Datasets:

WitchesSocialStream

/

HowItsMade

like 0

{ "things": [ "Pencils", "Metal Recycling", "Coffee" ] }

[ "The lead inside a pencil isn't actually lead.", "It's mostly graphite, which was discovered in england in the mid-1500s, giving birth to the pencil industry.", "In 1795, a french chemist invented a new type of pencil lead, made of graphite powder and clay fired in an oven, making it possible to produce leads with different hardness.", "For the pencil's body, you need a type of wood that's soft enough to sharpen, yet strong enough not to bend under the writer's hand pressure.", "This german pencil factory uses cedar from california.", "The wood is .", "2 inches thick and arrives precut in slats of 7 x 2 1/2 inches.", "One by one, the slats pass under a giant cutting wheel.", "It carves grooves that will become the channel down the middle that holds the lead.", "The next machine fills the grooves with glue, a special formulation that's slightly elastic.", "This cushions the lead so that it's less likely to break inside the channel.", "Every second slat moves onto another conveyor belt.", "The ones that stay on this line head toward the machine that lays in the lead.", "The lead is made of a graphite-and-clay mixture, baked in an oven at almost 1,500 degrees fahrenheit.", "The lead-laying machine's wheel loads itself with leads, their spacing matching the grooves in the slats.", "It's the same process for colored pencils, only the leads are made of wax, clay, and pigments with no baking required.", "Now for the slats that move to that other conveyor belt.", "An automated arm flips each one over, slides it across a glue applicator, then drops it onto a leaded slat on the other conveyor belt.", "All the steps to this point have culminated in what is effectively a lead sandwich.", "Now a plunger squeezes those sandwiches together with a full ton of pressure.", "It compresses them for an hour while the glue dries.", "After that, it's just a matter of slicing the sandwiches into pencils.", "The shaping machine makes the hexagonal profile in two steps.", "First, its upper cutter forms three sides on top, then its lower cutter shapes three sides on the bottom.", "As soon as the bottom side is cut, the pencils separate.", "A worker pulls a sample pencil from each batch coming off the line and manually sharpens it to spot-check lead quality.", "Then he applies force to the tip until it breaks.", "For a pencil to pass this strength test, it has to withstand at least 4 1/2 pounds of force.", "Now it's time to dress that bare wood.", "One at a time, the pencils shoot through a device called a lacquering head.", "It coats the wood in paint, yellow in this case.", "It takes four coats of paint to completely hide the wood grain.", "A fifth lacquering head paints a black stripe, this company's trademark.", "Then a sixth head seals the paint job with a transparent lacquer.", "From the paint line, the pencils make their way to a stamping machine at an astounding rate of 500 pencils a minute.", "The machine heat-transfers foil lettering from a plastic film to the painted wood.", "Last stop-- the rubber-tip assembly machine.", "First, it squeezes the top of the pencil to slide on an aluminum ferrule.", "Then it inserts a rubber eraser into the ferrule's other end and squeezes that tight.", "European-style pencils have a painted cap instead, the color indicating how hard the lead is.", "After a coat of transparent sealer, the pencils take a series of dips in the first color, then, once that dries, in the second color.", "The final coat is a high-gloss lacquer.", "The pencils are finally ready to roll...", "Across a grinding drum for sharpening.", "By the time they roll off, they're pointed perfection.", "Looking as good as they perform, today's pencils sure have the right stuff.", "There are two types of scrap metal-- ferrous and nonferrous.", "Ferrous scrap is scrap iron and steel that comes mainly from old cars.", "Nonferrous scrap metal includes aluminum, copper, lead, and nickel.", "And the best part is metals can be recycled indefinitely without losing any of their properties.", "Each year, north american auto plants build millions of cars.", "Eventually, they end up here, at a scrap-metal-recycling facility.", "It takes about two days to process the raw material, mostly old cars and appliances.", "Crane and bulldozer operators scan the raw material as they gather and stack it.", "They're looking for anything they can't process-- propane tanks, glass, or heavy iron that will not shred and that could cause damage to the machinery.", "An inspector goes into the stockpile to check the material more closely, then signals the crane operator that he can proceed with the next load.", "The crane's grapple delivers load after load onto a conveyor belt that leads into a shredder.", "The belt speeds up or slows down according to the weight of the material to feed just the right amount into the shredder.", "Here's the feed box that contains the shredder laid open.", "An inspector checks it daily for damage.", "There's a lot of wear and tear on this machinery.", "A 4,000-pound drum grabs the material as it comes off the conveyor and forces it into the shredder.", "Its giant hammers pound away at the cars, mattresses, and other recyclable items, shredding them into fist-sized chunks.", "An industrial vacuum sucks out bits of rubber or glass mixed in with the shredded steel.", "The steel pieces stick to these magnetic drums.", "Anything else falls through to a conveyor belt below.", "Here, pickers remove any unwanted material caught on the steel pieces, and the clean shredded steel is ready for shipping to customers like steel mills and foundries.", "The material the magnetic drums don't collect goes on for more processing.", "There's precious nonferrous metals such as copper or brass mixed in with shredded debris.", "It all goes into a machine called a trommel, where a rotating drum separates the material by size.", "Any leftover residue is just trash.", "But before it goes to a landfill, an inspector checks it to make sure no valuable material has slipped through.", "The material from the trommel is evenly dispersed onto a conveyor that takes it to a machine called an eddy current separator.", "Inside, a rotating magnetic drum creates a strong magnetic field that repels nonferrous metals right up and over a barrier into a storage bin.", "Any material that doesn't make it over the barrier goes through the separator one more time, just in case there's still some valuable nonferrous metals mixed in.", "A conveyor belt carries out the worthless residue to a trash heap.", "A different conveyor belt carries the nonferrous metal out of the separator and loads it into a bin for sale.", "It will go to another plant where they'll separate it by type of metal-- mainly copper, brass, and aluminum.", "After all that shredding, sifting, and separating, here's what's left of the average used car.", "Take away the rubber, plastic, and upholstery, and you have some shredded steel...", "And some valuable nonferrous metals.", "That's a lot of useful material thanks to some efficient recycling.", "According to legend, a goat herder in ethiopia discovered coffee around 850 a.d. eventually, the beverage reached italy, where the first european coffeehouse opened in 1645.", "Today, about 2 billion cups of coffee are drunk each day around the world, making coffee the second-most valuable trading commodity after oil.", "Coffee's flavor depends on the region where it grows and the way coffee makers roast and blend the beans.", "Here in costa rica, they grow coffee plants from sprouted seeds kept in containers for a full year before they transplant them into the field.", "From seed to first harvest takes about two years.", "Coffee plants flower over the course of three days, covering the fields with fragrant jasmine-like blooms.", "Over six months' time, the buds grow and ripen into red cherries that contain the coffee bean.", "Pickers harvest the red cherries, leaving the green ones to ripen.", "They'll return to pick the cherries from the same plant five times in three months as they ripen.", "Pickers do their best to have no more than 2 green for every 100 red cherries they harvest.", "They empty their bins into bags and load them into trucks.", "Each bin produces about 4 1/2 pounds of coffee beans, enough to make about 200 cups of coffee.", "The fresher the berry, the better the flavor.", "Cherries picked in the morning are at the wet mill, ready for processing that afternoon.", "At the wet mill, water channels wash the cherries and drop them off at a worm screw.", "It loads them into a pulping machine to remove the outer skin and fruit.", "A rotating drum presses the cherries against the wall of the pulper and squeezes out the bean.", "From the pulping machine, the beans flow in water to two large rotating cylinders.", "They sift the beans to separate them from any of the hard green cherries that pass through the pulping machine.", "Next, the beans bathe in more water, which draws out a thick sugary substance known as miel, \"honey\" in spanish.", "The coffee maker then feeds the washed beans to make sure they're no longer sticky.", "The beans then drop into the drying bin below.", "Workers now lay out the beans to dry in the traditional way-- outdoors on a cement patio.", "For four days, they rake over the beans as they dry in the hot sun.", "At night, they let the beans rest to extract the most flavor.", "Once the beans are dry, they go into a milling machine.", "Inside, large stones grind away the parchment-like hull from the bean.", "Drying methods vary among coffee makers.", "They're a closely guarded secret.", "The beans can also dry mechanically in rotating drums that pump in heated air.", "Workers closely monitor the process and empty the drums when the beans are dry.", "A supervisor smells them to check for a vinegar-like odor.", "That would mean the beans are fermenting, a result of improper drying.", "The dry beans have their husks removed, then go on to an oscillating table that separates them by weight into three grades, the heaviest being the first-grade beans.", "Workers pour out each grade into burlap bags.", "Their contents must weigh in at 152 pounds per bag.", "Finally, they stitch them up and stack them for shipping.", "Next, we'll see the whole process that turns these green coffee beans into a steaming cup of gourmet coffee.", "Coffee boasts more than 800 flavor characteristics, at least double those of wine.", "Roasting reduces the amount of caffeine in the bean.", "To achieve a dark-espresso roast, the beans remain in the roaster the longest, so they have the least caffeine.", "It's the concentrated brew that packs espresso's punch.", "These green coffee beans have just arrived from the wet mill.", "Workers pour them out into a blending bin that feeds a roasting machine heated to 356 degrees fahrenheit.", "At that temperature, the oils in the beans combust, and the beans roast in less than 20 minutes.", "The master roaster must regularly check their progress.", "When he determines they're ready, he sets off a light spray of water in the roaster to extinguish the beans.", "Then they pour into a bin where they're cooled by forced air.", "As they roast, the beans go from green to golden brown, then black.", "Before roasting an entire shipment of beans, coffee makers first test a small batch.", "They follow a standardized procedure at the plant's testing laboratory.", "First, they roast a half-pound of beans in a small gas oven for a few minutes.", "Then a professional taster measures out the beans and feeds them into an electric grinder.", "She prepares four separate cups of coffee with the same coarse grind.", "It takes 4 tastes to make sure all is well, 20 to detect the source of a problem roast.", "She begins by pushing aside the foam at the surface to release the intense aromas, a technique known as breaking the cup.", "She smells each cup in turn, a sure way to know if something is wrong with the roast.", "Next, she skims the surface to remove the grounds.", "She takes a sip, slipping the coffee over her tongue to get the full flavor before spitting it out.", "Now she can determine how she will balance the blend of beans to create a recipe for the perfect cup of coffee.", "Back on the factory floor, the various beans for the blend go into a grinder.", "It will produce the desired grind-- coarse, medium, or a fine espresso like this.", "Now the coffee is ready for packaging.", "It's a fully-automated process thanks to this machine that forms, fills, and seals the bags.", "Gourmet coffee must go piping hot from the grinder to the bag to ensure freshness.", "As the machine seals each bag, it pumps in nitrogen to replace the oxygen that makes coffee stale.", "The machine separates the bags, and they fall onto a custom-designed conveyor belt that weighs each one as it passes through.", "Over at the espresso machine, the barista demonstrates the technique required for a perfect espresso.", "She puts a quarter-ounce of ground coffee into the holder, tamps it down firmly, then wedges it in place.", "The machine applies water pressure to extract the espresso.", "The distinctive foam is a sign this coffee's first-rate.", "The barista also demonstrates how to use a french press or cafetière.", "She adds boiling water to the coffee grounds, then pushes them down to the base.", "Again, she applies pressure, manually this time, to extract the coffee's aroma.", "Finally, she demonstrates how costa ricans make a traditional cup of coffee.", "She places a chorreador, a fine cotton sieve, over the cup, pressing on the ground coffee with a spoon as she pours in boiling water.", "No matter which one you choose, with the right gourmet roast, all three methods will produce an outstanding cup of rich, flavorful coffee." ]

