on the comfort of each shape.", "This market research results in the final design-- a compact, hand-mounted dive-light with a user-friendly operating switch and three l.e.d. battery-life indicators.", "The housing's components are made of durable plastic pellets, reinforced with glass fiber.", "Workers load the pellets into an injection molding machine.", "The machine melts them and shoots the molten plastic into the proper mold for the component they are making.", "The machine then cools the plastic to a solid state and injects the newly formed part.", "This is the reflector.", "It combines the light from the six outer l.e.d.s into a single beam.", "It's coated in aluminum to increase the amount of light it reflects.", "A 3-d printer produces prototypes for all of the parts before they are manufactured.", "Guided by a computer, the printer shoots out plastic to build the part in three dimensions from the bottom up.", "Once the prototype is approved, they make a mold for mass production.", "This part is called the light pipe.", "It has oval covers for the three l.e.d. battery-life indicators and a waterproof seal.", "Once all the housing parts are molded, assembly can begin.", "They insert the light pipe into the main body of the housing.", "Then they attach a switch, which turns the light on and off.", "It also toggles the light between spotlight and floodlight modes.", "They don't need to pierce the housing to connect the switch.", "The switch slides a magnet over the outside of the housing.", "The magnetic field communicates through the housing to sensors inside.", "Next they insert and connect the circuit board...", "Then the lithium-ion rechargeable battery.", "They plug its connector into the circuit board.", "This cover holds the internal parts in correct alignment.", "A silicone o ring forms a watertight seal between the main body and the light head.", "They snap the reflector over the nine l.e.d.s, which are attached to a round circuit board.", "The circuit board is metal so that it will absorb the heat the l.e.d. lights generate.", "The screw-on aluminum bezel makes contact with the circuit board, transferring the heat out of the housing and into the water.", "They conduct the first quality-control test in water.", "The dive light is turned on to verify that it will run for 65 minutes on a full charge.", "In the second quality-control test, they submerge the dive light in a pressurized tank.", "This simulates the pressure the light would be subjected to at an underwater depth of about 300 feet.", "That's over twice the diving depth of a typical recreational dive.", "If the light doesn't spring a leak, it passes the test.", "They fully recharge the battery, which takes two and a half hours.", "At full charge, all three indicators light up green.", "As the charge drains, the indicators change from green to orange to red, then to flashing red, so scuba divers are never in the dark about how much juice is left in their light.", "Interchangeable sandals come with numerous ties that can be used to customize the look of a pair of heels.", "The mix-and-match possibilities are endless.", "The wearer can try out many different styles on a small budget.", "With interchangeable footwear, you can change the look without actually changing your shoes.", "With a variety of cloth and leather strappings to choose from, a pair of sandals can be made to look different each time you wear them.", "To make a pair of interchangeable sandals, they start with a piece of hardwood, like cherry, walnut, or maple.", "The employee cuts the wood to a workable size.", "Then computer-driven routers carve the rough shape of the sandals' heels, making two heels from a single block.", "The router sculpts a cup for the wearer's heel and carves a supportive structure for the arch of the foot.", "The router then shaves the sides of the heels and exposes the grain of the wood.", "Then a worker takes over, cutting away excess wood with a band saw.", "She rounds the back of the heels and further refines the structure.", "She now has a pair of heels.", "Another team member brushes rubber cement onto the soles.", "They are made of both natural and synthetic rubber.", "She applies glue to the heels, too.", "She presses the heels to the rubber soles.", "The glue takes 40 minutes to dry.", "Faux leather, backed by cushy padding, is used to make the footbed.", "This material is similar to what is used to make flip-flops.", "The worker transfers the footbeds to a silk-screen work station.", "She lowers a stencil with the company's logo on it.", "She applies acrylic ink and squeegees the ink across the stencil to transfer the imagine to the faux-leather footbeds.", "Another employee threads strong nylon cording through the holes in the footbeds to create loops for the interchangeable ties.", "He presses rivets into the footbed to hold the loops in place.", "Then he attaches the second part of the rivets to the protruding shafts.", "Using the special press, he flattens the rivets to secure them to the footbed.", "The loops are now firmly attached and should hold up to frequent tying.", "Another worker now glues the footbeds to the soles and heels.", "Next, she glues the rubber heel caps to the bottoms of the shoes.", "The caps provide tread and make the shoe more durable.", "A worker then sands the sides of the sandals, blending all the layers together.", "He buffs the sides against a fine grit abrasive to give the surface a nice sheen.", "Then he rubs an oil-based sealer into the wooden heels.", "This protects the wood from moisture and also accentuates the grain.", "It's time to test the ties.", "She threads the ribbons through the loops.", "They're good to go.", "With many colorful ties to choose from, these interchangeable sandals are many shoes in one.", "Racecar simulators help train racecar drivers off the track.", "They provide realistic visuals and sensations-- bumps, jolts, swerves-- whatever movement you'd feel if you were sitting in the driver's seat of a real racecar.", "This racecar simulator can be programmed to produce a range of racing scenarios and weather conditions.", "It can replicate any car on any track.", "First, a computer-guided laser cuts many of the simulator's parts from steel sheets.", "After workers sand the rough areas, a machine reads the final shape with a laser to make sure the part meets specifications.", "If a part requires bending, it is done with a press.", "This is one of the side brackets for the driver's seat.", "The simulator's main structure is made primarily of steel tubing.", "They saw the lengths required.", "Then a computer-guided mill drills holes for the bolts that will later be used to attach the simulator's components.", "Once all the steel tubes are ready, a welder puts them in a jig to align them correctly for assembly.", "The structure's tubular parts are welded together.", "Then the worker adds the simulator's sheet-steel parts and sprays the structure with industrial-grade paint.", "Now they mount an audio speaker and amplifier for the vibration system.", "Motion controllers that move the steering wheel and driver's seat are also added.", "They install the power distribution block and a sub-controller for each of the two actuators.", "They install the cables required for the simulator's components and plug them into a usb hub.", "Then they install the computer and plug it into the usb hub, as well.", "They cover the top of the structure with a textured aluminum panel.", "They bolt the bottom of the actuators to the structure and plug them into the sub-controllers inside.", "Then they mount the driver's seat and bolt the top of the actuators to the back of it.", "A worker installs the seat belt, along with the spring mechanism that yanks the belt back when you hit the brakes.", "They close in the sides of the main structure with aluminum panels.", "Next they assemble the simulator's three pedals-- gas, brakes, and clutch-- and mount the clutch mechanism to it.", "The pedal assembly is installed to the base of the steering frame.", "They mount the dashboard to the top of the frame.", "It's made of carbon fiber and contains the computer and audio controls.", "They attach the steering frame to the main structure.", "Then they assemble the steering wheel.", "Inside its base is a circuit board that controls the buttons on the wheel and gear shift.", "It's called the shift paddle.", "They mount the shift paddle to the base...", "Then flip it over to attach the wheel.", "Next workers assemble the display frame.", "It holds the simulator's three monitors and three front speakers.", "Then they roll in the rest of the simulator and plug the monitors and speakers into the computer.", "Finally, the steering wheel is mounted to the dash.", "It snaps in and out, allowing the driver to easily switch between steering wheel models.", "The simulator is run through several days of test drives before it ships out.", "Amusement parks also purchase these simulators to offer visitors a racecar driving experience.", "They can even link multiple simulators together to race against each other in virtual replicas of the world's most famous racetracks.", "In the 1980s, fiberglass doors came on the market.", "They were well-insulated and didn't warp in humid conditions like wood doors.", "However, they lacked the beauty and texture of real wood.", "That's now changing with technology that can make fiberglass doors look much more inviting.", "Fiberglass doors trick the eye and fool visitors.", "Even up close, they look like real wood.", "It's an illusion made possible with the help of technology.", "A wood-grain fiberglass door starts with a real wood door.", "A computerized cutter carves various panels.", "An employee sands away any marks left by the cutter.", "He gently scrapes the wood with a wire brush to expose the grain.", "He then assembles the panels of the door within a special fixture.", "Another team member scans the wood door with a laser to confirm its dimensional accuracy.", "With that confirmation, they're ready to use this wood door to make a fiberglass one.", "Next the worker pours a special silicone mixture onto the wood and leaves it to cure overnight.", "This step was demonstrated using a smaller section of the door.", "The silicone picks up all the definition of the wood grain, creating an exact copy of the door.", "Next an employee injects a different silicone mixture into a thin gap between the recently created silicone copy and a sheet of steel.", "The second silicone door copy is thinner, allowing for a better transfer of heat during the next process.", "They load the door copy, still on the steel sheet, into a chemical deposition chamber.", "The chemical heats the steel and the silicone, causing a nickel-vapor shell to form.", "The nickel shell has all the detail of the original wood door.", "An employee files the edges and adds a protective fiberglass cover over the top of the shell.", "Workers then lower the nickel shell into a mold base.", "They remove the protective cover and are ready to use the nickel shell to mold fiberglass door veneers.", "There are many nickel molds and a variety of door styles at this factory.", "The fiberglass material now unwinds into a cutting station.", "A worker slices it into uniform strips.", "The fiberglass has a dough-like consistency at this stage.", "He places a stack of fiberglass strips on the nickel door mold and lowers a hot press.", "The press squeezes and melts the fiberglass.", "It flows into the crevices of the mold.", "The fiberglass solidifies quickly.", "An employee removes it from the press and sands the ragged edges.", "Another member of the team confirms that the width and thickness of the panel are on target.", "They stain every first-run fiberglass panel to expose the transferred wood grain.", "This is a test.", "If the grain is good, it means there are no defects in the nickel door mold.", "It's time to assemble the fiberglass door.", "Rollers apply glue to external framing wood.", "The team builds a frame around the fiberglass door skin.", "They join the wood to plastic casing at the top and bottom of the door.", "They place a second fiberglass door skin on the top.", "Then they feed the door through rollers that squeeze it together.", "This activates the glue for a strong assembly.", "The glue takes over 24 hours to dry.", "Next they load the hollow fiberglass doors into an insulating press.", "The press closes, holding the doors tightly in place.", "A worker fills the hollow doors with polyurethane insulating foam.", "When foam begins to overflow through the vent holes, the worker knows the doors are full.", "He caps the fill hole...", "And runs a finger along the doors to remove any excess foam.", "Energy-efficient and stable, fiberglass doors are a great alternative to wood.", "With eye-catching wood grain, they're convincing imitations." ]

{ "things": [ "Glass Faucets", "Fire Truck Ladders", "Antique Clock Restoration", "Barbecue Utensils" ] }