{ "things": [ "Combination Squares", "Farmed Shrimp", "Ball Valves", "String Trimmers" ] }

[ "A combination square is a measuring tool you use when building with wood, masonry or metal to make sure something's straight, even and level.", "It's essentially a ruler with interchangeable sliding heads.", "The most basic head, called a square, measures 90 and 45 degree angles.", "This combination square comes with three heads.", "They lock into a groove on one side of the blade.", "The blade starts out grooved but blank.", "So to etch the graduations into it, they first coat the surfaces with photoresist, a chemical that hardens when exposed to ultraviolet light.", "Then they flash uv light on both sides of the blade through polyester film negatives of the graduations.", "The light hardens only the photo resistant hits through the clear parts.", "The rest remain soft.", "After manually masking the groove, workers put the blade through a photochemical etching machine.", "It washes off the soft photoresist that's in the pattern of the graduations, then hits that bared steel with a metal-eating salt solution, etching the graduations into the blade.", "Everything else is masked by hardened photo resist, which they wash off afterward.", "The blade measures in imperial units.", "They set it in this machine, which registers the location of the 1-inch mark, then grinds down the end of the blade until it's precisely 1 inch from that line.", "They run the blade through a sandblaster.", "It shoots glass beads onto the steel surface to make it microscopically rough.", "This will give the chrome plating a matte, rather than glossy finish, making the graduations easier to read.", "Before plating, they clean the blade by dipping it in acid.", "Then they submerge it in the electroplating tank for about 15 seconds.", "Now, the steel blade, with its graduations on both sides, is plated in chrome.", "The next step is called black filling.", "They apply black enamel paint to both sides of the blade, then wipe the surface clean.", "The black remains in the recessed graduations, making the numbers and lines easier to read.", "Fifteen minutes in an oven to bake on the blackfill, then a quality control inspection and the blade is finished.", "Meanwhile, in another part of the factory, this computer guided machine uses both milling and drilling tools to machine forged pieces of steel into heads.", "This is the forged square head, before and after machining to its finished shape.", "The next step is to harden the steel.", "They place the head into the furnace for 3 minutes at more than 1,472 degrees fahrenheit.", "The head comes out covered in black soot.", "So they sandblast it clean.", "The surface is now prepped for painting.", "The apply powdered paint electrostatically, running a positive electrical charge to the head and a negative one to the paint.", "This draws the paint to the part like a magnet, coating the entire service in an even layer.", "A 45 minute trip through an oven bakes on the paint.", "Then, they mount the head on a computer-guided machine that grinds that paint off the head's angle-measuring surfaces.", "They install the head's bubble level.", "First, they insert a white paper background, which makes it easier to see the air bubble.", "Then they insert the glass vial containing the bubble floating in a glucose solution.", "A dab of plaster at both ends holds the vial in its designated slot.", "They assemble the lock bolt that holds the head in the blade's groove.", "They mount it with a spring and a washer to prevent the lock from rotating and secure it with a nut.", "Then they close up the bubble level slot with an endcap.", "They run the unpainted angle measuring surfaces against the buffing wheel to polish the steel to a shine.", "The last step, inserting a scribing awl into its slot.", "You use the awl to make a scratch mark when you take a measurement.", "Now, the final assembly, the square head, the protractor head and the center head.", "All three come on the combination square.", "But when using the tool, you install only one at a time.", "By the late 1960s, fishermen just couldn't keep up with a growing global demand for shrimp.", "This gave birth to commercial shrimp farming.", "Most shrimp farms are located near the sea for access to salt water.", "The greatest producer of farmed shrimp is asia, with thailand being the largest exporter.", "Shrimp hatcheries raise the offspring of their breeding stock through three larval stages, then sell them to shrimp farms, which grow them to market size.", "As this model demonstrates, the shrimp farm first purifies the seawater it uses, through a system of treatment ponds containing fish that feed on microorganisms.", "Then the farm pumps the treated water to a culture pond, in which the juvenile shrimp grow to maturity.", "This is what the shrimp look like at about 2 months old.", "Shrimp farms are typically located on a coast for seawater access.", "Workers spread organic fertilizer before filling the culture pond to restore the soil bottom to optimum conditions between harvests.", "They pump seawater into the first treatment pond, where tilapia fish naturally purify the water by consuming floating microscopic organisms called plankton.", "Plant matter in fish feces settle at the bottom of the pond.", "A pump moves water from this first treatment pond to a second one.", "For another round of this natural cleaning process.", "Then a pump transfers the water from the second treatment pond to the cultural pond.", "Once the pond is full, they release the juvenile shrimp purchased from the hatchery.", "Workers regularly monitor the water's oxygen level and run aeration propellers when it drops too low.", "The agitation also helps debris settle at the bottom of the pond.", "Workers run a weekly water quality test on samples drawn from the treatment and culture ponds.", "Regularly monitoring the cultural pond is particularly critical because shrimp feces and urine break down into ammonia, which is toxic at high level.", "The test solution reacts to the concentration of ammonia in the water sample, turning a shade of yellow or green.", "They consult a color chart to translate this into a milligrams of ammonia per meter reading.", "Then they consult a table showing safe, dangerous and toxic levels.", "If the reading is above the safe range, they dilute the ammonia by pumping more treated water into the culture pond.", "Once a week, they also pull a few shrimp from the culture pond to extract their livers.", "First, they examine the shape of the organ.", "They examine it under a microscope to see how fatty it is.", "A well-shaped liver with sufficient fat indicates the shrimp was in good health, and, therefore, the others back in the pond are too.", "The growing shrimp are fed an all-natural diet, which includes probiotics, tamarind, which is soaked in water...", "And garlic.", "Workers add these three ingredients to the shrimp feed, which is a mixture of fish meal, fish oil, soy bean pulp and rice flour.", "Tamarind maintains the right level of acidity in the shrimp's gut.", "Garlic prevents bacteria buildup in the colon.", "And the probiotic solution provides beneficial bacteria, which prevents infections and improves how the shrimp digests nutrients.", "After blending and liquefying the three ingredients, they mix in 6 fluid ounces per 2 pounds of shrimp feed.", "Four times a day, at 8 am, noon, 4 pm and 8 pm, workers pour food onto an automatic feeding machine, which distributes it evenly throughout the culture pond.", "The shrimp feed over the entire 12 hour period, eating the equivalent of about 4% to 5% of their body weight.", "After 4 to 5 months in the cultural pond, the shrimp mature to market size, which is 20 to 30 grams.", "Once they're harvested, the farm drains the culture pond and starts the process all over again.", "The ball valve came into large scale industrial use during the 20th century.", "With a hollow and pivoting ball to control the flow of fluids, this valve is durable and resistant to contamination.", "It's why many industries rely on ball valves to keep production flowing.", "Ball valves control the flow of gases.", "In machinery used to produce high-tech products like led lights.", "It's just one way they contribute to the modern world.", "Making ball valves for led manufacturing starts with an 11-foot long steel bar stock.", "As coolant, a saw carves it up like salami, producing 50 or 60 steel pucks.", "Computerized tooling then drills holes in the pucks, as it begins to transform them into the valve center parts.", "The system changes tool bits automatically.", "Cutters square up the pucks, so that they'll fit in the led chip making machinery.", "A grinding tool mills the tops of the parts to a precise tolerance.", "Once the final shape has been achieved, a worker gives the part a sanding.", "He removes rough bits, known as burrs, and smoothes the entire surface.", "With a narrow blade, he then scrapes off any burrs in the holes that could impede the valve's function.", "With the deburring complete, he measures each valve body.", "Ceramic bits that look like aquarium gravel will now be used to polish the steel valve parts.", "The operator places the valve bodies in the cells of a drum tumbler.", "He puts the lid on the tumbler and sets it in motion.", "The friction polishes the steel, creating a smooth surface that won't block the movement of gas molecules.", "Next, they assemble flanges to the endcaps.", "After tack welding the two parts together, an operator places them in a revolving fixture.", "He welds them together, creating a substantial inside seam that will hold up to vacuum conditions.", "He scrubs off the heat stain inside the part, using a wire brush.", "The stain has also spread around the seams on the outside of the parts.", "So a worker rinses the outside of the seam with water.", "He washes off the stain using an electrified carbon brush and an acid cleaning solution.", "Then it's in to an ultrasonic cleaner, where soundwaves ripple through water to remove dust and cleaning solution residue.", "To assemble the ball valve, the technician places two rubber o-rings on top of an endcap.", "Next is a thick synthetic ring, which will secure the ball in the valve.", "He seats the valve body over it.", "He cleanses the hollow steel ball and inserts it in the valve body.", "He stacks more rubber sealers, another synthetic sealer and another endcap on top.", "He inserts long bolts into the four corners of the valve and secures them tightly with nuts to keep air from seeping into the valve.", "He attaches a handle to the stem, protruding from the valve body.", "He installs a stop pin to prevent the handle from opening beyond a quarter turn.", "Finally, he tightens the nut that locks the handle to the valve stem.", "He now secures the ball valve in a vise to hold it steady while he tests its function.", "When the whole of the ball is aligned with flanges of the endcaps, the valve is open.", "And when it's perpendicular to it, it's shut.", "Satisfied with its function, he transfers the ball valve to the laser engraver.", "The laser etches the serial number and other information onto the valve body.", "And now, one final test, the technician connects the valve to a vacuum pumping system and activates a leak-detecting device.", "While the pump draws a vacuum, he sprays helium gas onto the valve to detect any leaks.", "This ensures the valve will operate properly in a high vacuum environment.", "Some of these ball valves are manually operated.", "And others are computerized.", "Both versions are designed to hold up to high vacuum conditions and handle the flow.", "If you have grass or weeds to cut, but can't access the spot with your lawn mower, you need a string trimmer for the job.", "It's compact, letting you cut around and in between objects, and doesn't ride on the ground.", "So you can easily use it on a steep terrain.", "A string trimmer slices the vegetation in its path with a rotating nylon line.", "The motor that turns the spool of line is protected by a two-part housing made of polymer.", "The polymer pellets are pumped through pipes to the hopper, that feeds an injection molding machine.", "The machine melts them, then shoots the liquid plastic into housing-shaped molds.", "The machine then cools the molds to solidify the plastic and ejects the molded parts, which a robot grabs and places in a collection box.", "To make other plastic parts of the string trimmer, they install different molds on the injection molding machine and hook up the feed line for whichever color pellets they're using.", "To make the cutting line, an extrusion machine melts down plastic pellets, then forces the liquid plastic through a round die to form line.", "A cold water bath cools and solidifies the shape.", "Then, heated rollers stretch the line until its reduced to 3 millimeters in diameter.", "The line is wound onto large spools, which feed the machines that wind the finished trimmer spools.", "On the engine assembly line, an automated machine applies sealant to the magnesium engine pan.", "They place the cylinder on an assembly fixture, apply a gasket, then insert the piston.", "Already assembled to the crankcase, its up and down motion turns.", "Then they mate the engine pan to the crankcase.", "The sealant in between making that connection airtight.", "An automated machine screws the components together, then closes off the exhaust ports and pulls a vacuum to test the seal.", "If the engine assembly passes the test, it continues down the assembly line.", "They install a gasket...", "The carburetor...", "Another gasket and the housing for the air filter.", "Then they install a baffle, which distributes air so that it enters the air filter evenly.", "They attach a gasket under the muffler and screw the muffler onto the cylinder.", "The gasket and sealant on the screws ensure the only exhaust gases can escape through the muffler.", "Next, the flywheel.", "When it rotates, magnets inside produce an electromagnetic field the ignition uses to set off the spark plug that starts the engine combustion cycle.", "After mounting the clutch on the flywheel, they install the spark plug on the cylinder.", "This automated machine simultaneously tightens the spark plug, the clutch and the flywheel to specified torques.", "By this point, workers have welded a fuel tank to the motor housing.", "They've also installed a trigger, a trigger release, and a stop switch.", "They place the assembled engine into the housing.", "They also place the air filter into the filter housing.", "At the next station, they attach the other half of the motor housing.", "A robot tightens the screws to a specific torque.", "Next, they screw a cover on to the filter housing.", "Then they create the trimmer's powerhead by installing the starter cover.", "It contains the cord you pull to start the engine.", "Elsewhere in the factory, they build the shaft assembly, to which they'll later attach the powerhead.", "First, they put together the handle in the gearhead that turns the spool of line.", "Then they install the spool.", "When the cutting line wears down from use, you tap the spool against the ground to automatically advance more line.", "They insert the shaft assembly into the powerhead.", "The other end of the drive shaft connects to the gearhead.", "The last step is to attach the gearhead's deflector, which is designed to help prevent what you're trimming from flying up at you.", "To use the string trimmer, you fill the fuel tank with a gas and oil mixture.", "Then, just pull the cord to start her up." ]