[ "Glass faucets elevate indoor plumbing to an art form.", "The glass is hand-crafted in a range of shapes and patterns for visual effect.", "Metal components are fused into the glass to deliver one of the necessities of modern life, running water.", "Glass faucets are about both form and function.", "Glass faucets have a delicate beauty, but they're stronger than they look.", "The glass is very thick, allowing the faucets to hold up to heavy use.", "Making a glass faucet starts with chunks of clear glass.", "A glass worker loads the glass into an oven at 2,190 degrees fahrenheit.", "Another worker selects black and white billets of glass to add stripes and patterns to the clear glass.", "He preheats them so the glass won't shock and fracture when exposed to higher temperatures.", "With a metal rod, he gathers a clump of the clear glass from the main oven.", "With the chunk of glass, he picks up the preheated white cylinder, simultaneously exposing both to the flames.", "This process makes the glass flexible.", "Using a curved wood tool, the glass worker gathers the clear glass at the base and wraps it around the white billet, encapsulating it.", "He attaches the other end of the glass to a second metal rod.", "This allows the glass to stretch as he pulls it across the room.", "The glass is now over 35 feet long and pencil-thin.", "It starts to cool and solidify immediately as it's set down.", "The glass workers tap the glass against a piece of metal to break it into 8-inch pieces called canes.", "They shape another piece of clear glass by rolling it on a metal table called a marver.", "The glass worker blows through the metal rod, causing the glass on the end to bubble.", "It will eventually become the faucet and two handles.", "He adds a layer of black molten glass to the bubble.", "Another glass technician arranges the striped canes on a grooved iron plate and heats them with a torch.", "Meanwhile, a glass worker rolls the hot glass bubble onto the canes, which stick together.", "Then it's back into the furnace, and the white-striped canes melt into the black bubble.", "Next, the craftsman rolls the glass across the marver repeatedly.", "He pinches the canes at the top, closing them around the bubble.", "The glass is reheated to keep it pliable as the craftsman continues to form it.", "The craftsman transforms the bubble into a hollow glass tube then elongating the tube to its desired length.", "Using a pincer-leg tool, he forms the end into a round handle shape while another glass worker applies heat to the glass with a torch.", "This keeps the glass pliable.", "He then creates a hole for a piece of metal hardware.", "Then he applies molten glass to the metal hardware and inserts the hardware into the round faucet handle.", "This cuts the handle free from the rest of the glass.", "Using a forming tool, the craftsman refines the shape of the glass.", "Next, he preheats a metal mold.", "This stops the hot glass tube from fracturing as he bends it around the mold to shape it into the faucet.", "Once the faucet has taken shape, it's ready to go into the annealing oven.", "The glass is placed in the oven at a low temperature and then cooled.", "This process removes stresses and strengthens the glass.", "Meanwhile, using high-pressure water that contains fragments of garnet, a craftsman cuts steel trim rings and a display plate for the showroom.", "Next, the craftsman installs the glass faucet on the display plate by threading a nut to the faucet valve.", "He installs the trim rings at the base of the handles and assembles them to the display plate using the hardware that's been fused to the inside of the glass.", "The craftsman uses a rag to clean the faucet of any fingerprints and smudges.", "Finally, construction is complete.", "This unique glass faucet is ready to make a statement.", "Short fire trucks can easily access tight spaces around the scene of a fire.", "That's because they're lighter and can carry more water and equipment.", "However, it's difficult for smaller fire trucks to support the weight of long ladders.", "To compensate, manufacturers have built longer ladders on shorter trucks.", "This 108-foot-long ladder can be mounted on a single rear-axle fire truck.", "Typically, a ladder longer than 75 feet requires a tandem-axle truck to support its weight.", "The secret to the design of this ladder is that it's lighter, stronger, and durable.", "The components are cut from sheets and tubes of high-strength steel.", "Using a press brake, the machinist bends the parts, verifying the accuracy of each bend.", "Once all the components are prepped, the parts are welded together, then smoothed.", "This welded part is the turntable base.", "It rotates the ladder 360 degrees and provides a platform for the firefighter at the controls.", "This is the torque box.", "It supports the aerial pedestal to which both the ladder and turntable are bolted.", "To construct the ladder, technicians weld tubular rungs to vertical side rails called base beams.", "They reinforce the rungs with diagonal tubes called k-braces, which provide lateral structural strength.", "Welders fuse steel tubes between the base beam and the handrail to provide structural support.", "Next, an inspector from an independent testing company examines the integrity of the welding.", "Once the ladder passes inspection, it's put through a shot-blasting chamber, which pummels the surface with steel pellets.", "This process removes metal impurities and preps the surface for painting.", "Craftsmen apply two coats of primer, one top coat of color, then two clear coats of paint, sanding by hand between each application.", "Next, a three-part anti-skid treatment is applied to the turntable surface-- first, a coat of glue, then an abrasive material, then a coat of sealant, which is baked in an oven for 90 minutes.", "The ladder rungs are covered with snap-on non-slip covers made of fiberglass-reinforced plastic.", "The ladders are stacked in four or five compact sections.", "Technicians install a cable that enables the sections to extend and retract.", "The cable is attached to a hydraulic cylinder.", "Three telescopic sections of the aerial waterway are attached.", "This tube transfers water up to the top of the ladder so when the ladder extends, so does the waterway.", "This valve at the top of the waterway allows firefighters to hook up a hose to bring inside the building.", "The water monitor, driven by an electric motor, directs the water flow in all directions when the aerial waterway is being used without a hose.", "Next, the machinists install the turntable controls, which run the electrical power and the hydraulics that move the ladder.", "Then they attach the ladder to the aerial pedestal with a huge pin.", "A large bolt is inserted, which prevents the pin from sliding out of place.", "This is what's referred to as a rear-mount ladder, meaning it's installed on the back of the fire truck.", "When a ladder is installed behind the cab, it's called a mid-mount ladder.", "Assembly of the ladder is almost complete.", "Technicians bolt the turntable to the truck, then hook up the hydraulic line that operates the ladder.", "They install a swivel mechanism which enables the aerial waterway to move with the ladder and turntable.", "Before it leaves the factory, the ladder is put through a test run to ensure it meets the highest standards.", "An antique clock can only be repaired by an expert.", "This person would have either apprenticed under a clockmaker or studied timekeeping at a horology school.", "In today's digital landscape, horologists are becoming a vanishing breed.", "When your grandfather clock is struggling through old age, it's time for a visit to the master clockmaker.", "First step-- the dial and the mechanism are placed on a stand for observation.", "Two horologists inspect the clock for worn-down parts.", "The mechanism contains two gear trains-- one for keeping time, and another to regulate the hammer that strikes a bell on the hour.", "After the paperwork is completed, the clockmaker gets to work.", "He detaches the hands and dial to gain access to the gear trains and their linked components.", "He removes tiny screws to release the hands.", "Then he removes pins that release the dial's four feet, located within holes in the front plate.", "An artist restores the dial.", "The clockmaker unscrews the cast-iron bell and begins disassembling the assortment of parts, starting with the pallets.", "The pallets receive power from the clock's suspended weights and connect with the timekeeping gear train, which moves the pendulum.", "The shafts of the hour, minute, and second wheels converge at the center of the largest wheel on the front plate of the mechanism.", "The clockmaker disassembles these and other components.", "He lifts off the front plate to strip down the inner parts.", "The cables suspending the weights are made of woven brass.", "The craftsman cleans all the metal parts in an ultrasonic machine.", "Its high-frequency sound waves force the chemical solution into all the nooks and crannies.", "He rinses the parts and dries them in jeweler's sawdust.", "Each part is inspected under a magnifying glass to assess their condition.", "If a part is worn, the craftsman tries to restore it to its original shape.", "If it's too badly worn, he has to make a replacement with a computer-guided milling machine.", "The pin at the end of a gear is called a pivot.", "After measuring its diameter with a digital caliper, the clockmaker sets the disk of a filing machine to its corresponding measurement.", "He places the pivot between the disk and a fine-grinding disk, filing away any rough surfaces.", "Next, the craftsman works on the rear plate, hammering in brass sleeves called bushings into multiple gear holes.", "He widens the bushing just enough to insert the pivot and smooths out the hole.", "He inserts one end of the pivot in the rear-plate bushing, the other end in the front-plate bushing, and checks that the gear rotates smoothly.", "He does the same for each pivot hole.", "Then, all the parts are cleaned, and the mechanism is reassembled.", "This gear on the front plate is the hour wheel.", "The clockmaker attaches the hour rack, which connects to the gear train.", "This system regulates the striking of the bell on the hour.", "Once the mechanism is reassembled, the horologist attaches the dial to the front plate.", "The dial of this clock required no restoration.", "Even the original steel hands are still in good condition.", "When hands are in bad shape, the clockmaker creates replicas.", "When hands are missing, he makes new ones in the style of the period.", "During the entire reassembly, the clockmaker wears gloves to protect the steel and brass components from the natural oils in his hands.", "Restoring an antique clock can take several weeks of meticulous work.", "When it's done, the clockmaker mounts the clock back on the stand, connecting the weights and pendulum, and runs a test.", "the job is complete when the clock keeps time and the hammer strikes the bell to announce the hour.", "cooking over an open flame calls for a serious set of tools.", "Barbecue utensils are durable and designed to withstand the heat.", "Built longer than regular kitchen utensils, these tools enable the chef to keep an arm's distance from the flame, making barbecuing a safe and gratifying experience.", "When barbecuing, it's important to go big on tools.", "These substantial utensils will hold up to the intensity of the flame while also offering precision and control.", "Making barbecue utensils starts with a sheet of high-carbon stainless steel.", "A laser cuts out several parts, creating turner blades.", "Turner blades are broad, enabling the user to flip burgers and fillets without breaking them.", "They also have slots for draining grease and juices.", "A technician extracts the blades from the matrix and punches out the pre-cut drainage slots.", "The turner blades are placed on a rack which lowers the blades between two coarse rollers.", "An operator applies polishing compound to the rollers.", "As the rollers turn, the friction rubs off stamped information from the steel mill and other blemishes.", "Technicians buff the blades to a smooth, matte texture.", "This gives the blades a consistent polished finish.", "Next, the blade is clamped to a special carriage moving the blade back and forth as a grinding wheel carves a thin beveled edge.", "The beveled edge will make it easier to lift meat off the grill.", "An operator clamps the turner blade in a fixture.", "A hydraulic press bends the neck of the blade.", "High-grade walnut is the material used to make the utensil handles.", "It's a hard, durable wood with a grain that adds visual interest.", "Using a bandsaw, the operator carves the walnut block into smaller chunks.", "Each one will become a handle blank.", "He places the blanks on a conveyer that takes them through a spinning cutting head.", "The cutting head carves a taper into the end of the handle that will hold the blade tang.", "To refine the shape, a craftsman locks two handle blanks on a revolving table.", "Moving the handles against a router can make the handles smoother for gripping.", "It's quite a transformation.", "Multiple drill heads carve rivet holes on one side.", "The holes have a graduated profile to allow the rivets to sit flush to the wood.", "The craftsman drills corresponding holes on the other side.", "Using a circular saw, he cuts a slot for the tang-- or stem-- of the barbecue utensil to be inserted and drills one last hole for a piece of rawhide that will hang up the tool.", "Next, the craftsman inserts the tang into the slot in the handle and slides a post through one of the holes.", "This positions it for a female rivet to be installed from the front.", "Male rivets are installed on the other side.", "This completes the riveting steps and secures the handle to the turner blade.", "Using a coarse sanding belt, the craftsman smooths the rivets to the wood and sands off the metal tang at the protruding sides.", "Another technician rubs mineral oil into the wooden handle to give it luster and enhance the grain.", "A mixture of ground corn and mineral spirits serves as a gentle abrasive cleaner.", "The technician dries off the blade by plunging it into just the ground corn.", "With a compressed air gun, she blasts off the corn-cob remnants, examines the tool for defects, and props up the utensil under an engraving laser.", "The laser etches the company name into the metal.", "This barbecue turner will become part of a set which will act as an extension of the chef's hands, making it possible to cook over an open flame without getting burned." ]

{ "things": [ "Accordions", "Pineapples", "Artificial Joints" ] }

[ "The distinctive sound of the accordion appears in almost every kind of music.", "The piano-style keyboard on the right-hand side produces the melody, while the buttons on the left produce the chord accompaniment.", "In between are bellows that force air through reeds, producing that unmistakable accordion sound.", "the accordion is a beautiful and complex instrument.", "It contains up to 10 sets of steel reeds with different pitches.", "Each reed set goes into a wooden block.", "Under every section is an opening called a tone hole.", "The bellows drives air through it, vibrating the reed above to produce a musical note.", "These leather-and-plastic pads cover the slots on the accordion's aluminum reed plates.", "Each plate holds two reeds.", "Both reeds produce the same note-- one when you push the bellows, the other when you pull.", "They now apply a special wax to secure the reeds to the block.", "If they used glue, they wouldn't be able to remove the plate should a reed ever need repair.", "Each reed played corresponds to a specific note or chord.", "To assemble the keyboard, they begin with a lever made of fiberglass-reinforced plastic.", "It has a wooden core to give the keys sufficient weight.", "A long metal lever goes into the top.", "When the musician presses a key, its mechanism unblocks the corresponding tone hole, allowing air to flow inside and vibrate one of the plate's two reeds.", "Next, they drive in the steel axle on which the keys pivot.", "Then they apply suction to a keyboard-size tray.", "In it, they line up the plastic key tops.", "In top-of-the-line models, the white key tops are made of celluloid.", "With the suction holding the keys down, it's just a matter of flipping the tray and clamping it onto the keyboard frame.", "The tops adhere to the levers, which have since received a coat of glue.", "After about an hour, the glue is dry.", "They cut the suction, and the keyboard is finger-ready.", "Meanwhile, the reed blocks are in the hands of a tuning specialist, who pumps air with a foot pedal to vibrate the reeds one at a time.", "He compares each note to a reference tone from a tuning apparatus and files the reeds gradually until their pitches match.", "Now for the button keyboard.", "Starting with the valves, they install a wooden pallet over each tone hole.", "To that, they glue a steel lever.", "Then to that, they connect a brass rake.", "When the rake moves, it pulls the lever, which opens the valve, unblocking the tone hole.", "Air enters and vibrates the reed, producing the note.", "Each keyboard button opens three valves.", "That's why pushing one button produces a three-note chord.", "With the complex connections between buttons and reeds complete, the reed blocks go into a celluloid-on-plywood housing.", "It'll attach to the bellows made of strong pleated cardboard reinforced with leather and metal corner protectors.", "but before permanently attaching the bellows, all the reeds have to undergo a final and very extensive tuning adjustment.", "an accordion can have up to 600 reeds, so this meticulous reed-by-reed tuning can take up to 16 hours.", "they now pin the bellows' wood frame ends to the treble and bass housings.", "Then they cap each housing with a cloth-covered grille to keep out dust.", "After polishing the accordion to a high-gloss finish, it's time for a musical road test in white gloves.", "There's no sense in leaving fingerprints on that exquisitely polished surface.", "With the test checklist complete, the inspector signs off on it.", "You can't say this job's all work and no play.", "the pineapple is native to south america, but colonization spread it to other tropical areas.", "The latin name for pineapple is \"ananas,\" which comes from nana, what the natives called the plant.", "The english word \"pineapple\" came from the european explorers who thought that this strange but delicious fruit looked like a giant pinecone.", "Pineapples need temperatures between 73 and 86 degrees fahrenheit and full sun.", "It takes seven months for the pineapple plant to produce a bunch of little reddish-purple flowers.", "At this first bloom, as it's called, farmers spray the plant with ethylene, a natural gas that stimulates full flowering.", "As that happens, the stem of the flower bunch gradually thickens and becomes bulbous.", "This is the pineapple.", "Five months after first bloom, a year since the last harvest, a fresh crop of pineapples is ripe for the picking.", "But not before the farm has tested samples to make sure the sweetness level is just right.", "This is prickly business, so the workers have to wear gloves, long sleeves, safety glasses, and rubber boots.", "The pineapples travel from the field to the factory upside down.", "That way the crown of leaves bears the weight of the fruit during the bumpy ride.", "Upon arrival at the factory, the pineapples go through a 10-step cleaning in chlorinated water.", "This washes away insects and frog eggs.", "Frogs like to lay their eggs in pineapple crowns.", "A final rinse with clean water removes any chlorine residue.", "Now workers classify the pineapples and cut off misshapen crowns.", "A first-class pineapple has a straight crown and no more than three damaged eyes, those diamond shapes on the peel.", "If a pineapple passes the first-class test, it's fit for export.", "Second-class sells on the domestic market.", "Third becomes dried fruit, and fourth, juice.", "At the drying plant for third-class pineapples, workers first chop off the crown, and then about two inches from the bottom end.", "With a coring machine, they remove the pineapple's hard center called the heart.", "Knife-wielding employees work their magic, each peeling five to seven pineapples per minute.", "The coarse skin dulls the blades quickly, so they have to keep sharpening their knives about every half-hour.", "The peeled pineapples then move on to a slicing machine, which produces slices a little more than a half-inch thick.", "The average pineapple yields about seven slices.", "Workers place the slices on large trays...", "Load the trays on large racks...", "Then roll the racks into a gas oven.", "The slices bake for 24 hours between 147 and 151 degrees fahrenheit.", "This dries them almost completely.", "When they come out of the oven, their moisture level is 6%, just enough to ensure the slices are chewy.", "From the oven to packaging.", "These preservative-free dried pineapple slices stay fresh in the package for 18 months.", "Now back to the pineapple factory, where the first-class fruits pass under a shower of hot wax.", "Fans cool and harden the wax into a coating that creates an air barrier.", "This slows the ripening process, ensuring the pineapples don't overripen by the time they arrive at their export destination.", "Last stop is the packaging and labeling department.", "Workers box pineapples with and without crowns separately.", "Those with crowns are for export.", "The crownless ones go to a canning factory to be sliced, diced, or crushed.", "From the field to your table, pineapples are the fruit of many people's labors.", "Artificial body parts used to be the stuff of science fiction.", "Nowadays artificial joints, at least, are routine.", "An artificial joint is a prosthesis that surgeons insert to replace diseased or worn-out bone and cartilage.", "In nearly all cases, an artificial joint relieves pain and improves the range of motion.", "From your knees and hips to your wrists, elbow, and shoulders, if your joints go, you can replace them.", "An artificial joint has both metal and plastic components.", "The metal acts as bone, the plastic is cartilage.", "This factory makes the metal parts three ways.", "It either casts them, forges them, or machines them.", "Casting is the most complex method.", "The first step is to pressure-inject melted wax into an aluminum mold.", "This makes a pattern, a wax replica of the metal part.", "Now they build the mold for casting the part in metal.", "Workers fuse a group of patterns with hot wax to a holder also made of wax.", "The patterns will shape the cavity in the molds.", "They submerge the patterns in a thick liquid ceramic which soon hardens into a fragile shell around the wax.", "Then they sprinkle the shell with a mixture of two minerals-- silica sand and zircon-- to build up a strengthening crust.", "The shells now go into a furnace for about two hours.", "The intense heat hardens them and incinerates the wax inside, leaving a cavity in the pattern shape.", "The shells are now molds strong enough to withstand molten metal.", "That metal is cobalt chrome.", "In this crucible, the chrome liquefies in about 10 minutes.", "They remove the molds from the furnace and lock them to the top of another one above the crucible.", "Then they flip it over.", "The molten metal flows from the crucible into the molds.", "It solidifies within two minutes.", "Then they transfer the hot molds to a cooling bin.", "Cold air flows around them for about two hours until they're finally cool enough to handle.", "Then workers mount each tree on an automated machine that works like a jackhammer.", "Each mold disintegrates, freeing the cast-metal part inside.", "They use a saw to separate the parts from the tree, then a grinding belt to remove any unnecessary metal that hardened in the channels.", "Next, they laser-engrave a unique serial number on each part for tracking purposes.", "Every part undergoes a thorough inspection.", "They dust the part with fluorescent powder, then rinse it off.", "Powder residue settles in any flaw and glows under ultraviolet light.", "After inspection, they buff every part until the metal's so shiny, you can see a reflection.", "Another method for making metal parts is forging.", "They use a titanium alloy, which is more flexible than cobalt chrome, making it better suited for hip joints, in particular.", "They clean the metal, then heat it in a 2,200-degree furnace.", "This 660-ton press forms one piece at a time into a preliminary shape.", "Then they move it to the next die and stamp twice to refine and then finalize the shape.", "The last stamping on the third die trims off excess metal and adds detail.", "The forged part now goes into a sandblasting chamber which cleans the metal and gives the surface a matte finish.", "Here's what the part looks like before sandblasting and after.", "Now a computer-guided milling machine smooths away the rough edge that trimming the excess metal left behind.", "This removes all but the last bit, so they get rid of that with a sanding belt.", "But sanding leaves metal residue behind.", "So the parts now go for a bath in a water-based citric solution.", "The metal surface has to be perfectly clean in order to stamp on the serial number in ink.", "Quite a difference before cleaning and after.", "Each and every metal part, whether forged or cast, goes to the quality control department.", "There, using digital calipers, an inspector checks all the dimensions, then examines the part under a magnifying glass.", "So far we've seen two of the ways they make the metal parts of an artificial joint-- casting and forging.", "The third method is coming right up.", "The metal portion of an artificial joint plays the role of bone, while the plastic portion mimics cartilage.", "However, the plastic isn't your run-of-the-mill plastic.", "It's medical-grade polyethylene, meaning it's formulated to be lightweight, but also extremely durable so that it withstands years of wear and tear within the body.", "The type of metal they use to make the bone portion of an artificial joint depends on how flexible that joint has to be.", "A knee joint requires less elasticity, so they mold it out of cobalt chrome.", "A hip joint, on the other hand, needs to be more bendable.", "So for that, they use titanium.", "They either forge the shape in a press or mount the titanium block on a computer-guided mill.", "Under a steady shower of lubricant, the mill's 20-odd machining tools carve the block from all angles.", "After a primary rough machining, the mill's precision tools finalize the shape.", "From start to finish, machining just one part takes about half an hour.", "Now a robot takes over.", "It runs the part against a series of sanding belts, their grits progressing from rough to fine.", "This removes marks the machining tools left on the metal and polishes the surface to a mirror finish.", "The robot can't reach the edges, so a worker sands them manually and verifies the dimensions.", "Then the parts go for a thorough cleaning.", "The factory puts random samples through wear testing.", "The machines simulate joint movement, complete with fake joint fluid.", "The factory sprays some parts with titanium powder to help bone tissue to cling to them.", "This machine, called an optical comparator, projects an image of the part's coated outline against a technically perfect template.", "The technician makes sure the part and the template match.", "To become an artificial joint, the metal bone now needs its plastic cartilage.", "That requires polyethylene powder.", "A technician weighs out a specific amount, puts it in the outer sleeve of a mold, then inserts the mold's inner piece.", "The technician loads the mold into a press that applies both pressure and heat-- 374 degrees fahrenheit.", "The powder gets squeezed between the mold's two parts and turns into solid plastic.", "Using various instruments, they measure the molded part to ensure all its dimensions are exact.", "Now a computer-guided machining tool carves the grooves into which the metal part will slide.", "These details are far too intricate for a mold to shape.", "Then some final measurements to make sure the finished part adheres to the engineering specifications.", "Random samples undergo fatigue testing equivalent to 10 years of wear.", "Some plastic parts are just too complex to be molded outright, so, instead, the factory molds a block of plastic, then machines it.", "The block spins on a lathe as various computer-guided tools shape it.", "Samples of these also undergo wear testing.", "After a specific number of movements over a specific time period, technicians remove the parts and weigh them.", "By comparing to the starting weight, they can calculate how much plastic has worn off.", "The packaging room is what they call a clean room, meaning the air runs through a filter system to keep out dust and dirt.", "Workers pack the artificial joints against foam to protect the metal surface, because even the tiniest scratch can cause premature wear.", "After heat-sealing the packages, the factory ships them off to a sterilization plant.", "There, powerful gamma rays penetrate right through the packaging and kill off any bacteria that might be lurking inside.", "Make no bones about it, these joints may be artificial, but the movement they restore is as real as it gets." ]

{ "things": [ "Pipe Cleaners", "Blue Stilton Cheese", "Smart Electric Meters", "Telescopes" ] }

[ "The pipe cleaner was invented early in the 20th century.", "A wire core with tufts of yarn, it could be bent and twisted in any tight space, making it useful for cleaning a lot of things besides pipes.", "Its flexibility also offers a creative opportunity for those with a crafty bent.", "Today many pipe cleaners never get dirty.", "Instead of cleaning pipes, kids bend them and shape them to create crafts.", "The core component of every pipe cleaner is, of course, the wire made of malleable steel.", "There are two wires in every pipe cleaner.", "The wires will become intertwined with tufts of yarn, and it will all happen on a machine like this.", "But first here's a look at the two wires twisting together without the yarn.", "This wire core is the heart of the pipe cleaner.", "Without the tight twist, the yarn would just slide off.", "The spools of yarn unwind at the same time as the wire and head towards the machine.", "They'll use cotton yarn for pipe cleaners destined for actual pipe cleaning because it's absorbent.", "For the craft market, polyester fibers are more suitable.", "The colors are brighter.", "This orange yarn and the wire travel over tension disks to prevent slackening that would cause messy entanglements as the pipe-cleaner materials all head toward the forming machine.", "The yarn in the wire are totally in sync as they feed into the machine.", "The pile yarn rapidly winds around a metal former to coil it.", "At this point, the diameter of the pipe cleaner is set by using metal formers of different sizes.", "A sharp rotating blade cuts the coils to produce a series of short tufts.", "They stop the process briefly to give us a look inside.", "At the same time, the wires run in grooves around rotating rollers, and those yarn tufts now become trapped between the two wires.", "Together the wire and yarn tufts then travel over other rollers into a device called a flyer.", "The flyer was invented for twisting yarn.", "Each time the flyer rotates, it inserts one turn into the pipe cleaner.", "Bobbins then wind up the pipe cleaner.", "It all happens so fast, it's a bit of a blur.", "At the next station, numerous bobbins of pipe cleaners unwind simultaneously.", "They travel between a series of rollers.", "The rollers straighten the pipe cleaners, eliminating the curl created when they were wound onto the bobbins.", "A clamp then locks the pipe cleaners in position, and a carriage pulls them forward.", "The carriage moves in measured increments so a guillotine-style blade can cut the pipe cleaners to a precise length.", "In this case, it's 6 inches, a popular length for the craft market.", "The machine ejects the completed pipe cleaners, and a worker packs them up for retail.", "Each bag contains all the colors of the rainbow and then some.", "For thicker, fluffier pipe cleaners, they use a slightly different machine.", "Bobbins of polyester yarn rotate in the carousel to wind the yarn around the former and coil them.", "A sharp rotating blade cuts it into tufts.", "A carrier wire is used here to keep the pile under tension, after which the two core wires trap the tufts just as before.", "Another clamp twists the core wires and tufts as it pulls them forward.", "This transforms them into one thick and fuzzy pipe cleaner, which is then cut to any length the client orders.", "Production now focuses on pipe cleaners for medical and engineering cleaning jobs.", "Heat guns melt the fibers at the ends to seal them, ensuring they won't shed lint or fibers during the cleaning of sensitive equipment.", "You can see the difference this makes in the pipe cleaner on the right.", "Pipe cleaners today are no longer just for pipes.", "They're used to clean all kinds of things like bicycle gears or any gear at all.", "They can also be used for paint touch-ups, odd jobs in the garage, cleaning rifle barrels, wrapping electronics cables, and cleaning any long tube.", "But, of course, it's not all work and no play.", "There's always arts and crafts time.", "That's when things take a creative twist and pipe cleaners become anything you want them to.", "Stilton is a creamy and crumbly british blue cheese whose roots date back to the early 1700s.", "It tastes mellower and less salty than many other varieties of blue cheese.", "Always produced in an 18-pound cylinder format, it has veins of blue mold radiating from the center outward.", "The production of stilton is strictly regulated.", "Only half a dozen dairies in the world located in three specific english counties are licensed to produce it and only from locally produced pasteurized milk.", "It takes 20 gallons of milk to make each 18-pound cylinder of stilton.", "They begin by pouring milk in a vat.", "Next, they add starter culture, laboratory-grown natural organisms.", "Then they mix a blue mold culture called penicillium roquefort with distilled water and add this to the milk, as well.", "After about three hours, they stir in enzymes that coagulate the milk fat.", "After about 90 minutes, workers run a wire knife through the now-gelatinous milk, separating the fat, called curds, from the liquid, called whey.", "Then, overnight, they drain the whey out of the bottom of the vat.", "The next morning, the firm curds go through a mill, which breaks them up into a crumbly consistency.", "Workers weigh out portions of 24 pounds, each of which will become an 18-pound cylinder of cheese.", "After adding salt-- the company won't disclose just how much-- two workers gently hand-mix the portion, two different mixing styles blending the ingredients more thoroughly than one.", "Then they funnel each portion into a cylindrical plastic cheese mold called a hoop.", "The curd still contain whey.", "So workers stack the hoops for five days.", "Typically, cheeses are pressed to drain the whey-- not stilton.", "Here gravity does the job.", "The cheese drains under its own weight.", "Workers flip the hoop once daily to drain through both the top and bottom.", "After five days, they remove the hoop.", "The cheese, now drier, stands on its own, while, with a knife, they perform a critical procedure called rubbing up.", "They rub the entire surface with a flat blade, sealing all the holes so that air can't penetrate and cause premature internal mold growth.", "Now the cheese goes on to a stillage, a type of trolley, and begins its journey through the climate-controlled bluing rooms, named for the color of the internal mold growth which occurs there.", "Workers flip the cheese daily to prevent its cylindrical shape from distorting under its own weight.", "Within a week to 10 days, grayish white, sometimes orange, naturally occurring mold begins growing on the outside, and from that point on, when the cheese acquires a certain amount of mold, they move it to the next level room, then to the next one, and so on.", "At about the five-week mark, they mount the cheese on the turntable of a piercing machine.", "With each press of a foot pedal, the turntable rotates slightly, and long, stainless-steel needles pierce the cheese.", "These tiny holes permit oxygen to enter and kick-start the penicillium roquefort blue mold culture that the dairy put in the milk earlier on.", "Before long, blue mold gradually grows from the center of the cheese outward.", "To monitor the extent of the blue-mold growth, the dairy's cheese graters draw samples using a tool called a cheese iron.", "The iron reaches all the way to the core of the cylinder.", "When the sample shows that the bluing runs right through, the cheese is ready, more or less.", "The timing's actually a bit tricky.", "Stilton is a relatively young cheese, best eaten between 12 and 14 weeks.", "The dairy does its best to coordinate shipping so that the cheese is at its optimum quality when it reaches the customer.", "Therefore, it ships 8- or 9-week-old cheese to local stores and 7-week-old cheese to international customers so that the blue stilton will be an ideal 8 or 9 weeks of age when it arrives at its destination.", "Smart meters are electricity meters that don't have to be read by a person.", "Instead, they wirelessly send your home's electricity use to your utility in real time.", "Your bill then shows how much electricity you used and when, making it easier to better control your energy use.", "Old technology meters require a human being to take a meter reading once each billing period.", "Smart meters can report consumption in real time by wireless transmission.", "Inside the smart meter are three different electronic circuit boards, the brains of the unit.", "They're built on large, blank fiberglass panels.", "One panel yields six or eight identical circuit boards depending on the meter model.", "In the first machine, for tracking purposes, a laser etches a serial number for each future circuit board.", "The next machine applies a stencil on the pattern of the components to be mounted on the board, then spread solder and paste form across it.", "The board now wears solder paste shaped in position exactly to receive the upcoming components.", "The next machine's two lasers verify that the solder paste application is perfect.", "Depending on the size of a specific circuit-board component, there can be anywhere from 5 to 20,000 of them stored on a tape reel under a transparent, protective strip.", "Workers mount the rail for each component on what's known as a pick and place machine.", "This computer-controlled high-speed device peels back the protective strip and picks the required parts off each reel, then places them in their designated solder-pasted position on the board.", "Bulkier components are stored on a different-sized reel, which workers mount on another type of pick and place machine.", "It does the same operation as the previous one, only slower due to the larger-sized components.", "The boards now travel through a soldering oven.", "The precision-controlled temperature, peaking at 468 degrees fahrenheit, melts, then cools the solder paste, fusing all the components to the board.", "Next, each board undergoes testing.", "This machine applies electricity to ensure each and every component meets specifications.", "When the board gets the all clear, it moves to the next machine, which cuts it into separate circuit boards.", "Meanwhile, robots assemble the meter's digital display.", "They take a plastic half-circle housing and install a liquid crystal display into its rectangular window.", "At the next station, a robot uses a vision system to align snaps to attach a circuit board to the liquid crystal display.", "Assembling the meter body begins with a plastic base plate.", "The first station prints a serial number on the bottom.", "The next station then flips the base plate upright and installs the components of the remote disconnect switch.", "This switch enables the electric company to switch power on and off from any location.", "A switch cover closes up the base.", "The protruding wire will connect to a circuit board.", "The next station installs two terminals through the switch cover.", "These function as part of the switch operation as well as part of the meter's measurement of electricity consumed.", "Once those terminals are in, an automatic screwdriver secures the switch cover.", "Now the first of three circuit boards.", "This one, the metrology board, measures energy consumption.", "The unit comes off the automated line, and a worker completes the assembly.", "He attaches a connector to the digital display circuit board, installs the display, then connects the switch wire to the display's board.", "The metrology board sends its measurements to the display circuit board, which interprets the data and sends it to a third circuit board, which transmits it by radio frequency to the utility.", "Once workers have fully assembled the housing, they install a metal tamper-evidence seal.", "Every meter undergoes rigorous final testing.", "An automated station verifies the display using a vision system.", "It checks that the remote disconnect switch operates properly, that the meter measures electricity accurately, and successfully transmits and receives messages.", "The telescope was invented by a dutch optician four centuries ago.", "Before that, it was believed the earth was the center of everything.", "The theory that it actually revolved around the sun was discounted.", "In the hands of italian astronomer galileo, the telescope brought reality into focus.", "Modern telescopes are light-years ahead of those early versions, and through their eyepieces, the universe continues to unfold.", "A reflecting telescope bounces and concentrates light with mirrors.", "Production begins with the machining of cylindrical metal parts.", "These are baffles, and when screwed together, they'll block stray light that would interfere with the telescope's operation.", "More tools transform a solid aluminum disk into a ring with spokes.", "This part, called the spider, is a framework for supporting the telescope's secondary mirror.", "After coating the metal parts with a protective oxide, they plunge them into a vat of black dye.", "The dye soaks into the oxidized pores and seals the surface of the parts.", "Next, this molded disk of thick low-expansion glass will become the telescope's primary mirror.", "A diamond-edged tool rotates on a calculated tilt to make the glass slightly concave.", "To improve the concave profile, a worker coats the glass with abrasive.", "He adds a weight to a precisely curved cast-iron disk and spins it.", "The weighted iron disk bears down on the abrasive coated glass to fine-tune its curvature.", "A worker then examines the finely ground surface for scratches, and using a calibrated gauge, he measures the radius of the disk to confirm that the concave profile is precisely what it needs to be.", "The glass now spins while a cylindrical cutter aims dead center to cut out a hole.", "This center hole is sized to accommodate the baffles we saw earlier, and it will also enable the mirror to be held securely in the telescope.", "Next, the glass disk oscillates as an automated tool rubs a compound against it to polish it.", "A worker then applies some of the compound onto a polishing disk and works the surface of the glass against it repeatedly.", "This hand polishing improves the surface considerably.", "In the laboratory, a technician compares the primary mirror glass to a grid to verify that the dimensions are accurate.", "He aims a laser at the glass.", "A computer analyzes the reflected light.", "If the angle is off by 1,000th of the width of a hair, the telescope's image could be blurry.", "The glass is now ready for its mirror finish.", "They lock it facedown in a vacuum chamber.", "They add small amounts of titanium oxide, silicon monoxide, and aluminum.", "They close the chamber, tightly encasing the contents, and then pump out most of the air, creating a partial vacuum inside.", "They activate a 6,000-volt electrode.", "This sparks a glowing discharge of ions onto the now rotating glass disk.", "These ions blast any lingering contaminants from the glass to give it a serious cleaning.", "They heat the aluminum, titanium, and silicon pellets, which evaporate into a cloud of vapor.", "Atoms condense landing on the surface of the glass to form a glossy mirror surface.", "It takes just minutes for this highly reflective coating to be applied.", "This telescope mirror is now ready to reflect light from the stars and planets in the sky.", "Next, a technician screws lights into the metal housing for the primary mirror.", "He adds a mount mechanism for the eyepiece, complete with knobs for focusing.", "He flips over the assembly and slides the precision-made mirror onto the housing.", "A cork ring cushions the mirror so a retaining ring can be installed without a scratch.", "The telescope's primary mirror is now secure to the housing.", "He pieces together the three-part baffle, then screws it to the lens holder protruding from the center of the telescope mirror.", "He joins the baffle and mirror assembly to the telescope tube.", "The tube has already been equipped with a secondary mirror that will bounce reflected images from the primary mirror back for magnification and viewing.", "It's taken about six weeks to build this telescope.", "And now it's ready to help unravel the mysteries of the universe." ]