{ "things": [ "Wood Watches", "Steel Bicycles", "Raw Pet Food", "Replica Police Lanterns" ] }

[ "Sure, your mobile phone will give you the time, but not nearly as conveniently or fashionably as a wristwatch does.", "Watches come in a variety of materials, often combined with stainless steel.", "But one of the more creative pairings is stainless steel with wood.", "This company makes wristwatches which feature exotic hardwood accents.", "This particular model is a limited-edition series designed for new york yankees baseball fans.", "The blue-painted maple comes from wooden seats salvaged from the original yankee stadium, which opened in 1923.", "At the watch factory, a worker first cuts a strip of wood just over a third of an inch thick, then cuts it into blocks measuring around three fourths of an inch by a third of an inch each.", "Manufacturers will ultimately use these blocks to make the wood inlays in the links of the watch bracelet.", "The worker then cuts another strip from a piece of wood, this one nearly a quarter of an inch thick.", "The worker then cuts this strip into nearly 2-by-2-inch squares.", "Each one will become a ring called a bezel that goes around the watch dial.", "Another worker mounts one square at a time on a lathe and bores a hole through the middle.", "She mounts several board squares onto a steel mandrill that attaches to the lathe along with the bezel template.", "As the lathe turns, a steel roughing gouge rounds the squares to the diameter of the template.", "She takes one bezel at a time and cuts it to the required thickness, about a tenth of an inch.", "She then shaves wood from the underside so as not to remove the historic blue paint on top.", "To make the watch case, which houses the dial and movement, the manufacturers cut a blank piece of extruded stainless steel, then place it in a computer-guided machine.", "Under a continuous shower of lubricant, the machine's 12 different tools take turns shaping the piece into a watch case.", "The first tools bore a hole in the middle for the movement and carve a groove around the hole for the wood bezel.", "The next tools cut the outside profile of the case and the lugs for attaching the watch band.", "Then, the final tool drills holes in the lugs for the spring-loaded pins that attach the watch band to the case.", "Another computer-guided machine makes the watch band and links out of a bar of stainless steel.", "This machine reduces the bar and width, carves out the links and bores holes for the connecting pins.", "A process called ion plating puts a black finish on all the stainless-steel parts.", "Then, a worker assembles two bands and connects one to the watch clasp.", "Next, he attaches the watch case window.", "It's made of sapphire glass, a crystal that's exceptionally durable.", "He inserts the self-winding movement and dial.", "The dial is a sheet of brass with cut-out numbers and indices over a base.", "Coated in luminescent paint, the watch glows in the dark.", "He secures the movement to the case with a retaining ring, then inserts the crown, which sets the dial's hands.", "The worker screws on the stainless-steel case back.", "The watch's window of sapphire glass allows you to see the working movement inside.", "The case back is engraved with the name of the limited-edition collection and this watch's number in the series.", "He attaches the watch band to the case with spring pins.", "With the watch now fully assembled, it's time to inlay the yankee stadium wooden chair accents.", "Using a toothpick, a worker applies epoxy glue to the rectangular recess in each link.", "Then he places a wooden link piece in each recess.", "He follows the same process for the dial's wooden bezel.", "A worker sets the watch aside for 24 hours to let the adhesive set.", "Then the worker buffs the entire surface on a cloth polishing wheel.", "This process removes the fingerprints and dust and smoothes those historic wood accents.", "The watch automatically winds with wrist movement to reliably tell the time while nostalgically going back in time.", "If you're looking for an affordable bicycle that's durable and has great shock absorption capabilities, then a bike made of steel is for you.", "It's a bit heavier than a high-end bicycle made of aluminum or carbon fiber, but this rugged material buys you a smoother ride at a significantly lower price.", "This three-speed steel bicycle is sturdy and comfortable enough to ride recreationally or daily to school or work.", "A cargo rack in the rear can hold your purse, backpack or briefcase.", "The bike is made of chromoly steel, which is, pound-for-pound, stronger than standard steel.", "To prepare the bike's tubular parts including the frame, a worker cuts steel tube with a horizontal band saw into specific-length pieces.", "He then clamps certain frame pieces into a milling machine, which will cut a curve into one or both ends depending on the piece's location in the final assembly.", "This notch, as it's called, will let the tube butt up against the side of an adjacent tube when the bike's frame is assembled.", "The notched edge is ragged, so the worker smoothes it out with a small belt sander.", "Certain frame parts are straight, others bent.", "To make the bent ones, another worker places the piece of tube in a tube bender, a press that forces the tube against a curved dye.", "Once all the frame parts are ready, a welder clamps them in a fixture, which correctly positions them for assembly.", "He works with a welding torch in one hand and a rod of filler metal in the other.", "The torch melts adjacent tubes at their meeting point so that they fuse together.", "The welder also melts in some filler metal to strengthen the joint.", "The bicycle frame is made up of nine major parts.", "And the welder welds them to each other in two sections, forming the rear triangle and the front triangle.", "This is the rear one, which alone requires nine meticulous welds.", "Once each triangle is separately assembled, he welds them together.", "Another worker sprays the frame with powder-coat primer, then color.", "Powder coat is an industrial-grade, paint-like finish, which he bakes onto the metal at almost 400 degrees fahrenheit for 20 minutes.", "When the frame comes out of the oven, another worker presses steel caps into what's called the head tube, that vertical tube at the front of the frame which holds the handlebars on top and the fork for the front wheel at the bottom.", "Bearings inside the caps let the handlebars and fork turn left and right with ease.", "To put the bicycle together, the worker suspends the frame in an assembly stand and then inserts the bottom bracket, which will ultimately support the bike's drivetrain system.", "The bike's fenders are made of sheet steel that's shaped with pressure-applying rollers.", "The rear fender attaches to the rear dropout and at fender mounts at two other locations on the frame's rear triangle.", "He screws the cargo rack to middle and rear rack supports.", "Then, he inserts and bolts the rear wheel into the rear dropout.", "The wheel hub has three built-in gears.", "The hub and rim are made of aluminum, which is lightweight and doesn't rust.", "The wheel spokes are stainless steel.", "Next, the worker installs the drivetrain system, inserting the crank arms, already mounted to the chain ring, onto the bottom bracket.", "He tightens the bolt securely with a torque wrench.", "Workers then insert the fork into the bottom of the head tube and chrome-plated steel handlebars into the top mount, the front fender and front wheel, then install the pedals, vinyl seat, chain and chain guard.", "With the gear shifter and front brake lever on the handlebars, this steel bicycle is ready to hit the road.", "For some pet owners, feeding raw food to fido is a natural choice.", "It harkens back to the common ancestor of all dog breeds, the wolf.", "In the wild, wolves eat raw meat and occasionally some greens, so the theory goes that dogs are genetically predisposed to thrive on a raw-meat diet.", "Dogs have been domesticated for thousands of years, but when it comes to their diet, they can still go a little wild.", "Raw canine cuisine may be a foreign concept to some pet owners, but it's becoming more mainstream.", "The makers of raw dog food often mix fruits and vegetables with meat to provide fiber and create a balanced meal.", "The process starts with a lot of slicing and dicing.", "A food worker chops the fruits and veggies into smaller pieces so they'll be able to go through a grinder more easily.", "He also removes the seeds from the apples and the squash because the seeds aren't as easily digested as the rest of the fruit and provide no additional nutrition.", "This raw pet food recipe calls for a variety of fruits and vegetables.", "Though, in total, they will comprise just 5% of the meal.", "The rest of the raw blend will consist of meat, bones, organs and fish.", "Another food worker chops up the chicken, which has been organically raised and has even been approved for human consumption.", "Except for the breasts, all the parts of the chicken will be used in the main recipe.", "This includes the heart, liver, gizzards and the bones.", "Raw, whole sardines, anchovies and mackerel will add essential fatty acids to the raw chicken blend.", "All the ingredients have been prepared and are now ready for grinding.", "A worker feeds the components to the grinder in small batches interspersing the meat, fish and the vegetables.", "This ensures even distribution, as the grinder minces everything to a uniform particle size.", "The result is a thick emulsion of finely ground chicken meat, bones, vegetables, fruits and fish.", "She transfers the minced raw ingredients to a mixer.", "The revolving paddles further blend the food.", "After about 5 minutes in the mixer, all the ingredients have been combined into one homogeneous raw mass.", "This chicken blend is now complete.", "The worker divides it into 5-pound batches and scoops it into bags.", "She vacuum seals the bag.", "Removing all the air inside will allow the raw blend to stay fresh longer.", "Refrigerated, it should last for up to 10 days and, if frozen, it should be good for several months.", "For the furry members of the family, dinner is ready to be served.", "To make some raw pet snacks, a worker de-shells new zealand green-lipped mussels, a species that is believed to have fast-acting anti-inflammatory properties.", "After she cuts the mussels free from the shells, she places them on racks for air-drying.", "She transfers the rack into a drying tent where fans keep air circulating 24 hours a day.", "As the mussels dry, they shrink.", "After 72 hours in the tent, the moisture content is substantially reduced.", "Air drying has preserved the flesh of the mussels in the raw state while preventing damage to the nutrients and enzymes they contain.", "Now preserved, she packs the mussels into plastic bags and adds an iron oxide packet to absorb oxygen and prevent spoilage.", "This raw pet food is now ready to nourish the wolf in your dog.", "Before the invention of electricity, criminal acts were hidden by darkness.", "Police officers carried special lanterns as they pursued suspects.", "Today, craftsmen replicate these lanterns for the movie and television industries.", "These props are authentically replicated pieces of police history.", "With a thick bull's-eye lens to magnify the light from the flame, the 19th-century police lantern helped find bad guys on shadowy streets.", "To replicate a vintage police lantern, the craftsman starts with a piece of steel.", "Using a scribe, he traces around a pattern to transfer the outline to the blank.", "He marks notches for hinges and for the latch and etches the shape of the lens hole in the center.", "He draws two diagonal lines in the lens hole area.", "The point where the lines intersect determines the exact center.", "He punches a divot into the steel at this cross point.", "He scribes lines along the edges for bending into a reinforced border later on.", "He cuts out the hinge and latch notches following the transferred pattern lines.", "Next, he aligns the center divot with a punch and then activates the punch to cut out the hole for the lantern lens.", "The craftsman now bends wire to match the profile of the lantern door.", "He aligns the wire with the scribed lines on the edge of the door and folds the metal over it.", "Bending the door to the correct curvature completes the part.", "Following another pattern, the craftsman marks the location for vent holes in the blank that will become the lantern's main structure.", "He cuts out the vent holes where he's made the marks using a hand-operated punch.", "He then rolls the blank into a cylinder.", "It takes a couple of passes to achieve the correct curvature.", "Moving on to the lantern's lens holder, the craftsman crimps a bead around one end.", "This bead helps to retain the bull's-eye lens in the holder.", "Returning to the lantern body, he hammers the top rim around the cap.", "He preps the surface for soldering with a chemical cleaning agent known as flux.", "He then solders the joint to secure the top to the lantern.", "He also solders a raised panel to the back.", "This substantial panel serves as support for handles.", "He then cleans the solder joints with acetone.", "Next, he wraps metal hinges around the wire that runs through the notches in the door.", "He crimps the hinges together at the ends and positions the door on the lantern body.", "He adjusts the hinges so the ends sit level on the lantern.", "He solders the hinges to the steel structure.", "The craftsman inserts the bull's-eye lens assembly into the hole in the center of the lantern door, and he solders the joint.", "He pins and solders the two tiers of a copper chimney.", "He places the chimney over the hole in the top of the lantern and tucks more pins into holes in the chimney.", "The craftsman installs a decorative part in the top, one that won't obstruct the chimney hole.", "He assembles the handles to the raised panel at the back of the lantern.", "Once the soldered seam hardens, he files it down.", "The craftsman tests the latch on the door and confirms that it operates perfectly.", "After taping up the lens and handles, he spray paints the lantern black.", "Now it's time to assemble the oil-burning mechanism.", "First, the craftsman melts solder onto a threaded brass collar and transfers it to the oil tank.", "He reheats the solder to melt it into the joint.", "He inserts the wick in the tank and screws the burner to the collar.", "And that completes the lantern's light source.", "This replica police lantern will be a working prop designed to shine on tv and the movies." ]

{ "things": [ "Corn Tortillas", "Crankshafts & Camshafts", "Bush Planes", "Aluminum Bike Wheels" ] }