{ "things": [ "Yogurt", "Candles", "Neon Signs", "Bookbindings" ] }

[ "Today on \"how it's made\"...", "Yogurt...", "Candles...", "Neon signs...", "And book bindings.", "Your mother probably told you not to put anything with germs in your mouth.", "Well, it turns out she was wrong.", "Yogurt is one of the healthiest foods you can eat, yet it's chock-full of germs-- bacteria, to be precise, bacteria that are actually good for your digestive system.", "The first step in making fruit-flavored yogurt is to inspect the fruit.", "Workers discard any skin or pits that slip through and any pieces that are discolored or bruised.", "The fruit doesn't go into the yogurt as is.", "First, they turn it into jam.", "To give the jam just the right texture and taste, they have to weigh all the ingredients carefully before pouring them in the mixer.", "The first ingredient is water, followed by artificial and natural flavoring, and stabilizers to give the jam an even consistency.", "Certain types of fruit aren't colorful enough on their own, so the factory adds artificial coloring.", "Next comes two types of sugar-- fructose and sucrose.", "The mixer heats everything to 140 degrees fahrenheit to help dissolve the dry ingredients.", "The machine pumps out and refeeds the mixture so that it blends evenly.", "Then more coloring, followed by the fruit, followed by another hour or so of heating and mixing.", "Then they heat the jam to a minimum of 176 degrees fahrenheit for another hour to kill off any harmful bacteria.", "To prepare the yogurt, they mix different powdered milk products with milk and cream.", "For low-fat yogurts, they use fat-free milk and skip the cream.", "Once they've blended the ingredients, they heat them to 176 degrees fahrenheit or higher for just 30 seconds.", "That's all the time that's needed to pasteurize the mixture.", "While it's now bacteria-free, there's another problem.", "Milk and cream naturally separate because cream is lighter due to its fat content.", "So on to the next step, homogenization-- blending the milk and cream together.", "The homogenizer's pistons crush the fat globules.", "This enables the two liquids to merge.", "The mixture then goes into fermentation tanks heated to 113 degrees fahrenheit.", "Workers pour in a packet of live bacteria bought from a factory that breeds bacterial cultures for the dairy industry.", "Fermentation takes 6 to 20 hours depending on the style of yogurt.", "The factory manufactures the yogurt containers right on the packaging line using plastic sheets and paper labels.", "The machine heats the plastic and molds it into containers.", "A split second later, it wraps the containers in paper labels.", "You can view that dual operation best from underneath the machinery.", "Now they fill the containers with the combination of yogurt and fruit jam.", "To protect the yogurt from contamination, the air in this part of the machine is strictly controlled and filtered.", "The bacteria in the yogurt is what's known as good bacteria, the type naturally present in our intestines.", "They produce a compound called acetaldehyde.", "That's what gives yogurt its distinctive flavor.", "The red dots are electronic sensors that verify the fill level.", "The container covers are made of thin but strong aluminum.", "First, the sheet of covers passes upside down over a printer which stamps on the expiration date.", "Unopened, this yogurt will stay fresh for more than 40 days.", "Then the sheet of covers turns right side up to be heat sealed onto the containers.", "Finally, the machine automatically divides the containers according to whatever pack format the factory is producing.", "The invention of the candle can possibly be credited to ancient egyptians, who dipped reeds into animal fat and lit them.", "Today's wax candles provide a romantic atmosphere, light when there's power failure, and, when blown out, a grand finale to a rousing rendition of \"happy birthday\".", "At the heart of every candle is a wick made from woven or twisted cotton cord.", "To stiffen up that limp cord, they run it through a tank of liquid paraffin, a wax derived from petroleum.", "The cord then passes over a cooling drum whose cold surface instantly hardens the wax coating.", "The now rigid cord winds onto a spool, ready to be cut into wicks.", "There are several candle-making methods, all of which work on the simple principle that hot wax turns hard and white when it comes into contact with cold air or a cold surface.", "This process is called candle pressing.", "The hot paraffin travels from the holding tank to a set of sprinklers inside a 20-foot-high refrigerated chamber.", "The sprinklers shoot the wax upwards into the cold air.", "Like falling precipitation transforming into snowflakes, the wax droplets transform into wax flakes.", "They land at the base of the chamber, then travel to a hydraulic press.", "The press forms them into candles, using pressure but no heat, and pierces a hole through the middle for the wick.", "The air in this part of the plant has to be less than 77 degrees fahrenheit, or else the flakes will melt and stick together, jamming the machine.", "Now the candles travel to the wicking machine, which cuts and inserts a wick into each candle.", "Another candle-making method is the dipping process.", "They install 96 wicks on each frame of an automated dipping machine.", "One after another, the frames dip the wicks into a tank of clear paraffin.", "As the frames rise from the tank, gravity pulls the wax downward, creating a conically shaped coat of wax.", "By the time a frame has made the circuit and returned to the tank, the wax coat is hard and white.", "The wicks go for a second dipping, followed by another go-round.", "This continues until 25 dips later.", "The tapered candles are .", "8 of an inch in diameter.", "To turn these white candles into colored candles, they dip them into a vat of dyed paraffin...", "Then immediately after into cold water to harden the color coat.", "To produce votive candles, the factory uses an automated molding process.", "They heat each molding table, flood it with paraffin, then cool the table.", "The wax overflow compensates for the shrinking that occurs during the 20-minute hardening phase.", "Once the wax hardens, they scrape off the excess and remelt it to use for the next batch.", "A pin inside each mold created a channel for the wick.", "Now another type of automated wicking machine inserts a wick and secures it in place with the metal clip at the base of the candle.", "They make certain specialty candles on a manually operated dipper rather than by automated machine.", "These altar candles are made of paraffin and 66% pure beeswax, as required by vatican law.", "To create their cylindrical shape, the worker has to flip the frames after every dip to equalize the wax.", "It takes 90 dips to build a 3-inch diameter.", "The candles still come out slightly tapered, so they go through a heated die to adjust their shape.", "No longer just a staple of religion, ritual, or romance, today's candles are a hot decorative item.", "Neon signs are made of glass tubes bent into letters or shapes and filled with inert gas.", "When the electric current hits the electrodes in the tubes, electrons flow through the gas, making its atoms glow.", "The type of gas and glass determine the color of the light.", "In a clear glass tube, argon gas gives off blue light while neon gas produces red light.", "To create vivid designs, they can parlay those two base colors into more than 80 additional colors by using glass tubes that are colored with fluorescent powders.", "For instance, blue glowing argon gas in a yellow tube creates a green light.", "To shape the tube, they use a glass-blowing technique.", "Following a pattern drawn on a fire-resistant sheet, they mark where they have to bend the tube.", "Then they heat each spot on a device called a ribbon burner, whose propane flame is a blazing 1,200 degrees fahrenheit.", "Within half a minute, the glass softens enough to be pliable.", "They gently bend the tube, then blow into the uncorked end to restore the tube's original diameter.", "With each bend, they check the shape against the pattern, every so often pressing a wooden block along the tube to equalize the width.", "Argon gas emits steel-blue light, but this blue-colored tube will change that to dark blue.", "After shaping, they cut off the excess and rub the coloring powder off the ends.", "Now they can attach these glass casings, which contain electrodes.", "They fuse an electrode to each end of the tube using a propane hand torch and a flexible latex blowing tube.", "They seal the glass around one electrode but leave the other one open.", "Then, using what's called a crossfire burner, they create a tubulation, a thin tube with a bubble that will act as a passage way into the open electrode.", "They fuse the tubulation to that electrode...", "Then carefully inject a drop of mercury into the open end of the tubulation.", "Argon gas needs a touch of mercury to brighten the color it emits.", "Neon gas doesn't.", "Using what's known as an end torch, they fuse the open end of the tubulation to a long glass tube leading to a pumping system.", "They connect the electrodes to the system, then power it up.", "The pump vacuums out the air, then injects the gas.", "The electrical current makes the atoms in the gas glow.", "To trap the gas inside the tube, they use the crossfire burner to remove the tubulation and seal off the open electrode, making sure the drop of mercury has descended into it first.", "They dip the back of the sign into black paint.", "This will make the lettering or design stand out.", "They use a brush to spread the coat evenly and remove the excess.", "Next, they'll light up the sign at high voltage for a half hour.", "This will dry the paint and, more importantly, transform the liquid mercury into vapor that spreads throughout the sign.", "Using transparent clips, they mount the sign onto a black plexiglas background to make it stand out even more.", "Finally, they connect the protruding electrode wires to a transformer.", "This transformer converts the standard 110-volt current from our electrical outlets into high-voltage current, into the 3,000 to 15,000 volts you need to light up a neon sign.", "Hardcover books have bindings made of heavy paperboards covered with cloth, leather, or plastic.", "Soft-cover books have flimsier paper bindings.", "While bookbinding on a commercial scale is all mechanized today, you can still find craftspeople who skillfully bind books by hand.", "Book bindings date back to second-century egypt where christian monks sewed sheets of papyrus together, then enclosed them in leather-covered boards connected by strips of hide.", "Monks in medieval europe stitched together handwritten parchments, binding them between wooden boards often covered in leather.", "Sometimes they were embellished with gold leaf and gems.", "The 16th century saw the arrival of cheaper printed books with simple pasteboard bindings.", "Today, commercial bookbinding is highly mechanized.", "The process starts with large sheets of paper, each containing several consecutive pages of the book.", "A worker positions a stack of each sheet into a machine appropriately called the guillotine.", "Its sharp blade drops down and chops off excess paper.", "After trimming, the stack moves into a machine called the folder which folds each sheet into book size with the pages in the right order.", "As we see here in slow motion, the machine starts by perforating the fold line.", "Then the sheet moves along the conveyor belt until it hits the stopper to the far right.", "That stop position aligns the perforation between two rollers.", "Watch in slow motion how those rollers pull the page down, pressing a neat fold.", "This process repeats itself for each fold of the sheet.", "The result of all that folding is what's called a signature, a unit of pages in the correct order but still attached to each other.", "A book is made up of several signatures.", "Another machine now assembles them in the right sequence, along with the cover, for binding.", "There are many different binding methods.", "This one is called wire stitching.", "As we see here in slow motion, the machine drives heavy-duty staples right through the spine of the signatures and cover.", "The staples are cut from steel wire that's so strong, you have to tear the book apart to remove them.", "Here's another slow-motion look at the stapling action.", "This is another binding method called perfect binding.", "First, a scanner ensures the pages are in order.", "Then the covers go on.", "With traditional bookbinding, they sew these components together.", "In the perfect bind process, they glue them together.", "To do that, the machine first feeds the assembled books, spine side down, onto trays.", "The trays compress the pages.", "Then a saw underneath cuts off the folds, detaching the pages from each other along the spine.", "But that cut creates a smooth edge to which glue would have difficulty adhering.", "So a second saw notches the spine, creating a rough, glue-friendly surface.", "The notched spine now runs over rollers that coat it in hot glue.", "Finally, two conveyor belts merge-- one with the book's pages assembled with the notched and glue-coated spine, and the other with the book's cover.", "The machine presses the cover onto the spine.", "The book now travels along the conveyor belt for another 30 seconds, during which time the glue air dries.", "By this stage of the process, with either binding method, most pages on the unbound sides of the book are still attached by folds.", "To separate the pages, the books go through a machine called a three-knife trimmer.", "It cuts the folds off the three sides simultaneously.", "The book is now finished.", "Fine-quality books still have some bindings.", "But your average book today is wire stitched or perfect bound.", "Those newer methods are far less costly, yet still produce books that are sturdy and durable." ]

{ "things": [ "Aluminum Boats", "Alpine Horns", "Luxury Watches" ] }

[ "The first aluminum boat was launched as a simple skiff in the middle of the last century.", "Fishermen loved the lightweight hull because it could be pulled in and out of the water more easily than the wooden boats of the day.", "Decades later, aluminum boats have gone high-end, but they still have that lightweight appeal.", "Since aluminum hulls aren't as heavy as other types, these boats will go farther on a tank of gas.", "They make them from high-grade aluminum that's corrosion-resistant.", "Rollers flatten the metal, and a blade called a slitter cuts it to length.", "A computer-guided router then makes precise cuts to produce parts that will fit together perfectly, like this bracket to reinforce the stern.", "They cut the boat's larger components with a computerized plasma torch.", "It can cut a wider path than the router.", "They transfer the cut parts to a pallet.", "This is the boat's bottom panel.", "A long piece of aluminum will be the gunnel, which is the upper edge of the hull.", "They bend it around a wooden template to give it the correct curvature.", "Next, they reinforce the bow with an extra plate of aluminum to withstand pounding waves.", "They brace the other end with numerous stiffeners and screw them into place.", "The screws act as a clamping system, until the parts of the boat can be permanently attached.", "A line of caulking helps waterproof the seam between the hull and the back of the boat, called the transom.", "Again, screws hold everything together, as the painstaking clamping continues.", "They join the two sides of the bow and hold the ends together with a vise grip.", "This strip of aluminum will act as the spine of the bow.", "It's called the brace plate.", "More screws tack it into position.", "They attach the sides to the rest of the hull.", "Now they drill hundreds of holes along the seams and plug them with rivets.", "They extract the clamping screws and fill their holes with more rivets.", "They install the gunnels on the rim of the hull.", "And now it's time for the tank test.", "They lower the boat into a tank to confirm that it's watertight.", "If they find any leaks in all those rivets, they'll make the necessary adjustments.", "They spray foam into the bottoms and sides to keep this boat afloat in the event that something punctures it.", "And then they rough up the surface to allow paint to better adhere.", "They move to the interior and install felt on the storage panels to give them a more finished look.", "Then they lay the carpeting port to starboard.", "Next comes the plastic fuel tank.", "All they have to do is connect the fuel-line hoses and secure them with a stainless steel collar.", "The dash panel fits onto the front.", "It's pre-wired, so they simply connect it to the boat's main wiring harness.", "Next, they apply lubricant to the motor's propeller shaft.", "This allows the propeller to slide on easily.", "They tighten it with a pneumatic ratchet.", "Then they hoist the motor onto the stern and bolt it into position.", "With the luxurious interior now complete, this metal boat bears very little resemblance to its utilitarian predecessors.", "This particular model doubles as a fishing boat and a pleasure craft.", "And it proves that aluminum boats are no longer just a basic form of transportation.", "The alpine horn dates back some 2,000 years to the celtic tribes that inhabited the northern slopes of the alps.", "Traditionally, mountain dwellers blew the horn to announced daily activities, such as round-up time for livestock.", "As modern communications reached those altitudes, the horn's role became strictly musical.", "an alpine horn's sound travels about 5 miles, thanks to the instrument's length and shape.", "Following a centuries-old tradition, the horn maker harvests spruce at a specific time in the lunar calendar, when tree wood is supposedly most resonant.", "Once the spruce logs dry out, which takes at least nine years, he saws them into planks.", "Then he traces and cuts out the shape of the horn's curved bell twice-- once for each half.", "He measures and marks how much wood he must hollow out with his drill press.", "It's tricky because from top to bottom, the bell's inside cavity progressively widens and deepens.", "Next, he runs glue along the perimeter of both bell halves, then joins them with a sheet of newspaper in between to prevent a permanent bond.", "He'll have to pry them apart later to finalize their shape.", "Once dry, he tears off excess newspaper, traces the circumference of the bell's top and bottom openings, then measures and draws the bell's shape between those two openings.", "Once again, following the lines he drew, he cuts out the shape.", "To check his work, he uses a series of sizing templates.", "He lines them with charcoal, then slips the first template onto its designated position at the top of the bell.", "The charcoal marks any wood that he still needs to shave off.", "He repeats this procedure with each template, working his way down until the bell is rounded to the proper external dimensions.", "Now for the bell's internal dimensions.", "The horn maker detaches the halves.", "He scores a line running the length of the bell half on each side.", "This marks the inner-wall thickness he's going to create.", "Using a grinder with a rough grit abrasive, he wears away the wood right up to the score lines.", "The holes he made earlier tell him how deep to grind.", "Then he switches to a finer grit abrasive to grind the walls down another millimeter.", "He checks his work with a measuring gauge, then glues the halves together again, this time permanently.", "The horn maker constructs the bell's other section in halves, as well, rounding them off on a lathe.", "He coats them in glue and wraps them in rattan.", "The rattan solidifies the structure somewhat but is primarily for decoration.", "Once the glue dries, he'll glue aluminum connecting dowels to each section.", "These will enable the musician to assemble and disassemble the horn parts.", "The bell is truly the alpine horn's showpiece.", "Horn makers typically embellish it with painted scenes or motifs.", "This horn will boast a colorful bouquet of traditional swiss flowers.", "Fully assembled, an alpine horn is between 10 and 13 feet long-- the length determining the pitch of the instrument.", "Musicians use lip movements to modulate the vibration of the air column inside.", "Different vibrations produce different notes.", "throughout most of the 19th century, the wristwatch was a piece of jewelry worn by women.", "Men carried pocket watches.", "It was during the boer war in 1899 that british soldiers decided fumbling around for a pocket watch during battle was a serious waste of time.", "The tools of the trade haven't changed much since pocket watches ruled the day.", "In this swiss workshop, the mechanisms are meticulously handcrafted, just like they were centuries ago.", "The watchmaker starts by polishing parts to a mirror finish.", "He mixes his lavender and almond oils with a diamond paste.", "He extracts a part called the cage from its storage solution, sets it in the paste, and polishes it against a zinc block.", "He brushes the dust off the cage with a soft piece of wood.", "Another watchmaker polishes its edges, removing tiny bits of material so other parts can fit to it.", "The technician attaches gears to the cage.", "These gears are the balance and escape wheels.", "He fixes the gears on tiny rubies because they don't wear down easily.", "The second half of the cage completes this mechanism, called the tourbillion.", "Invented in 1789, these rotating gears in a cage counteract the effect of gravity on timekeeping for more accurate results.", "The watchmaker now magnifies the assembly and projects the image onto a screen to confirm that the gears and levers are interacting correctly.", "Next, he secures a wound-up spring in a barrel.", "This is the main spring that powers the gears of the watch.", "He dips a pin in some grease and uses it to lubricate the spring.", "Then he caps the mainspring with a cover and tamps it down with a special tool.", "He carefully positions the barrel in its slot on the main plate.", "The watchmaker now installs another series of gears on the main plate.", "They'll transfer power from the spring to the tourbillion.", "He attaches the bridge to the gears to act as a pivot as they turn.", "Another spot of grease keeps these wheels turning efficiently.", "With the spring barrel and its transmission gears assembled, production now reaches a critical moment.", "He places the mechanism in a holder that makes it easier to install the tourbillion.", "It's a tricky job.", "The cage must be precisely positioned for its gears to receive power from the spring.", "He now transfers the mechanism to another holder to insert the winding stem.", "Next, he engraves the circular pattern onto a bridge plate.", "This high-end finish is called perlage.", "The technician attaches the textured bridge to the dial side of the watch.", "He assembles more gears and a numbered wheel to the bridge.", "These gears will provide the date information for this timepiece.", "Another bridge secures the gears that lead to the date wheel.", "He fastens it with tiny screws.", "He slides the second date wheel onto its axle and checks the setting mechanism.", "We'll have the up-to-the-minute details as this watch gets a beautiful face.", "Even in the age of digital and electronic wristwatches, the mechanical watch has an appeal that's timeless.", "Some are among the most complex in the world and can cost in the six-figure range.", "At that price, time is truly a luxury.", "In a factory nestled in the scenic swiss countryside, a highly-skilled team has assembled the inner workings of a luxurious tourbillion wristwatch.", "Now a watchmaker fits the handcrafted face onto the mechanisms.", "Using a special tool, he presses the hands onto an axle at the center of the watch.", "This enables him to set the time and date.", "The watch will be encased with 18-karat red-gold bezels sealed against the elements with rubber rings.", "He now fastens the middle casing to the mechanism, then completes the installation of the winding stem and crown.", "The watchmaker lubricates the bridge for the auto-winding system, then engraves a parallel-ribbed pattern onto it.", "This adds visual interest to the bridge, making this luxury watch look good inside and out.", "After the bridge has been set with jewels, it's ready to be installed at the center of the watch, where its jewels will keep parts from rubbing against each other, causing wear and tear.", "An artist now engraves the rotor that's to be attached to the bridge.", "It's this part that will automatically wind the watch.", "It's a signature piece that can reflect the customer's individual taste.", "This stylish-looking rotor is now ready to be secured to the bridge.", "Once installed, even the slightest movement will cause this rotor to oscillate, and that action winds up the mainspring of the watch.", "The watchmaker now shields this timepiece with a glass dome and then vacuums dust from the next gold bezel.", "He carefully cleans this clear sapphire window because even the tiniest speck of dirt could cause the watch to fail.", "He snaps the front bezel onto the watch, then, using a special device, he presses the bezel to secure it.", "This action also squeezes the rubber ring between the bezel and the watch to create waterproof seal.", "This watch will now be water-resistant to a depth of nearly 330 feet.", "The back casing screws into place so it can be removed for maintenance work during the life of the watch.", "Using a special tool, he tightens the casing to just the right tension.", "He then inspects the watch to confirm that the rotor moves freely within the case.", "Next up is a computer analysis of the mechanism.", "A device holds the watch and simulates wrist movements, while the computer evaluates its accuracy.", "that's the sound of a minute repeater, which is a feature on some models.", "When triggered, it chimes the time.", "And now this watch takes the plunge into a container of water.", "If bubbles appear, it would signify a leak.", "But there are none, so this watch is waterproof.", "This incredible watch will set you back $150,000.", "But it will be an heirloom piece that stands the test of time." ]