[ "The corn tortilla is the original flatbread invented, legend has it, thousands of years ago by a mayan peasant to feed his king.", "A royal appetite may have been the inspiration for this unleavened creation, but it soon gained mass appeal and became a staple of the mexican diet.", "The corn tortilla has been popular for thousands of years.", "In the last century, demand has grown as people in many countries acquire a taste for tex-mex cuisine, like tacos, enchiladas, and nachos.", "Corn tortillas are now mass-produced in factories, and the process starts with grade-\"a\" corn-- dehusked and removed from the cob.", "There are millions of kernels in one truckload.", "They unload onto an elevator that takes them several stories up to deposit them in a silo.", "They're stored here until the factory is ready to start production.", "They then spill out of the silo and into big steel cooking vats.", "A worker adds water, completely immersing the corn.", "He activates a steam-injection heating system, and as the temperature rises, he tosses in numerous scoops of powdered limestone.", "It acts as a preservative and helps soften the kernels during cooking.", "As they soften, the outer skin, or pericarp, loosens, releasing starch and creating a foamy effect.", "After 45 minutes, they turn off the heat, and the corn steeps for eight hours.", "With the kernels softened even more by the long soak, it's time to wash off a lot of the loosened pericarp.", "A little pericarp still clings to the cooked corn, but that's part of the plan.", "It will act as a bonding agent when the corn is shaped into tortillas.", "The corn now funnels into a spiraling blade that delivers it to a grinder.", "They add water and a preservative.", "The auger moves the ingredients between two volcanic stones that grind everything into a corn mash.", "The mash has a grainy texture similar to couscous.", "That changes when they press it through an extruder.", "The extruder kneads it into a dough called masa.", "As the masa exits the machine, it's collected by a worker.", "He transfers the corn dough to a machine called a pre-sheeter.", "Here, automated paddles push the masa between two sets of rollers.", "The rollers press it into a thick sheet.", "The sheet of dough travels through another machine called the sheeter cutter.", "In this machine, more rollers squeeze the dough paper-thin as a die cuts out round tortilla shapes.", "They roll and cut 84,000 tortillas an hour on the sheet cutter.", "Another big roller takes up the matrix to be reused in the next batch of dough, as the cut tortillas head into the oven.", "Once inside, the tortillas zigzag back and forth on three tiers of conveyors.", "The lowest tier has the lowest temperature, and the top tier, the highest.", "This three-tiered approach gradually bakes the tortillas in just 21 seconds, producing corn tortillas with just the right consistency.", "A vacuum system suctions the tortillas to the next conveyor to keep them from falling off, as they now head to a cooling station.", "Here, the tortillas again move to and fro-- this time on nine conveyor tiers to cool.", "From a handful of corn kernels to a piece of round unleavened bread, once the corn has been cooked, the transformation happens in just minutes.", "Whether the tortilla is made from white corn, yellow corn, or dyed other colors, the taste will be much the same.", "Exiting the cooling zone, the tortillas move into lanes.", "These lanes orient the tortillas in single file so they land in slots and stack up neatly.", "A sensor keeps a running count, and when there's a pile of 40, a trapdoor opens and sends them to the packaging line.", "These tortillas are now ready to add a little latin sizzle to the menu.", "Packaged in stacks of 80, they're headed for restaurants and cafeterias-- fried, steamed, or just warmed in the oven.", "When they start adding the fillings, things could get spicy.", "In every vehicle, there are rotating shafts.", "The crankshaft converts the pistons' vertical action into the circular motion that drives the wheels.", "At the same time, the camshaft turns to open and close airflow valves.", "These precision parts are behind every successful start-up.", "Life on the road can be tough, and a good crankshaft has to keep on turning when the engine is under stress.", "The crankshaft starts with a forged steel shape.", "A computerized blade shaves off excess metal from sections called counterweights.", "They offset the load of the engine's pistons and connecting rods, and this process slims them down to create a balance.", "A computerized drill bores holes into one of the bearings to reduce the overall weight.", "Next a worker removes marks the computerized tools have left on the metal.", "He sands the entire crankshaft.", "The surface must be completely flawless for it to operate smoothly.", "Fine glass beads blast the part as it revolves in a rotisserie-like device to knock off sharp edges and give the crankshaft a consistent finish.", "The crankshaft then spins in a lathe, as a blade slices away a precise amount of metal from each of the counterweights.", "This machining provides enough clearance for the engine's pistons and rods to function.", "The crankshaft then takes another spin in a device that has sensors to detect any imbalance.", "It calculates that just over 29 grams of metal still needs to be removed.", "Once the adjustment has been made, he measures the degree of straightness.", "If it's off even slightly, he corrects it by applying pressure with a press and tapping a special radius chisel.", "He then measures again to confirm he's done an even job.", "On the left is a crankshaft that hasn't been balanced or straightened.", "On the right is one that has.", "Production now moves to the engine's other rotating shaft-- the camshaft.", "Machining transforms a steel billet into the basic shape.", "Like the crankshaft, this camshaft will need a lot of fine-tuning.", "An automated tool first etches the part number and date onto one end, and then they get down to the precision work.", "The camshaft must also be completely straight, so the technician measures it from one end to the other and makes adjustments where needed.", "Next he selects a master template of a camshaft lobe and places it in a grinding machine.", "This master is the pattern to be copied by a grinding wheel.", "Once it's been locked in place, he activates the grinder.", "It carves into the camshaft as it rotates and rocks back and forth in the machine.", "The grinding wheel moves down the camshaft to shape all 16 lobes to the exact contours of the template.", "This is how the camshaft looked before the master grinding...", "And after.", "Next a computerized probe measures the profile of each lobe and confirms that the dimensions and lift are identical.", "At the next station, the camshaft spins to allow a worker to completely coat the journal bearings with a blue dye.", "The dye masks the bearings to keep them smooth while the rest of the camshaft is being parkerized.", "Parkerizing will give the camshaft an etched finish, which protects against wear.", "They start with a quick rinse.", "Then they plunge the camshafts into hot phosphorus acid.", "The acid microscopically etches the metal while other chemicals in the bath add a thin graphite coating.", "They rinse the residue.", "After the finish has dried, a worker buffs the journal bearings as the camshaft spins.", "This completely rubs off the blue dye and polishes the metal.", "He then wipes down the entire camshaft with a dry rag.", "He places the camshaft on a perforated metal shelf and floods it with oil.", "Some oil drains away, but a residue clings to the part, and that residue will prevent rusting.", "Once packaged, this rotating shaft is on its way to a garage or car factory, where, ultimately, it will do its part to help set the wheels in motion.", "Bush planes are designed to fly in and out of remote areas.", "They're engineered to be able to take off and land on short runways.", "They can also be outfitted with floats to be able to land on water or skis to land on snow.", "Some are made of metal, and others of tube and fabric construction.", "A bush plane starts out as a design on paper.", "This company handcrafts four-seater tube and fabric models-- the tubes forming the airplane's skeleton, the fabric, its skin.", "Welders construct a tubular frame for the fuselage, the plane's main body.", "The tubes are chromoly, a type of steel that contains chromium and molybdenum, which makes it stronger than standard steel.", "Machinists make the aluminum fuel-tank components...", "And prepare the landing gear.", "Here, they're threading the axle for the tail wheel-- a small, rugged wheel at the back, which helps steer the airplane on the ground.", "The landing gear consists of this tail wheel and two bigger wheels at the front.", "They all have large low-pressure tires, which enable the plane to take off and land on rough terrain.", "Workers spray aluminum pieces called ribs and spars with anti-corrosion paint, then rivet them together to build the internal structure of the wings.", "Using a crimping tool, they make tiny indentations in the ribs to perfect the alignment.", "Then they rivet on a skin of aluminum panels, about 1/50 of an inch thick in most areas.", "They construct the wing's hinged surface, the flaps, and ailerons the same way.", "The factory's paint shop sprays the wings, flaps, and ailerons with highly durable urethane paint, and the fuselage frame with powder-coat paint, which is then baked on for extra durability.", "Now for the meticulous job of applying the fabric skin.", "The material is heat-shrinkable polyester, commonly used in the aircraft industry because it's thin, lightweight, and exceptionally strong.", "Workers brush an adhesive similar to contact cement onto the painted tubing, then adhere the fabric, working around the frame section by section.", "Once the fuselage is completely covered, they run a hot iron over the fabric.", "This shrinks it taut around the framework.", "After letting the adhesive dry for a couple of hours, they take strips of fabric, coat them with a urethane-based adhesive, and reinforce the seams.", "It's the same construction process for the tail components.", "At the front of the fuselage now, they install the pedals, which control both the brakes and the rudder, which moves the tail from right to left.", "Then the cockpit instrument panel, a thin sheet of aluminum with laser-cut openings for all the flight instrumentation.", "Next two linked control yokes.", "They move a series of chains, which maneuver certain components such as the aileron control sprockets.", "Mechanics ran the fuel lines and most of the wiring within the fuselage frame prior to the fabric application.", "Now they install a stainless-steel fire wall between the cockpit and the engine.", "This seals the cockpit from engine heat, noise, and exhaust gases.", "After installing the landing gear, brakes, and windshield, workers mount the engine and exhaust system.", "Next the plane's aluminum propeller.", "Other workers are busy installing the fuel tanks inside the wings.", "The fuselage now goes to the paint shop.", "When it comes back, workers bolt on the wings, supporting them from underneath with steel wing struts.", "The wings on a bush plane are positioned higher than those on other types of aircraft to give the pilot better ground visibility.", "After rigging up the flight controls and installing the interior trim, workers install the doors, plexiglas windows, and cockpit seating.", "Each bush plane is inspected at every stage of the production process.", "When it's completed, it undergoes a nose-to-tail final inspection.", "And then a company pilot takes it out for a test flight.", "A serious cyclist won't pedal just any bike.", "It's got to have wheels made of strong-yet-lightweight material such as carbon fiber or aluminum.", "Advanced bicycle wheels have tubing and spokes, shaped as aerodynamically as possible to lower wind resistance.", "These elite-level racing wheels are made of aluminum.", "They're designed to generate a smooth ride with optimum responsiveness to the rider's acceleration.", "The starting material-- long, straight tubes of extruded aluminum, preshaped with a wheel-rim profile.", "Workers load one extruded tube at a time into a metal bender.", "The machine coils the tube around and around, forming four connected rims.", "After measuring to ensure the diameter is exactly what it should be, they mount the coil tube onto a cutter.", "With a single downward slice, it separates the four rims.", "They fuse the cut ends later on.", "First the rims need a bath in a tank of acid.", "The acid removes dust and other contaminants and etches the surface of the metal, both of which help ensure full adhesion of the anti-corrosion coating they later apply.", "Next a multiphase heat-treatment process.", "This restructures the aluminum molecules, making the metal harder and stronger.", "They join the two ends of the rim by riveting on an aluminum connector tab.", "Then they weld the joint to reinforce it.", "Using a sharp, vibrating cutting tool, a computer-guided machine smooths the weld line until it's nearly invisible.", "This makes the rim appear seamless.", "Now for that anti-corrosion coating.", "The process is called anodization.", "In a tank, they plate the aluminum with a protective chemical, using an electrical charge to draw the coating particles onto the rim surface.", "For this model, the anodized coating is black.", "However, there are several color choices.", "Next a computer-guided machine shaves off a minute amount of anodized metal from nearly a third of the rim surface.", "This creates a smooth, perfectly flat area for the brake pads to grip.", "The next computer-guided machine drills holes for the tiny aluminum nipples, which hold the aluminum spokes to the rim.", "Now it's time to assemble the wheel-- a manual task entrusted to specialized bicycle technicians, as it requires a level of craftsmanship no machine can perform.", "The first technician inserts a spoke into each slot of a carbon-fiber-and-aluminum flange-- part of the hub at the center of the wheel.", "Once every spoke is in its respective spoke seat, as it's called, he sandwiches them with a locking ring.", "Now for the rim end of the spokes.", "The next technician places a small steel plug inside a spoke nipple to make it magnetic.", "Then she puts the nipple into the rim, and, using a magnet, draws it to a spoke hole, then through the hole toward the inside of the wheel.", "Then she removes the steel plug and inserts the free end of a spoke into the nipple.", "She repeats the procedure for each spoke hole.", "This is known as lacing the wheel.", "The next technician holds each spoke steady while tightening its nipple with a spoke wrench.", "Tightening the nipple straightens the spoke.", "The process of perfectly aligning the wheel by straightening every spoke is called trueing the wheel.", "This gauge tells him when the wheel is finally trued.", "For quality-control assurance, this robotic machine inspects each spoke and makes any necessary tensioning adjustments.", "Depending on the model, a high-end bicycle wheel can have anywhere from 10 to 46 spokes.", "Different spokes for different folks." ]