{ "things": [ "Cast Iron Cookware", "Biodiesel", "Clothes Hangers", "Stone Wool Insulation" ] }

[ "Cast-iron cookware is renowned for its superior ability to retain heat and diffuse it evenly.", "Bare cast iron, however, requires regular oiling to ward off rust-- not so with enameled cast iron.", "A glass-enamel coating encases the iron, making the cookware entirely maintenance-free, forever.", "Since 1925, this french company has been producing enameled cast-iron cookware.", "Its high-end products are renowned for their thin walls, which makes it the most lightweight cast-iron cookware available.", "The secret-- the mineral levels in the iron recipe.", "At the foundry, they begin with pig iron, which has high carbon content.", "Then they melt in a calculated amount of steel to further boost the carbon level.", "The melting oven heats the metals to 1,520 degrees celsius, liquefying them in just 45 minutes.", "Workers add a powdered chemical to agglomerate the natural impurities in the iron, then scoop those bonded impurities out.", "Meanwhile, workers mount a two-part mold template onto a machine which produces the sand molds with which they'll cast the cookware.", "The machine injects the sand mix into the templates.", "The mix contains clay, water, and proprietary ingredients which makes the sand compact well.", "Compaction is critical because just one single grain of sand displacing from the mold would produce a flaw on the cookware.", "It's essential that the pouring temperature be precise and consistent, so they transfer the iron from the melting oven to a temperature-maintenance oven.", "From there, they pour the molten metal through a mere 1/10th-of-an-inch gap between the mold halves.", "The process is entirely automated because the pouring angle and speed are critical.", "The molten iron cools and solidifies in 20 minutes.", "Then the molds drop onto a vibrating mesh conveyor.", "The shaking releases the cast cookware from the mold, along with the metal that solidified in the flow channels leading to the mold cavity.", "The cookware moves into a closed chamber where a high-pressure gun blasts the surface with steel balls to remove all remaining grains of sand.", "At this stage, the cookware has rough excess metal where the two parts of the mold met.", "So now workers smooth away these burrs using a grinding wheel on the outside...", "And a grinding pin in the tight spots.", "The cookware is now ready to be prepped for enameling.", "A machine now blasts the entire piece with steel grits, making the surface texture uniform so the enamel will adhere evenly.", "The first coat of enamel is strictly to protect the cast iron and prevent it from rusting.", "Enamel is a form of glass.", "However, this enamel is engineered to be flexible because metal cookware naturally expands as it heats and contracts as it cools.", "After a trip through a dryer, the enamel goes into an oven at more than 1,500 degrees fahrenheit for about 45 minutes.", "During this firing, the hair-thin enamel coating becomes translucent.", "The second coat of enamel completely seals the porous surface.", "It's made of some 20 components, including enamel chips, pieces of clear glass, and pigment powders for color.", "An automated spray system coats the inside first.", "Workers wipe the edge to prevent the piece from sticking to the conveyor, then the handle because they'll paint that a different color.", "They spray the handle manually, then the automated system coats the rest.", "The iron recipe contains a high level of the mineral silicate, which helps the enamel adhere well.", "Once again, the cookware goes through the dryer, then into the oven at more than 1,500 degrees fahrenheit for about 45 minutes to vitrify the enamel.", "Once the cookware cools, it undergoes a final visual inspection, the last of 30 quality-control checks throughout the production process.", "Enameled cast-iron cookware lasts for generations because it doesn't warp over time and remains food-safe for life.", "Biodiesel is a more eco-friendly diesel fuel that's made from vegetable oil or animal fat.", "Unlike regular diesel and gasoline, producing biodiesel doesn't require petroleum.", "Instead, the raw materials are locally available and can be recycled from waste.", "If your car has a diesel engine, it can run on biodiesel fuel, usually without requiring any modifications.", "While biodiesel and petroleum diesel are similar in energy efficiency and fuel economy, biodiesel is more eco-friendly.", "For starters, it can be made from what would otherwise have been waste-- for example, from vegetable oil from the kitchen of your local fast-food joint.", "The restaurant simply discards its used fryer oil in a receptacle out back.", "Every few days, a vacuum truck comes by to collect it.", "In its current state, the oil contains water and food particles, making it unusable for biodiesel production, so the truck transports it to a filtering plant.", "There, they pump the oil into a holding tank, then heat it up to draw out the water.", "Once they drain the water, the oil is ready to enter a multi-stage filtering process.", "First, the oil goes through a vibrating sieve which strains out the larger pieces of debris.", "After this first filtering, the oil is already visibly cleaner.", "Next, it passes through a second vibrating sieve.", "This one has a finer mesh.", "Therefore, it catches smaller particles of debris.", "After this second stage, the oil looks clean but still contains microscopic debris, so it enters the third and final filtering stage-- passing through 20 ultra-fine filter cloths which trap any particle larger than one micron in size.", "A micron is about 80 times smaller than the width of a human hair.", "The captured debris leaves a muddy residue on the filters.", "That vegetable oil, which once deep-fried potatoes, is now ready to cook up some diesel fuel.", "Another source of oil for making biodiesel is beef tallow-- oil derived from cow fat.", "Biodiesel producers typically buy tallow from facilities like this one, which specialize in cleaning cow hides for leather tanneries.", "Sharp, revolving blades shear off the fat from the back of the hide.", "The fat drops onto a conveyor, which moves it into a steam-injection cook tank.", "The tank heats the fat to a gentle boil, extracting the oil.", "Everything else leaves the tank and drops into a waste container.", "The oil moves onward, passing through a two-stage filtration process.", "Whether the raw material is vegetable oil or beef tallow, the biodiesel producers refer to this main ingredient as feedstock.", "When the feedstock arrives at the biodiesel plant, it goes into a holding tank until production time.", "This demonstration illustrates the production recipe.", "They take the feedstock and combine it with methanol, a type of wood alcohol, as well as with a catalyst, which triggers a chemical reaction.", "A processing unit mixes everything thoroughly while applying heat and pressure.", "The resulting chemical reaction produces a harmless byproduct, glycerin, a common ingredient in soaps and cosmetics.", "Processing consumes much of the methanol.", "Then they remove even more, leaving just a tiny percentage of it in the finished biodiesel.", "To ensure their fuel meets international regulatory standards, the plant's quality-control lab samples from each production run.", "In this flammability test, they heat the fuel to 275 degrees fahrenheit, then apply a flame to see whether the gases ignite.", "If they do, they have to remove more methanol to make the fuel safe.", "If they don't ignite, the fuel meets international safety standards.", "Biodiesel costs more at the pump, but emits significantly less carbon dioxide and monoxide and 85% fewer cancer-causing agents into the air we breathe.", "Until the mid-1800s, people folded or laid their clothes flat or hung them on hooks or pegs.", "Once it became more common to store clothes in a wardrobe, someone-- historians don't know exactly who-- invented the clothes hanger, a hanging device shaped like human shoulders.", "Since the mid 19th century, hundreds of inventors have patented various shaped hangers, many of which are still being produced today.", "This czech company makes wooden hangers in several styles.", "It uses beech, a hard and durable type of wood.", "The damp logs air-dry outdoors for seven months, then go into a kiln for three to four weeks.", "Drying the wood is critical.", "Otherwise, the hangers would expand and contract with temperature changes and eventually crack.", "Workers first use a band saw to slice the logs into 2 1/2-inch-thick planks.", "Then they put each plank through a broaching machine.", "Inside, a toothed blade planes the wood, rendering the top and bottom surfaces level and smooth.", "Next stop is a grinding machine which contains abrasive belts.", "Workers feed the planks into the machine one at a time.", "As each plank passes through, the belts above it sand the tops silky smooth.", "When the plank exits the machine, workers flip and refeed it to smooth the other side.", "An automated saw cuts each plank in half...", "And trims the halves to a specific dimension.", "The now-smaller planks go into another grinding machine which sands the sides smooth.", "Now the hanger shaping begins.", "Workers stack 10 planks and, using a circular saw, cut them to the same length, the ends at a 60-degree angle.", "They mount four planks at a time on a milling machine and cut a tongue-and-groove profile on the edges.", "They'll later connect the hanger parts by fitting the tongues into the grooves.", "Stacking six planks now, they trace a hanger-shaped template on the top surface, then carefully follow the trace line with a jigsaw.", "Each plank is now roughly shaped into a half a hanger, which they call a lamella.", "This particular hanger is designed for dresses, so they mill a groove in the shoulder of each lamella for garment straps.", "Then an automated milling machine refines and finalizes the hanger's shape, smoothing the roughly cut wood in the process.", "Next, with strong cabinetmaker's glue, they coat the tongues and grooves of two lamellas, then fit them together on a press.", "They let the glue dry for a day, then saw the point off the top.", "This creates a flat area into which to insert the hanger's hook.", "There's already a hole for it there, made when they milled the tongue-and-groove profile.", "Next, they sand the joint to remove excess glue and smooth out any nicks or tears in the wood.", "Then they round the angular joint.", "To seal and protect the wood, they now spray the entire surface with varnish.", "When it dries, they do a rough sanding, then apply a second coat and let that dry.", "Many customers want their logo printed on the hangers they order.", "The printing machine coats a logo-embossed rubber pad with ink.", "A sponge dabs the pad, then stamps the logo onto the hanger.", "Finally, the hanger's iron hook-- it's either nickel-plated for a silver tone or brass-plated for a gold tone.", "Workers position the hook.", "Then a press rams it into the wood 4/10 of an inch deep.", "The hook has screwlike threads at the base which grab and lock into the surrounding wood.", "For certain models, the factory stains or paints the wood prior to varnishing it.", "After all, many people like their clothes hangers to make a fashion statement, too.", "An erupting volcano led to the invention of stone wool insulation a century and a half ago.", "It was observed that volcanic lava could be whipped into woolly tufts by prevailing winds.", "Soon, this was being replicated in factories to produce stone wool for insulation.", "Shaped into batts, stone wool insulation can be tucked snugly between the studs of a framed wall.", "It acts as both a thermal and acoustic insulator.", "And here's the soundproofing proof.", "In this demonstration, an activated alarm goes into a box lined with stone wool.", "When the lid is closed, the sound is contained.", "And when it's lifted again, the annoying sound is back.", "They make stone wool from basalt rock and slag recycled from the steel industry.", "The process is fueled by coke, which is a form of coal.", "Basalt rock is solidified lava formed when rock melts underground and then quickly cools.", "After the rock has been partially crushed at the quarry, a loader scoops it onto a screen to separate the bigger pieces from the fine particles.", "The particles will be processed into briquettes, which can be used in the production of stone wool, along with the bigger pieces of rock.", "The rock and briquettes, along with the steel slag, melt into lava in a furnace.", "Temperatures reach 2,700 degrees fahrenheit-- as hot as a volcano.", "A spinning machine whips the lava into thin stands of stone wool in a process that's like making cotton candy.", "The strands form tufts, and a little binding solution holds them together.", "A spray of oil adds water repellence.", "Now a fleecy web, the stone wool rides a conveyor to the factory's upper level, where it spills into a huge pendulum device.", "The pendulum swings to and fro to layer the stone wool in a zigzag pattern.", "The number of layers varies, depending on the kind of insulation being made.", "The now-layered stone wool travels between rollers that compress it substantially, adding density to the wool.", "Automated pushers tuck in the pack on each side as the wool enters a long oven.", "The heat cures the binder applied earlier, allowing the compressed fibers to hold their shape.", "The now-tighter pack exits through a cooling zone and travels under a roller which squeezes it to make the fibers more flexible.", "Circular blades then slice the moving mass of stone wool lengthwise.", "A branding tool burns the r-value and company name onto the surface of the insulation as it moves forward.", "Robotic arms swing back and forth to slice the insulation to its final dimensions.", "Instead of sharp, steel blades, these robots use high-pressure water jets to make their cuts.", "The jets do a precise job without generating dust or waste, and the stone wool doesn't absorb the water from the jets.", "The sheer density of the wool makes it moisture-resistant, along with the oil added to the fibers during spinning.", "To demonstrate stone wool's water-repellent qualities, they pour water directly onto the surface.", "There's no absorption.", "The water just runs off.", "In this routine test, a worker torches the wool, and it doesn't catch fire.", "Stone wool can withstand temperatures of almost 2,200 degrees fahrenheit due to its natural properties.", "It's even cool to the touch on the other side.", "Once it's passed several quality-control tests, the insulation heads for the packaging line.", "Grippers pull on a roll of plastic tube packaging, and hot jaws cut and seal one end to form an open bag.", "Mechanical fingers hold the other end open as machinery slides it over a metal spout.", "A compressed stack of insulation is pushed into the spout.", "The spout expands, and the insulation is released into the bag.", "The spout then retracts, and the process is repeated.", "Machinery heat-seals the open end.", "From a pile of basalt rock and recycled steel slag to a bag full of insulation, it's been a wild and woolly ride." ]