{ "things": [ "Levels", "Hot Dogs", "Abrasive Grains", "Sandpaper" ] }

[ "Today on \"how it's made\"...", "Levels...", "Hot dogs...", "Abrasive grain...", "And sandpaper.", "The level was invented in the 17th century to keep structures plumb and true.", "Without it, buildings would lean, floors would be crooked, and maps would have inaccurate elevation information.", "No matter what you're making, this critical tool always gives it to you straight.", "It's a centuries-old concept, but still measures up.", "Center the little bubble, and you're perfectly straight.", "Production begins with a length of laminated birchwood.", "An automated router carves out several holes, three of which will enclose the vials.", "The other two will serve as handgrips.", "Next, it's time to tackle the wood's perimeter.", "Grooves are cut along the length of the wood for the level's brass binding.", "Strips of brass are unwound into a forming machine.", "Rollers iron out the curl from the coiling.", "Other rollers then crimp the brass.", "This process will allow the strip to fit into those grooves in the wood.", "Lengths of brass binding are loaded into a machine that slides them into place.", "This reinforces the edges of the wood.", "Over at another station, a machine melts and molds the plastic for the vials.", "Each one is slightly curved inside so the bubble has a place to sit.", "The vials wind their way through a vibratory feeder.", "It takes them to a gripper that rotates each one so the open end faces up.", "In goes a squirt of yellow mineral spirits, leaving just enough room for a bubble to form.", "A robotic arm plugs the vials with plastic caps.", "Then this sonic welder melts the caps onto the vials using high-frequency sound waves.", "Now it's time for inspection.", "A tiny camera photographs the bubble and sends the picture to a computer that makes sure the bubbles are the right size.", "For this production run, the bubble should be about half an inch wide.", "If it's on the mark, the computer allows the vial to move on.", "A printer then hot-stamps centering marks onto the vial.", "But this spirit vial isn't quite ready for business.", "First it needs to bake for 24 hours.", "The heat exposes any flaws, and the defective vials are rejected.", "The vial is illuminated with a bright red light as it slowly spins between rollers.", "A camera photographs the bubble, and a computer scans the image to check for shifting.", "Too much shifting could compromise the level's accuracy.", "The vials that pass the test then go on to a molding system.", "Melted plastic is injected into the crevices to make a cradle for each vial.", "Next, a technician glues the cradled vials in the openings in the wooden framework.", "This is precision work.", "Each vial has to sit perfectly level, so technicians rely on a magnified image to check their progress.", "Some vials are installed vertically to gauge if the walls are plumb, while the horizontal ones let you know if the floor is level.", "Acrylic-rimmed windows are fitted over the vials to protect them.", "Rubber caps are screwed on to both ends of the level.", "And finally, the trademark stamp goes on.", "These levels are now ready to straighten up any jobsite.", "When we return, the real skinny on an all-american favorite.", "Hot dogs are an all-american fare.", "But most likely it was german sausage makers who first came up with the idea.", "In fact, there are reports of german immigrants selling them from pushcarts in new york's bowery as far back as the 1860s.", "A century and a half later, hot dogs are still the number-one treat on the street.", "Traditional hot dogs are made from a mix of pork, beef, and chicken.", "The cuts they start with are called trimmings-- pieces of meat left over from cutting steaks or pork chops.", "The trimmings are ground the same way butchers chop up hamburger meat-- by pushing the cuts through grated metal plates.", "Processed chicken trimmings are added to the ground meat, followed by food starch, salt, and other flavorings.", "These flavorings vary depending on where the hot dogs are to be sold because people in different regions have different tastes.", "Water is sprayed into the mix, and everything is blended together in a big vat.", "Corn syrup adds a dash of sweetness.", "The addition of even more water helps to disperse the ingredients and make the hot dogs juicier.", "Another machine then purees the meat batter into a fine emulsion and vacuums out any air.", "Long rolls of cellulose tubing are loaded into the stuffing machine.", "It pumps the meat puree into these casings, twisting it every 5 1/4 inches-- the length of one hot dog.", "It takes just 35 seconds to make a chain of hot dogs that would span a soccer field twice.", "Then three of those hot-dog chains are linked together to make an even longer string, and they're loaded several at a time into another machine, which drapes the hot dogs onto moving racks.", "The process is carefully timed so that a twist always lands on the bar.", "The racks shunt the hot dogs through a liquid smoke shower, then into an oven with several cooking zones.", "The liquid smoke seeps through the casing and adds flavor to the dogs as they bake.", "Hot out of the oven, these franks are drenched in cold, salty water to chill them in preparation for packaging.", "The hot dogs then file down to an unloading zone.", "Here, a machine pulls them off the bars onto a conveyor.", "Then the hot dogs slide off the conveyor into metal containers.", "If you've been wondering about those black stripes on the casings, all is about to be revealed.", "The stripe is a marker attached to the casing.", "The absence of a black stripe means the hot dog is cooked and ready for packaging.", "Inside the peeler machine, a tiny knife slits each casing along the top.", "Then steamy air blows the casings right off the dogs.", "This machine peels 700 hot dogs a minute.", "An inspector makes sure the casing has been completely removed and that there are no defects in the dogs.", "Then it's into a device that looks like a plastic bicycle chain.", "The sprockets position the hot dogs for packaging.", "This factory manufactures an incredible 300,000 hot dogs an hour.", "That's close to 2 1/2 million per shift.", "They really do churn them out like sausages.", "Fire up the grill, and a mouthwatering meal is just minutes away.", "Up next, the hot scoop on abrasive grains.", "It takes true grit to make sandpaper, as in abrasive grains.", "People have been using abrasive minerals to sand and polish things for centuries.", "Today, these minerals undergo heavy processing to make the grade, from very superfine to very coarse.", "Whether you're working on metal or wood, the right grade of abrasive grit is essential for finishing the job.", "The factory starts with bauxite, a naturally occurring mineral that resembles clay.", "They add alumina, a white powdery material that's actually derived from bauxite.", "The bauxite and alumina are blended with other minerals, then released into an electric arc furnace.", "Here, three large electrodes use intense electrical current to heat the mix to over 3,600 degrees fahrenheit.", "That's hotter than an active volcano.", "In fact, the mixture looks a lot like lava as the minerals melt and blend together.", "Standing well back and using a long ladle, a technician takes a sample for chemical analysis.", "If the mix is right, the molten minerals are emptied into a big steel pot.", "The searing liquid weighs several tons, so a crane is needed to transport it to a cooling area.", "24 hours later, with the material hardened, it's time to bring in the wrecking ball.", "It cracks open the hardened concoction, which is still quite hot at the core.", "The wrecking ball is dropped repeatedly to break up the hardened minerals.", "Next, the lumps of abrasive material are transferred to a conveyor system.", "Metal-plated crushers break them up into fist-sized chunks.", "A magnet picks up any excess iron.", "And then it's into the roll crusher, where iron cylinders grind the chunks to bits.", "Workers assemble screens in decreasing mesh sizes to make a kind of shaking sieve.", "It sifts the mineral particles through the screen with largest mesh first, then continues to sort the grits in progressively smaller sizes.", "For some perspective, we placed a quarter against the various mesh sizes.", "As you can see, only the finest particles could pass through tightest weave.", "The bits of grit bounce across the screens and fall into hoppers-- a different one for each size.", "The coarsest grains will be used for rough-sanding jobs.", "The smaller the grain, the finer the finish.", "The finest grits are virtually microscopic.", "The next step is to inspect the grain's shape.", "A sample is funneled into a cup.", "Then it's weighed.", "A higher weight means the bits are densely stacked and therefore blockish in shape with blunt edges.", "A lower weight means they're flat and sharp.", "A different test is used for the most minuscule grits.", "The particles are suspended in an an electrolyte solution.", "Then an electrical charge is applied.", "This allows inspectors to count and evaluate the grits via computer.", "Now these abrasive grits are ready to be packaged and shipped out.", "Coming up, we'll go to the sandpaper factory, where the abrasive grits meet their ultimate destiny.", "We'll have the nitty-gritty on that process next.", "To make sandpaper, you need a lot of grit.", "There are thousands of tiny abrasive grains on a single sheet.", "The whole idea is to create friction.", "By rubbing the sandpaper against wood or metal, you can remove defects and create a uniform surface.", "It's ironic that something so abrasive can make things look so smooth and polished.", "Sandpaper often isn't made from paper at all, but fabric like poly cotton.", "The cloth is unwound into a machine with a printing press.", "Rollers lined with rubber printers stamp product information onto the cloth.", "The cloth then travels underneath the printing press, where more rollers apply a heat-setting adhesive to the unprinted side.", "A computerized system measures the density of the coating to ensure that it's been applied correctly.", "Then the cloth is pulled one floor down to the electrostatic pit.", "Here, the environment is kept hot and humid-- perfect for applying abrasive grains to the cloth electrostatically.", "The grains are poured onto a conveyor belt in the pit.", "The conveyor moves the grains under the rolling cloth and between electrodes and ground plates.", "The system generates an electrical field that triggers a mini sandstorm.", "Once airborne, the abrasive grains stick to the adhesive-coated cloth and become embedded in it.", "This method allows for even distribution of the grains across the cloth.", "The grain-coated cloth now rolls out of the pit and back up to the main level of the factory.", "A technician cuts a swatch of the sandpaper, then peels away layers and makes three different cutouts-- one of the cloth alone, another of the cloth with the adhesive coating, and a third, the grain- and adhesive-coated cloth.", "He weighs each cutout to confirm that the sandpaper has been formulated precisely to specification.", "He also examines the gritty surface under a microscope to make sure the grains are standing up evenly.", "This production run gets the go-ahead, so workers move the sandpaper through a hundred-yard-long oven.", "It has three different heating zones, each progressively hotter.", "The increasing heat bakes the grains into the adhesive.", "The sandpaper is now rough enough, but it's not quite ready for use.", "In the next step, a coat of resin is rolled over the gritty surface, binding the grains to the base.", "After the resin is cured to the surface, these jumbo rolls of sandpaper are stored in a warehouse until it's time to cut them down to size.", "Some rolls are sliced into big sheets.", "These will be made into commercial sanding belts-- the kind used in heavy manufacturing.", "Another machine punches out sanding discs.", "And at this station, four rolls of sandpaper are simultaneously unwound into a machine.", "It carves the four layers into rectangles.", "These rectangles won't be used for sanding, but as grip tape for skateboards.", "From refinishing your furniture to nose-grinding at the skate park, sandpaper will always give you an edge.", "And with so many grits to choose from, there really is a sandpaper for every job." ]