{ "things": [ "Alkaline Batteries", "Wheelchairs", "Flutes", "Cowboy Boots" ] }

[ "Today on \"how it's made\"...", "Alkaline batteries.", "Wheelchairs.", "Flutes.", "And cowboy boots.", "A battery produces an electric current when its positive end, called the cathode, and its negative end, called the anode, connect via a conductive pathway in the battery-operated device.", "This pathway conducts electricity when three components-- two electrodes and an electrolyte-- interact.", "These alkaline batteries are the rechargeable type.", "They last for years, depending on how you use them.", "The factory begins production by cutting nickel-plated steel into oval pieces, then gradually shaping each piece into a tube, called a console.", "The console houses some important chemical ingredients-- graphite, which conducts electricity...", "Silver catalyst, which reduces chemical-pressure buildup...", "Manganese dioxide, the main ingredient in the cathode...", "Barium sulfate, which binds the cathode ingredients, zinc, the main ingredient in the anode, a gelling agent to keep the zinc particles suspended, and finally, potassium hydroxide, which interacts with electrodes to produce electricity.", "This 25-head press shapes the cathode's powdered chemicals into hollow pellets.", "The press churns out 25,000 pellets an hour.", "A machine called a console press then inserts three pellets into each console-- three because these pellets are so fragile that three smaller ones are easier to manipulate than one big pellet would be.", "Here's the insertion in slow motion.", "The next machine makes a ridge on one end of the console to help seal it.", "Plastic holders, called pucks, hold the consoles still as nozzles apply a sealant to the top, which is the negative end of the console.", "Next, they cut a roll of paper into small strips.", "These strips are called separators.", "They have microscopic holes that permit the flow of ions, electrically-charged molecules, between the cathode and the anode.", "A hot-melt glue machine deposits a small amount of glue into the separator, now rolled, and seals the positive end of the paper tube.", "The glue cools and hardens over the next minute and a half, as the consoles move along a conveyor.", "The next machine injects an electrolyte-- a potassium hydroxide solution.", "It takes nine minutes to soak through the separator liner into the cathode pellets.", "Nozzles then inject about .", "15 ounces of zinc gel into the anode cavity.", "Only about 2/3 of the gel weight is actually zinc.", "The other 1/3 is this company's closely guarded trade secret.", "It's what makes these batteries rechargeable.", "The zinc gives the gel its silver-gray color.", "A welding machine fuses 1 1/2-inch nails onto the cap of the battery.", "This is where the current collects before it's discharged.", "The machine ejects the cap when finished, and another machine inserts it into the negative end of the battery.", "This cap includes a safety feature crucial to rechargeable batteries-- it can resist high pressure.", "But if heat or power surges cause excessive pressure, a tiny vent prevents the battery from exploding.", "The machine folds over the console lip to enclose the contents.", "A rotating, three-head crimping machine then makes a ridge in the finished battery to reduce the chance of leakage.", "An electrical testing machine contacts each battery for 200 milliseconds to ensure it has at least 1.5 volts.", "These batteries will be ready to use right away.", "No need to charge them first.", "The labeling machine uses light sensors to time the labeling of each battery casing.", "The plastic label lists technical information and adds additional insulation.", "Then three seconds in an oven at 388 degrees fahrenheit shrinks the labels to a tight fit.", "Spain's king phillip ii was the first disabled person to get around on wheels.", "He ruled from a rolling chair with foot rests in the 1500s.", "Today's wheelchairs are widely available, but at a price of a few hundred to several thousand dollars, depending on the features.", "This wood, leather, and steel chair is a world war ii antique.", "A modern wheelchair literally runs circles around it.", "With more than 150 possible design options, today's wheelchair fits the user and the user's lifestyle.", "The wheel rim is aluminum.", "The spokes-- steel.", "It's much like a bicycle, except for these-- six steel brackets that later fasten to a hand rim for propulsion.", "Tires are either pneumatic, with an inner-tube of air, or rigid-- just one solid piece of rubber.", "A machine stretches the tire to fit the wheel rim.", "Workers install 12 washers, called spacers, along the hand-rim.", "Six of these 1/2-inch spacers can be removed later to adjust the chair's overall width, if necessary.", "The spacers on the hand-rim align with the brackets on the wheel.", "Workers join them with industrial-strength, 1 1/2-inch steel screws.", "Replacing a wheel and hand-rim like this costs more than $100.", "You buy replacement parts much like you do car parts-- through specialized dealerships.", "Bearings make the wheels roll with ease.", "Installing them is a delicate operation.", "Workers use special custom tooling to insert the bearings with extreme precision.", "The tires are rigid and have no treads because they're designed for smooth indoor surfaces.", "An aluminum cross-frame is what enables the chair to fold.", "They assemble it with six or seven screws per side, depending on the depth needed for the seat, which they'll install later on.", "The front part of the wheelchair is called the front frame.", "Workers lubricate the parts so they'll be easier to install.", "This also enables the wheelchair to fold with ease.", "They install the rear frame of the wheelchair then make sure the cross-frame folds correctly.", "Workers test the height-adjustment lever for the armrest.", "Then they install a removable aluminum footrest, setting it to the desired length.", "It has a heel loop to prevent the user's foot from slipping off.", "The chair has a foldable sling seat.", "It's made of nylon and attaches to the frame with six screws on both sides.", "You can adjust the armrest height from 8 to 11 inches and the tension in the backrest with 3 velcro straps.", "The backrest is made of nylon and comes in nine different heights.", "Workers insert the wheel axle into the frame, adjusting it to fit with the optional features of the chair, such as a particular style of armrest.", "The axle has a quick release so you can remove the wheel in seconds.", "This plastic-and-aluminum hand lever is a parking brake.", "It keeps the chair still when transferring to a bed or toilet.", "This motorized chair has an electrical controller.", "The user commands it with a joystick.", "The chair runs on two 12-volt batteries that power up in eight hours from a household socket.", "Workers squeeze the inner tube into the rear wheel rim.", "The air valve slips through and the front and back parts attach with screws.", "Now the rear wheel can go onto the motor.", "They attach the seat and the joystick box, which has on/off and speed-control switches.", "The battery-pack provides 85 amps an hour.", "That's enough power for 16 hours or 25 miles.", "The batteries connect to the charger and controller to power up the wheelchair.", "A steel bumper and plastic rear hood, called a shroud, protect the back of the wheelchair from the elements and against minor collisions.", "This motorized model can glide at a leisurely pace or zoom around at a top speed of just over 7 miles per hour.", "The transverse flute has been an orchestral instrument since the 1700s.", "You play it in a horizontal position, blowing across an oval hole in the mouthpiece.", "The air hits a sharp edge inside, producing sound.", "You turn that sound into notes by pressing the keys that open and close the flute's holes.", "they begin production by inserting a solid steel bar into a sterling silver tube.", "Then, using a press, they lengthen it and taper it, reducing the diameter to just under 3/4 of an inch.", "This tube is part of what's called a head joint, one of three sections that make up the flute.", "The other sections are the center joint and the foot joint.", "Next, on another machine, they insert a second tube for the center joint.", "This device drills small holes to mark the position of each tone hole, the raised rim around each of the flute's holes.", "Now they insert titanium washers, called spiders, in the holes to help position the tone holes.", "They place a tone hole around each spider, securing it temporarily with copper wire.", "Once they solder the tone hole, they'll remove the spider.", "They solder little posts onto three strips of metal, called ribs.", "The ribs and posts will later hold the flute's keys in place.", "Next they use what's called a profile cutter to shave the tone holes by minute amounts, to perfect the flute's sound.", "Now, using a wax injector and rubber molds, they create wax duplicates of the 120 different parts that make up the flute's 20 keys.", "Now they build what's called a tree.", "Using tweezers and a heated pen, they fuse the wax duplicates to a wax trunk that's 6 1/2 to 10 inches tall, depending on the type of flute.", "Then they place the tree in a perforated steel flask covered in masking tape.", "They pour in 1/4 gallon of plaster, which hardens around the tree.", "Then they remove the tape and heat the flask.", "The wax melts through the holes, leaving plaster cavities in the shape of the key parts.", "The keys are made from tiny particles of silver or gold.", "These ones have a reddish hue because of their high copper content.", "The craftsmen pour a carefully measured amount into the casting machine's upper chamber.", "The machine heats the metal for 12 minutes.", "The plaster flask goes into the casting machine's lower chamber.", "They release molten metal into the cavities.", "Once the metal cools, they shatter the plaster under cold water, exposing a tree of silver key parts.", "Using a pneumatic cutter, craftsmen snip off the key parts.", "They have a dull finish because the silver isn't yet polished.", "Now they solder the key parts together and polish each finished key with a soft rotating brush.", "They also solder on a riser, which attaches the mouthpiece's lip plate to the head joint tube.", "They cut away excess metal from the opening of the lip plate.", "Then they use a lathe to cut out a hole in the head joint tube.", "A template ensures they position the hole correctly.", "Once again, they use copper wire to hold the parts together until soldering.", "They solder the lip plate assembly to the head joint tube, using a gas-and-oxygen torch.", "Next, they mount the keys using tiny wires called straight springs.", "The spring helps open and close each key over the corresponding tone hole.", "They test each key's seal, called the pad, for air leaks.", "A thin strip of plastic slides out if it's improperly sealed.", "The pad is made up of a plastic washer and a felt cushion, surrounded by a synthetic wrapper as thin as tissue paper.", "A pad lasts for about five years and is very expensive to replace-- about $75.", "It's just one of up to 100 components in a flute, depending on the model.", "This company's flutes come in silver, gold, and platinum.", "They range in price from $8,000 to $43,000.", "Once all the keys are in place, a quick wipe to remove any pesky fingerprints.", "An engraver inscribes the serial number and company logo.", "After 120 hours of painstaking work, the flute is ready for its musical debut.", "cowboy boots have been kicking around since the 1800s.", "You can wear them on the ranch or just as a country-style fashion statement.", "Most cowboy boots are made of cowhide and sell for about $200.", "For something more exotic, though, how about a pair made of ostrich skin for a mere $500?", "Production starts with a machine called the clicker that works like a cookie cutter, slicing leather into various sizes of soles from standard to extra wide.", "The clicker also cuts the other boot parts, such as the shaft, the section above the ankle.", "This programmable, automated stitching machine decorates the shaft with embroidery.", "The machine works on a dozen boots at a time, using up to 15 different thread colors.", "Workers steam the shaft to soften up the leather.", "Synthetics just don't mold to the foot the way animal hides do, so this company uses only the real thing-- python skin, walrus skin, bison skin, even ostrich skin.", "Cow- and pig-skin boots make up the bulk of production, though, because they're the most affordable.", "Workers perforate the shaft, then layer a different-colored leather underneath to create a design.", "This company produces 20 basic patterns, but clients can also order custom designs.", "They line the shaft with pig skin because it breathes better than a synthetic lining.", "Workers stitch together the shaft sections, including the underlays, from the inside out.", "Piping covers the seams.", "A roller turns the whole thing right side out, flattening the piping for a more comfortable fit.", "The next machine glues a cotton strip to the leather insole.", "They'll later attach this strip to the foot section of the boot.", "Next, they temporarily attach the sole to a plastic mold, called a boot last.", "This makes the sole rigid while they attach other parts of the boot.", "They glue a hard, synthetic cup to the heel section to give it the desired shape.", "Then they apply a fibrous cotton form between the layers that will shape the toe area.", "Now they attach the sole to the shaft.", "Using a laser as a centering guide, they stretch the toe section over the boot last, bringing the two largest pieces of the boot together.", "They stitch on a leather strip to attach the sections.", "This strip, called a welt, is a traditional part of boot-making.", "It's what makes the boot very durable.", "They attach a steel shank for arch support...", "Then apply a mixture of granulated cork and hot glue.", "This layer will make the boot conform to the contours of the wearer's foot.", "They attach the sole to the shaft with industrial-strength glue.", "The fact that it's glued as well as stitched means you can simply rip it out and replace a worn sole.", "This feature greatly extends the life of the boot.", "A cutting machine trims off the excess leather.", "Then they stitch the sole to the welt.", "They stitch using interlacing threads.", "This binds the pieces even more strongly.", "The final layer of the sole can be either leather or rubber.", "It all depends on who will be wearing the boots and where.", "A rancher in sunny texas may prefer leather.", "But in the cold and snow, you're better off with rubber.", "Now for the heel...", "They load a driving machine with nails.", "The pattern varies according to the type of heel.", "This company produces eight heel styles.", "A laser guide ensures they nail the heel to the boot perfectly centered.", "With a brush, they coat both the heel and the edge of the sole in black or mahogany dye.", "Finally, they brand the manufacturer's name in gold foil.", "Some boots have pull holes at the top for getting your boots on fast, to make it to the rodeo on time." ]

{ "things": [ "Automatic Transmissions", "Silver Miniatures", "Hot Air Balloon Baskets", "Darts" ] }

[ "Today on how it's made...", "Automatic transmissions...", "Silver miniatures...", "Hot-air-balloon baskets...", "And darts.", "Your car's all-important transmission is a system of gears and levers that transfers power from the engine to the wheels.", "With a manual transmission, you have to shift the gears yourself, but with an automatic transmission, the car's computer determines when it's time to shift and sends an electronic signal to activate or deactivate the appropriate gear.", "The transmission allows the engine to operate in its most efficient range, or powerband.", "It's assembled inside an aluminum housing called the transmission case.", "At the heart of the transmission are three sets of planetary gears, so named because there are smaller gears rotating around a larger central gear.", "The first gearset is called the final drive.", "It harmonizes the engine speed and driving speed.", "The final drive is attached to the differential, a component that lets the wheels move at different speeds so the car can turn.", "Workers install the steel parts connected to the shift lever, which puts the car into drive, reverse, or park.", "First, the manual detent lever.", "Then, the forward clutch support.", "The piece protruding from it is called the park paw.", "The actuator rod connects the detent lever to the park paw.", "It locks a gear that immobilizes the car when you shift into park.", "Now for the transmission's five clutches.", "Depending on what the transmission needs to do, clutches either let gearsets rotate or lock them in place.", "This clutch is called the forward clutch.", "By moving the input gearset and the reaction gearset, it enables the car to go forward when you shift into drive.", "Two clutches installed as one unit go in next.", "The coast clutch allows the car to coast in low gear and to brake progressively in higher gears when you take your foot off the gas.", "The second clutch is called the direct clutch.", "It locks the two gearsets so there's no reduction in speed.", "Next, the reverse clutch.", "It moves the reaction gearset so the car can back up.", "A clutch is made up of layers of metal and friction material, such as resin-impregnated paper.", "The transmission's second clutch uses both the input and reaction gearsets to switch the transmission into second, third, and fourth gears.", "With all the gearsets and clutches now in place, workers can connect the transmission to the rest of the car's electronics.", "These cables are known as the harness.", "Next come the drive chain and two sprockets.", "This hookup is the critical link between the transmission's gearsets and its torque converter.", "The torque converter is the component that transfers power from the engine to the transmission.", "The sprockets in the final drive convert the engine speed to the appropriate transmission gear.", "The car's computer directs this hydraulic control system to change gears as needed.", "The computer triggers an electronic switch called a solenoid to open a specific control valve.", "This applies hydraulic pressure, which engages the clutch around the relevant planetary gears.", "When the hydraulic pressure is released, it disengages the clutch and locks the gears.", "Now the final connection for the shifting mechanism, linking this manual valve to the detent lever.", "The shift lever moves the detent lever, which makes the valve direct hydraulic pressure accordingly.", "This steel bar, called the output shaft, directs transmission power from the final drive at one end of the transmission to the driver's side front wheel at the other end.", "Next, workers install springs and servos, part of the hydraulic control system that helps engage and disengage the clutches smoothly.", "This tube assembly goes in next.", "The control valves route hydraulic fluid through these tubes to the different clutches.", "Now the torque converter.", "It spins a shaft that turns the sprockets and drive chain that we saw earlier.", "A steel bar called a stub shaft is the final link, sending transmission power from the final drive and differential to the front wheel on the passenger side.", "Up next, making silver masterpieces on a miniature scale.", "Collecting and displaying miniatures isn't just child's play.", "It's become a serious hobby for grown-ups, who even buy fine silver in miniature.", "Avid collectors spare no expense because, after all, it's the little details that make the difference.", "In the world of miniatures, there's no need to downsize one's expectations.", "Here, you can find all the little luxuries.", "This silverware is no cheap reproduction.", "It's a tiny version of the real thing.", "To make it, silversmiths use tools and techniques that have been handed down over generations.", "This is a workbench from the 18th century.", "Today, they use one that's nearly identical.", "To make a miniature mug, workers begin by dividing its measurements by 12 so that the finished product will have the same proportions as the original.", "Next, a strip of silver is rolled out to about 0.02 of an inch thick.", "Then, small, round disks are punched out.", "A blast from a torch softens them so they'll be easier to work with.", "A dunking in acid eats away any impurities and leaves a frosty finish.", "One of these disks is set on a lathe.", "As it spins, a series of tools begin to give the thimble-sized mug its shape.", "Any mistake is a big one when you're working in such tiny dimensions, so the silversmiths have to work with great care.", "During the machining process, the frosty finish left by the acid is removed.", "The mug is buffed to add luster to its finish.", "And now it's time to make the mug's base.", "It's tapered to make a perfect fit.", "Small fragments of silver solder are placed between the two pieces.", "Then, the parts are heated to almost 1,500 degrees to fuse them together.", "Next, leftover silver pieces are cut up, and the scraps go into a crucible.", "A pinch of borax is added.", "This mineral will prevent unwanted oxides from forming as the scraps are melted down.", "Silver is far too precious, so workers don't want to waste even a single scrap.", "The molten silver is poured into a plaster mold.", "Then the mold is plunged into cold water.", "The temperature change causes the plaster to explode, exposing three tiny silver handles.", "One of the handles is soldered onto the little silver mug.", "And now all the pieces of the miniature are in place.", "Next, the miniatures are placed in a bucket of steel shot and soapy water.", "The friction cleans and polishes them.", "The soapy water is strained out, and the gleaming miniatures are revealed.", "Each silver miniature has to meet the same purity standards as full-sized silver pieces.", "In this factory in britain, the regulations have been around for 700 years.", "The maker's mark, called the hallmark, is the stamp of authenticity.", "Hallmarking a miniature can be a bit awkward, and some articles are just too tiny to mark.", "When it comes to replicating silverware, it seems no job is too small, and there are plenty of shining examples in the world of miniatures.", "When we return, behind the scenes at a hot-air-balloon factory.", "Did you know that some hot-air-balloon baskets are more than 20 feet long and can carry more than 30 people?", "This pioneering form of human flight was invented in france in the late 1700s, and ever since then, passengers have been taking to the skies for an unforgettable ride and an awesome view.", "It all starts with a little high-tech basket weaving.", "First, the frame is constructed.", "Workers cut pieces of stainless-steel tubing.", "They manually round the corner pieces, then weld all the parts together.", "A sheet of plywood is cut for the floor.", "Then holes are drilled into it for stainless-steel support cables.", "These cables will reinforce the floor against the passengers' weight.", "After marking off the area that the basket walls will occupy, workers run the cables under the floor, which is lying upside down, leaving extra cable on both ends to come up the sides of the basket.", "Then they notch a groove that is the width of the cables and runners.", "Runners are length of ash wood that protect the base of the basket and give it rigidity.", "After bolting the runners down, workers use a branding iron to burn the company logo into the floor.", "A spray coat of lacquer will prevent moisture from rotting the wood.", "Larger baskets need diagonal reinforcement cables for extra support.", "The basket walls are made of cane-- the stiff stems of a tropical asian plant.", "The cane soaks overnight in a water tank.", "By morning, it's supple, and the weavers can begin their craft.", "They start by installing uprights, attaching each one to the frame at the top and bottom with a thin piece of cane.", "Then they feed the support cables from the floor up through the frame.", "The uprights are 18 inches apart along the sides and 4 inches apart around the corners.", "The weavers fill the gaps with thinner uprights every two inches.", "The uprights are tied to the frame and floor with rope.", "Once they're installed, it's time to build the basket walls from the bottom up by interlacing horizontal canes.", "A pair of weavers can finish a small basket in a day.", "Large baskets can require a 4-person team and take up to three weeks to complete.", "Weavers use two techniques-- randing, going in and out with one cane, and waling, weaving three canes at once.", "Waling makes a more solid basket but one that's significantly heavier, because it uses triple the amount of cane.", "Some models have stainless-steel steps woven into the basket.", "These give passengers a better foothold when climbing in.", "The weaving ends just below the top of the frame.", "Weavers finish off the job by splitting the remainder of each upright down the center with a utility knife, then flattening and wrapping what's left around the frame.", "The weavers integrate rope handles at the top of the basket so passengers have something to hold on to during the ride.", "They also put handles at the bottom for carrying the basket.", "Now they pad the frame with foam, cutting holes to let the support cables through.", "The foam provides both comfort and safety, cushioning passengers from the hard metal during a bumpy ride.", "After taping the foam pieces together to prevent shifting, workers slip on a leather cover and lace it closed.", "Finally, with a few bangs of the hammer, workers expose the short tubing to which the load frame will connect.", "The load frame carries the burners high above the basket.", "A heating coil surrounds each burner.", "To make this piece, workers first wrap a stainless-steel tube around a form, then rivet on a reinforcement band.", "The basket carries lightweight fuel tanks containing cold liquid propane.", "The propane flows upward into the coil.", "When the pilot fires up a burner, the flame heats the coil, transforming the propane flowing inside from liquid to gas.", "The gas feeds the flame, which heats the air inside the balloon.", "Hot air is lighter than cool air, so the balloon literally rises to the occasion.", "Up next, the art of the dart.", "The game of darts dates back to the middle ages, when english soldiers looking for fun began pitching arrows at the bottom of an empty barrel.", "When winter came, the soldiers moved their game indoors, but they couldn't throw big arrows around inside, so they used shortened versions, and the game was on.", "Today's darts are finely crafted little missiles.", "Production begins with the flight shaft, the piece that the dart's wings are attached to.", "Workers load aluminum rods three yards long into a machine that has several cutting implements.", "This army of tools works on the aluminum rod from all angles...", "Shaping it into dozens of shafts.", "Threads are cut into the shaft's exterior, and one of its ends is hollowed out so it can be screwed onto the dart barrel later.", "A cross saw cuts slots into the other end for attaching the wings.", "Oil flushes away the shavings.", "It also keeps the tooling cool, so it stays sharp enough to cut through metal.", "The completed shafts fall into a bin to await further assembly.", "Next, brass rods are loaded into a similar machine.", "Its tooling carves the brass rod into barrels-- the main part of the dart that you grip.", "One end of the barrel is threaded and tapered so the shaft can be screwed onto it.", "This tapering also makes the dart aerodynamic.", "Next, tools with angled grooves cut ridges on the outside of the barrel to make the dart easier to grip.", "The process is called knurling.", "Another tool then cuts the brass barrel to the correct length.", "Some dart barrels are made from tungsten, which is quite dense, so the barrels can be slimmer.", "Slimmer darts can give you an advantage in tight scoring situations.", "That's why pros often prefer tungsten darts and have them custom made, even choosing their own knurling grip.", "These are knurling wheels-- another way to etch the grip pattern into the dart barrels.", "Knurling wheels come in an assortment of patterns, all designed to help you keep a firm hold until the dart takes flight.", "Now it's time for the darts to get their sharp points.", "A hydraulic press forces steel tips into the hollowed ends of the dart barrels.", "With the point now snugly in the barrel, the dart is ready for its wings.", "Dart wings are made from polyester film, which first winds through printing rollers.", "Some print jobs involve just one basic color while others layer many colors to build up a design.", "In the world of darts, the wings are known as flights.", "A machine cuts out the flight shapes, and they accumulate in big piles.", "Flights are made in various shapes.", "This is just one of them.", "Workers fold the cutouts together to make a flight.", "They check each one for symmetry, because an out-of-proportion flight could wreck a player's game.", "Now it's time to screw the shaft to the barrel of the dart.", "The polyester flight slides into cross slots on the end of the shaft.", "And now this set of darts is ready to take aim.", "It takes less than a minute to make a dart...", "But less than a second for this flying missile to find its mark." ]

{ "things": [ "Filigree Glass", "Fish Food", "Motor Homes" ] }

[ "Filigree glass is a highly advanced form of glassmaking.", "The artists first produce threads of colored glass, then weave these threads together in intricate patterns, encasing them within clear crystal.", "Then they use complex glassmaking techniques to shape these patterned rods into breathtaking works of art.", "The filigree glass technique was invented in the 1500s by master glassmakers in murano, italy.", "Their then-secret process incorporated ancient methods from mesopotamia, the birthplace of glassmaking some 2,000 years earlier.", "It all begins with a blend of mostly silica sand, soda ash, and lime.", "They heat the mix to almost 2,400 degrees fahrenheit, melting it over several hours into lead-free liquid crystal.", "With a steel rod called a punty, the glassmakers roll some molten crystal on a metal table as it cools and solidifies-- a shaping technique known as marvering.", "Then they use the post they've shaped to pick up a piece of densely colored glass called a color bar.", "They melt the color on the end of the crystal post.", "At the same time, they heat another color bar into molten a state.", "Then they perform a process called overlaying.", "They push the molten colored glass over the other color bar, then marver until the colored glass symmetrically encases it.", "They encase the color in clear crystal and reheat some more, then prepare a new bit of clear crystal on another punty.", "They use it to grab the free end of the color overlay.", "The glassmakers pull, stretching the crystal like taffy into what's known as overlaid cane, a thin rod of crystal with a thread rod of colored glass inside.", "It takes tremendous expertise to stretch the rapidly cooling glass to a consistent diameter without twisting or breaking it in the process.", "They snip the long cane into manageable lengths.", "Next, they cut the colored rods into the size required...", "Lay out the rods in a precise configuration, heat, then roll them onto a precisely sized piece of molten clear crystal.", "Now they repeat the pulling process, but this time, to create the internal pattern they want, they twist both punties.", "They use an electric drill to ensure steady, uniform revolutions.", "The rod this creates is called a complex cane.", "After it cools and stabilizes overnight, they cut it into the lengths they need to create the filigree glass piece.", "The colors and pattern inside a complex cane are determined by the choice and layout of the overlaid cane rods rolled onto the molten crystal.", "The filigree pattern is now determined by the way in which they lay out the complex cane rods.", "After fusing the laid-out rods, they wrap them around a collar of hot crystal at the end of a blow pipe.", "While rolling the piece on a glass blowing bench, they use a scissor-like tool called jacks to close off the end.", "They snip off the excess with shears.", "Then, they roll the hot glass on a wet wood block to smooth and round the bubble.", "They blow in some air to produce the shape of a pear, stick a punty to the bottom of the pear, then use cold tweezers to shock the hot glass into breaking along the separation line and transfer off the blow pipe.", "Now they take some hot crystal from the furnace and roll it in fine, granulated colored glass.", "They reheat to melt the color into the crystal...", "Then attach a bit of glass to the top of the pear to form it into a stem.", "They smooth the cutoff edge with a small torch.", "They take another bit of molten colored crystal to shape a leaf.", "This crimping tool imprints the veins.", "Every filigree piece these canadian master glassmakers create is signed by way of a piece of cane bearing their initials.", "They fuse it to the piece in a discreet location.", "Now the finishing touches-- reheating, then some shape-tweaking with tools and wet newspaper.", "With the artist's work done, it's time to enjoy the spectacular fruits of their labor.", "Flake foods for aquarium fish were invented in the middle of the last century, and what a difference this invention has made.", "Before they came along, pet fish were fed live food from rivers and streams-- a food source that wasn't always accessible.", "The invention of flake and other dried foods made life in a fish tank a whole lot easier.", "Just a few sprinkles and dinner is served.", "It's not much like the live water fleas or bloodworms the fish would feed on in their natural environment, but it contains the nutrients and vitamins they need.", "These dried tidbits can be supersized to appeal to larger fish that prefer to chow down on something more substantial.", "Each formulation consists of up to 40 different ingredients.", "The main components are fish meal...", "Wheat flour...", "Soy and paprika oils.", "They also add food colorant because fish are drawn to certain colors.", "They follow a precise recipe and measure the ingredients carefully.", "They blend the smaller components together first.", "They include lecithin-- a blending and thickening agent also found in foods humans consume-- and calcium for bone strength.", "The main ingredients-- the fish meal, flours, and oils-- are piped from silos into big tanks and mixed with hot water.", "They add the smaller premix and blend everything together to produce a thick slurry.", "They spray the slurry onto the surface of a series of rolling heated drums.", "As it flows over these drums, the slurry cooks and dries into a thin film that's like a paper sheet.", "As the sheet rolls off, a long rotating blade chops it up to produce big flakes.", "They're pretty chunky at this point and will need to be broken up into bite-sized versions.", "Next, they fall down a chute and into a plastic bag.", "A worker transfers them by the bagful to the next conveyer.", "The various colors represent the different formulations.", "The green are veggie flakes, while the red are protein-based.", "They all head into a spiraling device known as the tumbler.", "It spins to toss the flakes around.", "This mixes then breaks them into smaller flakes.", "After several minutes in the tumbler, the flakes fall onto a series of screens to grade them by size-- small, medium, and large.", "They land in separate bins, now mixed and sorted by size.", "Meanwhile, the production of fish-food sticks is underway.", "Machinery presses a food mash through the small holes of an extruder plate to create spaghetti-like strings.", "As the strings exit, rotating knives cut them into sticks.", "The sticks dry and solidify.", "A worker routinely examines them for size and form.", "The next worker wheels a hopper full of flakes above a chute and removes the trap door.", "The mix falls down one floor onto the packaging line.", "At the same time, a column of empty cans heads toward the flakes.", "The fish food flakes fall through special openings that funnel them into the cans.", "Machinery cuts out aluminum foil caps and slaps them on the tops of the containers.", "Hot circular irons then seal the caps to the cans.", "This conveyor belt is also a computerized scale which keeps track of the amount of product in the cans.", "Then, devices spin by to twist plastic lids onto the threaded rims of the cans.", "As the cans pass by on a carousel, applicators press glue-backed product labels onto them.", "And these fish food flakes are done.", "In its various formulations, dried fish food offers a range of feeding options.", "Some contain additives that enhance the growth and color of the fish.", "Others are geared to a fish's specific tastes, because even pet fish can be discriminating diners.", "A motor home is a fully equipped house on wheels.", "The class \"a\" types are shaped like a bus, the largest models more than 40 feet long and spacious enough to sleep up to six people.", "When parked, the exterior room walls slide outward, expanding the width by more than a yard.", "Motor homes have driver and passenger seats at the front, and in the back, the essentials of a small house-- kitchen, bedroom, living room, bathroom.", "The factory buys a ready-made standard-length steel chassis from an automotive supplier with motor and other components already installed.", "They then lengthen the chassis by cutting each side and welding on an extension piece.", "They also extend the pre-installed exhaust system and electrical wiring.", "Then, they weld on steel plates to reinforce the splices in the chassis.", "Next, they lower the steel basement frame, which has compartments for the water supply, waste collection, and storage.", "Before installing the frame, they attach three pairs of sliding hydraulic cylinders called rams.", "Each pair operates a slideout room at the push of a button.", "After bolting the frame to the chassis, they spray each welded joint with an anti-rust coating.", "Then, they test the rams to make sure they slide in and out properly.", "They lower the preassembled steel cab structure onto the basement frame and weld it to the chassis.", "The motor home's front end is made of fiberglass with a bumper and headlights built in.", "Workers connect the headlights to the electrical system, then attach the front end to the cab structure.", "Then, they install the hood and make any necessary adjustments.", "Next, they load up the compartments in the basement structure, starting with the freshwater tank made of durable white plastic.", "Water runs from this tank through flexible plastic water lines to the sinks, shower, and toilets.", "Next, the drainage line for sewer waste.", "It runs to a plastic tank that's gray to differentiate it from the water tank.", "Now they run a line of heavy-duty adhesive along the steel grid of the basement structure and set down the motor home's floor.", "The floor construction is like a sandwich-- aluminum on the bottom, plywood on top, with a high-density hard foam in the middle to muffle noise and absorb road vibration.", "After securing the glued floor with screws, they staple carpet underpadding onto the plywood...", "Except in the kitchen and bathroom areas, where they lay down vinyl or ceramic tile flooring and cut holes in it for heat registers and drains.", "Then they install carpet over the underpadding.", "The pieces are precut to the motor home's layout-- large pieces for the main areas, small ones for closets and the cab.", "Now, workers hook up what they've built so far to a chain mechanism that tows down an assembly line.", "First, overhead lifts lower the motor home's three slideout rooms-- dinette, living room, bedroom-- onto their respective rams.", "Workers bolt the rooms to the rams, then test them.", "Next, workers install the bathroom cabinetry, plumbing, and wiring.", "Then the motor home gets its three remaining walls.", "They're fiberglass on the outside, decorative paneling on the inside, with foam and an aluminum structural frame in between.", "The back wall has a luggage compartment accessible from the outside of the vehicle.", "Like the headlights on the front end, the vehicle's taillights are integrated.", "The roof structure is the same as the walls.", "It has electrical wiring built in and cut-outs for ceiling lights and air-conditioning vents.", "The inner structural frames of the roof and walls interlock.", "A line of screws running the length of the roof secures the connection.", "A generous application of sealant, then on goes the roof cap with built-in clearance lights to finish off the front end.", "At this point, the outside of the motor home is almost complete.", "However, there's still much interior work to come.", "Everything on the inside is designed to maximize living space and storage space.", "And even though the motor home has just one bedroom, pullout beds in other areas add additional sleep space.", "One of the last jobs remaining on the outside is to install the door.", "It fits perfectly because they constructed it using the piece they cut out of the side wall to make the door opening.", "Next, some decorative detailing on the vehicle body, including an adhesive vinyl decal bearing the model name.", "On the inside, workers are busy applying the finishing touches.", "They hang cabinet doors...", "Install under-cabinet lighting...", "And hook up the kitchen appliances.", "The stove is a special compact size manufactured specifically for recreational vehicles.", "Customers buying motor homes have a choice of window coverings.", "This order calls for double-duty roller shades-- one setting filters daylight, the other blacks it out.", "The installer uses a gauge to adjust the blinds to the correct drawing tension.", "Then, she installs decorative valances to hide the edges and pull cords.", "In the cab, workers bolt the base of the driver and passenger seats to the basement frame.", "Then, they bolt a seat-belt receiver to each seat base.", "The seats, upholstered in high-end synthetic leather, attach into their respective bases.", "Workers install the dinette, which sits in one of the slideout rooms.", "The bench seats have a storage area underneath, and the seats and table convert into an extra bed.", "At the rear of the motor home is the bedroom, which is the second slideout room.", "The bed has storage space underneath for blankets and pillows.", "Regulations designate certain seats safe to sit in while the vehicle is moving.", "Those seats are equipped with safety belts.", "The couch in the living room, the third slideout room, has a few hidden features-- an air mattress which inflates and deflates at the push of a button for an extra bed, and a drawer underneath for storing pillows and blankets.", "The bathroom has a toilet...", "Sink...", "Shower stall...", "And lots of cabinet space.", "Back on the outside, workers install a rear-view camera on each side wall.", "When the driver activates the right turn signal, the right side camera automatically turns on.", "The left turn signal, the left camera.", "The cameras transmit the image to a dashboard monitor.", "Every motor home this factory produces undergoes extensive water-infiltration testing.", "Hundreds of sprayers shoot several straight minutes of simulated heavy rainfall from all angles, including underneath-- with the slideout rooms both extended and retracted.", "Inspectors check everywhere, even inside cabinets.", "If they find any leaks, they seal them and run the water test again.", "And finally, one last mechanical verification of the slideout rooms, now that they bear the additional weight of the furnishings.", "This expansion feature is the secret to the motor home's spacious feel, as it increases the floor-space width by nearly five feet.", "The slideouts operate only while the motor home is parked.", "With smart design and ingenious use of limited space, a motor home lets you hit the road without leaving the comforts of home behind." ]