{ "things": [ "Miniature Furniture", "Garden Steam Locomotives", "Hovercraft", "Folding Bicycles" ] }

[ "Selecting furniture is a matter of scale, especially when it's a dollhouse room.", "Miniature furniture is sized for really small spaces.", "A popular scale is 1/12 of full-sized furnishings.", "But as far as attention to detail, there's no need to scale down one's expectations.", "These are replicas of full-sized antiques, meticulously copied in miniature.", "This grandfather clock is modeled on an 18th-century one, and for the craftsman, no detail is too small.", "He first measures and cuts numerous components from pear-tree wood.", "This wood's small grain scales down well to make the miniature clock look more authentic.", "The parts are too thin and small to nail, so he glues them together, beginning with the front of the clock's trunk.", "He applies the glue sparingly with a tiny brass tool to prevent messy overflow.", "He installs the sides on the front of the clock trunk.", "And he adds a substantial-looking pearwood base.", "He spiffs up the front of the base with veneer paneling that's protected by a layer of tape for now.", "He carves angles and trim to make it fit neatly around the paneling.", "He now peels away the tape to reveal the swirled burl of the veneer wood, which has been cut from the root of a south-asian tree.", "He rubs the paneling against sandpaper to smooth its surface and expose more of the wood grain.", "Once the feet have been installed on the clock, he applies a strip of molding above the trunk.", "The crisp profile of this limewood trim is a classic touch.", "Carving a mini gable with the thin blade of a fretsaw is tricky, especially with this intricate design, called a swan neck.", "He sands the edges to finish off the job.", "The swan-neck gable is one of numerous little parts that, when pieced together, form the hood of the clock, which holds the face and clockworks.", "He joins the hood to the trunk, and with the basic structure now complete, he glues a tiny wooden crest to the center of the swan neck.", "He tapers it with a surgical scalpel.", "After staining the clock a deep antique mahogany, he sands it to make it look more authentic.", "He then brushes on coats of shellac sealer.", "It both protects the wood and provides a smooth surface for the next finish.", "After the sealer dries, he sands it a little and then applies two coats of traditional french polish.", "This mix of alcohol and shellac gives the cabinetry a high-gloss finish.", "Once it dries, he buffs the wood with wax to enhance the sheen.", "The clock door with its exotic veneer is also stained, polished, and waxed.", "Then, using tweezers, he positions tiny brass hinges on the door.", "He presses little brass pins into holes in the hinge to secure it to the door.", "He files the pinheads until their flush to the hinge.", "He now dips the pendulum and its weights in acid, which gives them an antiqued finish.", "He installs them in their compartment in the cabinetry.", "He now sets the clock upright...", "And paints the back basic black.", "He inserts a piece of clear acrylic into the opening of the clock hood.", "Acrylic has a slight wave to it that looks like old glass.", "This small watch movement is what will make this miniature grandfather clock tick.", "Using double-sided tape, he attaches it to the dial.", "He fastens the hands to the clockwork shafts, and then he lowers the dial and clockworks into the hood compartment.", "He signs the back with a paint-filled pen which makes his signature stand out against the black background.", "And finally, he glues a tiny tassel to the door handle.", "Including drying time for the various finishes, it has taken over three days to make this miniature grandfather clock.", "No small effort, but it's the little details that make a difference in a small space.", "It's out of the basement and into the backyard for the model train set.", "This trend is called garden railroading, and it merges two hobbies-- gardening and model trains.", "These outdoor train sets are often larger and more rugged than indoor ones, so people can hop aboard for a tour of the perennials.", "These garden-variety train sets have become the fastest-growing segment of model railroading.", "People design gardens to the scale of these trains to provide the perfect backdrop.", "This particular locomotive is a quarter of the size of the 19th-century original.", "It starts with a sheet of copper, cut to precise measurements with a guillotine blade.", "An employee then turns the crank of a machine to curl the sheet into a cylinder shape.", "This cylinder will serve as the barrel or outer casing of the boiler.", "The next worker assembles the boiler's internal components.", "He groups together numerous copper tubes and welds them to a firebox at one end and a copper plate at the other.", "He's now ready to enclose the firebox.", "He installs it on a base plate and then builds a protective shell around it.", "He then encases the heat tubes in the barrel.", "These boilers come in various sizes, depending on the scale of the locomotive being made.", "Next, a lathe spins as tools contour a bronze cylinder.", "This sizes it to fit a piston that sets the steam engine's wheels in motion.", "The cylinder on the right is the one that's just been machined.", "More tools transform basic steel disks into the train wheels.", "They make four wheels per locomotive.", "The next worker inserts a pre-cut sheet of steel in a device that, when activated, bends it in two places.", "The folding action shapes the sheet into the locomotive cab.", "Then it's into the paint booth for seven coats of epoxy paint.", "This gives this model train cab a heavy-duty gloss.", "With a steady hand, a painter now applies plastic tape around the perimeter of the cab to create a kind of linear stencil.", "He arcs the tape at the corners to soften the look.", "And then he brushes two coats of oil-based paint into the tape stencil.", "He allows three days for each coat to dry.", "Then he peels off the tape to reveal the crisp, clean lines that now frame the cab.", "He adds black border next to the white to give more depth to this custom paint job.", "They carve a piece of bronze into a valve to control the flow of steam to the piston.", "They assemble the locomotive chassis and paint it.", "They install the wheels and the network of pipes and parts that make them turn.", "They run compressed air through the system to confirm everything works.", "The worker adds a little oil to lubricate the wheels and the rest of the parts.", "He then opens the steam chamber to check the valve-and-piston action, which is the driving force of this steam locomotive.", "He pulls the forward and reverse lever to confirm that the wheels run in both directions.", "He applies the brakes, and the wheels grind to a halt.", "Now that everything on the chassis is checked out, this steam locomotive is ready for the chimney and boiler.", "The steam dome and a safety valve go on next, followed by the cab and roof.", "And this garden steam locomotive is now complete.", "A worker now shines a light through the boiler tubes to examine them for any obstructions.", "He pokes a brush through them to be certain and then gives them the all-clear.", "It's time to fire up the boiler using real coal.", "Hot gases flow through the tubes to heat the water in the boiler.", "Like a big kettle, this locomotive builds up steam.", "The pressure increases until it's ready to roll.", "Aboard one of these garden locomotive replicas, one can relive the heady days of steam engines.", "A hovercraft rides on a cushion of air created by powerful fans.", "This enables the craft to travel over both land and sea.", "The concept actually dates back to 1870, but it wasn't until the middle of the 20th century that a british inventor perfected it and the idea got off the ground.", "This model of hovercraft is equipped with a single fan.", "It both inflates the skirt, lifting the vessel about 10 inches, and creates thrust to propel the hovercraft over virtually any surface.", "Production begins with a hull made of lightweight polyethylene.", "The fabricator installs aluminum skids on the bottom to protect the hull during landings on rough surfaces.", "He screws plastic attachments for the hovercraft skirt into pre-marked positions on the hull.", "The technician drills 65 holes around the hull.", "The fan's air will pass through these holes to fill the hovercraft skirt.", "The hull consists of a thick, hard outer layer and a low-density inner layer that makes the material buoyant.", "It's what keeps the hovercraft afloat during stops on water.", "The crew now fastens the seat base and console in the front of the hull.", "Once it's secure, they fit the gauge panel in its slot.", "The team then moves to the back of the hull to install the drive belt, pulley, and the main drive frame.", "This pulley will transfer power from the engine to the fan.", "Once they confirm everything