{ "things": [ "Grinding Wheels", "Compost", "Window Blinds", "Milk" ] }

[ "Today on \"how it's made\"...", "Grinding wheels...", ".compost...", "Window blinds...", "And milk.", "A grinding wheel is a tool used to grind down, polish, or cut materials such as metal or glass.", "Like a sander, it uses abrasive grains to wear away the surface in minute particles.", "Grinding actually sharpens the wheel by breaking apart the grains and creating new sharp points.", "A grinding wheel is made from several chemical and mineral ingredients.", "The formula varies according to what the wheel will be intended to grind, polish, or cut.", "For metalwork, they use abrasives that are aluminum-oxide based.", "For cutting cement, stone, and other nonmetal objects, they use abrasives that are silicon-carbide based.", "Even within those two categories, the formulas will differ.", "A wheel designed for hard steel will be different than a wheel designed for softer metals.", "Computer-programmed scales automatically weigh out the various ingredients, including additives such as iron oxide-- for wheels that cut or grind iron-- and the mineral cryolite, which lubricates the abrasives.", "Powdered and liquid resins bond all the ingredients together.", "The powdered resin and additives are the first ingredients to go into the mixer.", "After about a minute, the abrasives and liquid resin go in.", "Another five minutes of churning, and the mixture is the consistency of damp beach sand.", "They screen out any globs or chunks so that the mix has a smooth and even texture.", "A device called a shuttle spreads the mixture into a wheel-shaped mold.", "The diameter and depth of the mold cavity corresponds to the dimensions of the specific grinding-wheel model.", "At the base of the mold is a reinforcement disc made of fiberglass.", "Next, a galvanized-steel ring goes in the center of each wheel.", "Its four small anchors grip the mixture.", "This ring is designed to protect the shaft that spins the grinding wheel.", "A hydraulic press now compacts the material, applying up to 5,000 pounds of pressure per square inch.", "That's the weight of about 30 cars.", "Every single grinding wheel coming off the line is weighed to ensure it meets design specifications.", "Next, the wheels go into an oven whose temperature rises gradually from 70 to 390 degrees fahrenheit over a period of 24 hours.", "This cures the resin, bonding all the ingredients together.", "When the grinding wheels come out, they're hard as a rock.", "The last step of the production process is labeling.", "The automated machinery moves the wheels from station to station using suction.", "It applies eight drops of hot glue around the center, then slaps on the first label.", "The label bears the manufacturer's logo and lists the grinding wheel's dimensions, its intended use, and the maximum spin speed.", "The equipment then flips each wheel and glues a second label onto the other side.", "This label lists the safety information.", "The diameter of a grinding wheel can range from 2 inches to more than 20 inches.", "It can be just .", "04 of an inch thin or up to 1/2 an inch thick.", "The smallest wheels are designed for things like auto-body work while the largest ones can cut through railway tracks and thick-metal construction beams.", "Many gardeners are relying on nature to nurture their gardens.", "They're choosing compost-based soil mixes over chemically fertilized mixes.", "Compost is decomposed organic matter.", "Not only is it environmentally friendly, it's chock-full of nutrients and useful micro-organisms.", "Composting is the ecological alternative to burning or burying organic waste.", "It all starts at this composting factory with manure from farms, biodegradable solid waste from paper mills, and grass clippings and leaves from local governments.", "Some materials arrive in bulk, others in plastic garbage bags.", "Workers carefully inspect the leaves and grass clippings, removing any nonbiodegradable objects that got into the bags-- things like pieces of plastic, rubber, or metal, shards of glass, or even stones.", "After combining all the waste ingredients, they add bulking materials such wood chips and bark.", "Then they stack the mixture in outdoor piles to decompose.", "The mix's makeup is by no means random.", "It's scientifically designed to create an ideal environment for live micro-organisms.", "Billions of bacteria and fungi grow and reproduce, feeding on the nitrogen and carbon that are naturally present in the organic matter.", "They slowly and gradually transform the waste into compost, which, when ready, will look like rich, black earth.", "All this microbiological activity heats the waste piles to a steaming 150 degrees fahrenheit, even in the dead of winter.", "The factory turns the piles monthly to aerate them.", "This stimulates decay and ensures it occurs evenly throughout the pile.", "The active-breakdown phase takes 6 to 10 months.", "A curing phase follows-- an additional six to eight months, at the end of which the compost stabilizes.", "Because the outdoor piles are exposed to precipitation, high concentrations of nitrogen, phosphorous, and potassium leech into the runoff water.", "Drainage ditches collect and carry this water to holding ponds.", "From there it goes through a treatment system consisting mainly of aeration and settling ponds.", "As we see in this demonstration, they aerate the water and add certain chemical compounds.", "The pollutants bond and settle at the surface to be skimmed off.", "The treated water has to meet strict government regulations before it's released to the environment.", "Back to the compost now.", "Once the curing phase is over, the compost goes through a screening process which removes any lumps or foreign objects such as pebbles or partially decomposed wood chips.", "The finished compost comes out silky-smooth.", "Before the compost is sent to market, it undergoes strict quality-control testing.", "The factory's laboratory conducts detailed chemical analysis to ensure the compost is at precisely the right level of maturity and that it contains the correct balance of nutrients and stabilized organic matter.", "Then, a series of growth-chamber tests.", "To ensure the product performs well, the lab germinates seeds and grows test plants in compost-based mixes.", "Once the quality-control department gives the green light, the compost can be shipped out either in bulk or packaged bags.", "Compost is sold as is or added to soil mixes.", "It improves the soil structure and actively retains moisture and fertilizers.", "Compost is a chemical-free way to nourish plants and stimulate their defense systems.", "This gives them extra strength to grow fast and stay healthy.", "Today's window blinds come in many styles-- roller shades, roll-up shades, pleated shades, and horizontal blinds, to name just a few.", "The advantage of horizontals is that you can leave the blind drawn and simply tilt the slats to let in tons of light, a bit of light, or no light at all.", "Most manufacturers make their wood horizontal blinds from basswood.", "It's a hardwood, so it's durable.", "It's lightweight, so the blind doesn't end up weighing a ton, and it absorbs wood stain evenly.", "First they feed the rough wood through a planer.", "They cut it down to 2 inches-- the width of the slats.", "Then, following a laser guideline, they trim off any excess and square the piece, using a straight-line ripsaw.", "Now the piece goes through a machine that's specifically designed to cut thin slats of wood.", "Its sharp steel blades slice right through, creating up to 15 slats, each .", "2 of an inch thick.", "Here's the piece of basswood before slicing and after.", "The slats now pass under an oscillating sander to prep them for staining.", "After cutting them to the width of the window, workers spray wood stain on both sides of each slat, then a coat of sealer to lock in the color.", "Once the sealer dries, they sand the slats manually to prepare them for a final protective coat of lacquer.", "Next, using a die, they punch two slots in each slat 6 inches from each end.", "These are for the color-coordinated cords that will operate the blind.", "Now for the assembly.", "They hang ladder-shaped cords called ladder tapes from the blind's headrail, then slide one slat onto each rung.", "Then they thread the blind cord through the slots in the slats, hooking it up to the control mechanism hidden in the headrail.", "A cord dangles down the front for raising and lowering the blind.", "They also mount a wand, or cord, for tilting the slats.", "The excess ladder tape is tucked into a bottom rail.", "To make aluminum blinds, they start with long strips of preformed steel.", "These will be the blind's headrail and bottom rail.", "Workers cut them to the required length, which is the width of the window.", "They make holes in the headrail for the cord lock-- the device that locks the blind to the desired height-- and the tilter, the mechanism that angles the slats.", "Now they install those components.", "The cord lock snaps right into the hole-- no hardware required.", "That's known as a pressure fit.", "They pressure-fit the tilter, as well.", "Next come the tape rolls, through which they run the ladder tapes.", "They cut the appropriate length and color of blind cord, then thread it through the cord lock.", "The tilter turns a rod, which turns the tape roll, which tilts the ladder tapes, angling the slats.", "And speaking of slats, they're cut from rolls of 1-inch-wide aluminum.", "Workers simply feed a roll into the forming machine.", "Then the rest of the process is automated.", "First the machine gives the flat metal a semicircular curve.", "Then it punches cord holes and then, as you can see on the far left of the screen, cuts it into slats.", "But that's not all-- this same machine also assembles the blind, sliding a slat onto each rung of the ladder tapes.", "All that's left to do by hand is thread the blind cord and install the bottom rail.", "From this point on, it's just window dressing.", "Getting milk out of a cow has sure come a long way since the days of sitting on a stool and doing it by hand.", "Today's cutting-edge dairy farms are fully automated.", "Sophisticated equipment feeds the cows, cleans up their manure, milks them, and even checks the quality of the milk.", "Historians aren't sure when humans first began drinking animal milk.", "They believe that people in ancient babylon, egypt, and india raised dairy cattle as early as 4000 b.c. for centuries, the family cow was the main source of milk.", "But as cities became more populated, keeping your own personal cow became rather impractical, so farmers living outside city limits began to establish dairy businesses.", "The key to good milk output is a good diet.", "Every day, a dairy cow chows down up to 100 pounds of feed-- a mix of hay, grass, and grains, supplemented with minerals and proteins such as soy.", "On a hot day, she can drink the equivalent of a bathtub full of water.", "Cows produce milk only during the lactation period that follows the birth of a calf.", "Starting at 15 to 17 months of age, they're inseminated yearly for about six years.", "The newborn calf suckles for a couple of days, then goes to a separate area to be raised.", "But the mother continues to lactate for another 10 to 12 months, producing about 12 gallons of milk per day.", "This is the milk that's collected for human consumption.", "The barn floor is automatically cleaned around the clock to prevent the cows from walking in their manure, which would spread disease and infection.", "Animal welfare is at the core of this state-of-the-art dairy farm.", "A happy and stress-free cow produces better milk, so these cows aren't confined to stalls.", "They walk around freely inside or outside, eating and drinking as they please.", "They scratch themselves against this motion-triggered brush.", "It improves their blood circulation and cleans their hides.", "Each cow wears an identification tag.", "It emits a low frequency-- a different one for each animal.", "This enables the computerized milking system to collect data on each cow's milking habits and monitor the quality of her milk.", "No traditional twice-a-day milking here-- the cows decide when they feel like being milked.", "Just like the pressure in our bladders tells us when it's time to go to the bathroom, when the cows find the pressure in their udders uncomfortable, they just mosey on down to the milking stall.", "The stall is designed not to force the cow into an uncomfortable or motionless position.", "It sets up in such a way that she's not separated from the herd.", "Scientific research shows that separation induces stress.", "As it prepares to clean her udder with disinfectant and water, the robotic milking system reads the i.d. tag and records that this cow is number 328, coming in for a milking at 4:41 in the afternoon.", "Next, a laser pinpoints the exact location and position of the four teats.", "It feeds that information to the computer, which then guides the robot to attach the teat cups one by one.", "Once the robot detects the presence of milk, extraction begins, each suction cup simulating the sucking action of a nursing calf.", "A sophisticated machine analyzes the milk.", "If the quality is not up to par or if the machine detects signs the cow has an infection, milk with elevated temperature, or minute traces of blood, the system automatically rejects the batch and red-flags the problem cow.", "As the udder-cleaning brushes get disinfected, the robot tracks the output of each teat separately.", "That way, no teat is undermilked or overmilked, which can lead to health problems.", "Once the suction cups come off, the robot disinfects each teat.", "As bessie goes on her way feeling mighty relieved, the robot disinfects the teat cups for the next cow.", "The milk that passes inspection collects in a jar, then gets transferred to a giant refrigerated reservoir.", "They wash out that jar between cows.", "To keep the milk fresh, they store it at 37 degrees fahrenheit-- about the temperature of your refrigerator." ]