moves freely, they assemble the fan to the main drive frame with high-tension bolts.", "This duct will divide the fan's air into two streams.", "One stream will be directed under the craft to provide lift.", "The other will be routed out the back to generate thrust.", "They now return to the cockpit to attach handlebars to a steering mechanism.", "The engine can be either a two-stroke or four-stroke, depending on the amount of power desired.", "They connect it to the drive assembly and protect that connection with metal casing.", "Once the engine has been bolted into place, they equip it with a radiator...", "An air filter...", "An exhaust system...", "And a waterproof box containing the electrical components.", "Then they connect the fuel tank to the engine and cover the engine with a polyethylene hood to keep it dry.", "They install seating, including a rear bench, that accommodates three.", "Then the installer attaches two rudders to the fan duct.", "He links them with a bar so they'll move in tandem.", "These steering parts are made of marine-grade steel to prevent rusting.", "A quick check confirms the rudders are operational.", "The hovercraft's skirt is made of the same material used on shoe soles-- sturdy polyurethane nylon.", "They assemble the skirt to the hull in 65 different pieces.", "The worker loops each segment over a side bumper and secures it with a steel clip.", "He then attaches the bottom of each skirt piece to the little hooks on the hull.", "He uses plastic cable ties for this job, and there's a good reason.", "If the skirt becomes snagged on something, these ties will break and free that section.", "Then other parts of the skirt will balloon out to fill the breach and maintain the air cushion.", "And they also won't have to replace the whole skirt, just the section that's been damaged.", "After a final inspection, they take this hovercraft for a test spin.", "They check the steering and overall performance and enjoy gliding on air.", "A folding bicycle is a compact set of wheels.", "In seconds, it folds up into a neat little bundle, less than a third of its full size.", "The concept has been around for well over a century, and in recent years, it's on the comeback trail as urban commuters discover the advantages of downsizing this mode of transportation.", "A few quick folds and this bike no longer carries the rider.", "He carries it.", "The bike can then be carted onto public transit or into the office, and that makes it a handy way to get around town.", "They lubricate the rim of tubing, which makes it easier for machinery to pinch that end.", "The next machine uses several blades to trim the pinched end and cut a small groove.", "These exact cuts will enable the team to precisely install a hinge to the tube.", "Hinges are now gripped by a moving clamp that angles them for contouring and the drilling of holes for bolts.", "It's computer choreographed to produce a hinge that will attach snugly to the main tube.", "Once the hinge has been bonded to the main tube, a technician checks the job by exposing it to a magnetic field.", "Variations in the field would indicate a flaw, but he finds none.", "So next, he secures the tube on a work table so a tool can make scoops in the other end.", "Scooping this end will enable it to interconnect with another part of the bike frame.", "A hydraulic tool then bends the main tube to give it a slight curve so it will arch around a bicycle wheel.", "You can see the difference in this before-and-after shot.", "The main tube of the bike frame now undergoes a process called shot blasting.", "An operator turns a crank to make the tube revolve in an enclosed chamber as nozzles blow fine grit at the hinge point.", "This cleans up some of the rough patches.", "A little manual filing smoothes the area around the hinge.", "Smaller parts of the bicycle frame take a tumble with ceramic bits, and this agitation action improves the finish on these parts.", "Further down the production line, a worker locks the main tube in a jig.", "He butts a bracing tube to it at just the right angle...", "And then melts metal into the joint in a process called brazing.", "As the metal cools and solidifies, it seals the two parts.", "He now fits the bottom bracket onto the scooped end of the main tube and brazes them together.", "The frame of a folding bicycle is much more complex than that of a conventional one-piece a-frame bike.", "There are six parts to assemble in tight alignment, and that means there's absolutely no room for error.", "Once the main frame assembly has been painted, it's ready to be joined to the rear frame.", "He attaches it by bolting the hinge.", "He twists the bolts to just the right torque.", "He tests the folding and unfolding action of the rear assembly and then checks the lock to confirm that it functions properly.", "He installs the steering mechanism and wheel fork in the front of the frame...", "And bolts the front wheel to the fork.", "He verifies that the assembled steering column and handlebars are in working order...", "And then slides them into place at the front of the bicycle.", "He adjusts the position of the column so it folds at just the right angle.", "He then attaches the rear wheel, along with the gear hub, to the frame.", "He secures the chain wheel and pedals to the bicycle and fits the chain into the sprockets, joining the two ends so the chain will travel in a perpetual loop.", "He flips the bicycle around to install the seat, and it's time to fold.", "The rear frame flips neatly under the main tube assembly.", "The front wheel locks on to the rear frame.", "Sliding the seat pillar down locks the fold, and he lowers the steering column.", "After a final inspection, this folding bicycle is ready for the big city.", "And when dodging traffic becomes too much of a hassle, its owner can always fold it and take public transit." ]

{ "things": [ "Navajo Rugs", "Crude Oil", "Kaleidoscopes", "Titanium Dental Implants" ] }

[ "Rug weaving is a traditional art practiced by the navajo, an indian nation located in the united states where colorado, new mexico, utah, and arizona intersect.", "They originally wove blankets and clothing.", "Then, in the early 1800s, they began weaving rugs for sale.", "While many weavers create contemporary designs, navajo rugs typically feature bold geometric patterns.", "The wool-preparation and weaving techniques developed by the weavers' ancestors have been proudly passed down from generation to generation.", "Everything in a navajo rug comes from nature, starting with fleece-- raw wool sheared from a sheep.", "Working a handful at a time, the weaver removes the mats and tangles and places the wool on carders-- wooden paddles with metal teeth.", "By pulling one carder against the other, she straightens the wool fibers, lining them up in the same direction.", "This prepares them to be spun into one continuous strand of yarn.", "After three or four pulls, she flips the carders to straighten the fibers on the underside.", "Then she rolls up the fleece and adds it to the other rolls in the spinning pile.", "She spins the fleece one roll at a time with the traditional spindle that she lays against her thigh and rotates towards her with one hand.", "This movement twists the carded roll of fleece into a strand.", "When she reaches the end of the roll, she connects another and resumes spinning and keeps repeating this process until she's produced one long, continuous strand from about 50 rolls.", "Then she respins the strand to thin it out to the final weaving size.", "When she's done, she checks the entire length of the strand, pulling on the thicker areas to thin them out so that the entire strand is a consistent size from one end to the other.", "Here you can see the difference in thickness between the first spinning and the second.", "To infuse her wool with color, she prepares natural dyes-- sunflowers for yellow, walnuts for tan and brown hues, and cactus bugs for bright red.", "She puts the bugs in a stocking and soaks them in warm water overnight.", "Then, she submerges them in a pot of water, pours in the presoak water, as well, and simmers for 45 minutes to an hour and a half, depending on how vibrant she wants the red dye to be.", "Meanwhile, she soaks the yarn in warm water for at least a half-hour to open up the fibers so that they'll absorb the dye.", "After wringing out the yarn, she immerses it in the pot of hot dye and simmers for at least 45 minutes, depending on the amount of bugs, water, and wool.", "She stirs frequently to ensure it dyes evenly throughout.", "It's the same process with plant dyes, except that she doesn't presoak the plants overnight before boiling them in water.", "The shade of color depends on the ratio of plants to water during dye preparation, then of dye to the quantity of wool.", "Proportionally more plants than dye, the darker the shade.", "Proportionately less, the lighter the shade.", "Sunflowers and walnuts are just two of many plants the navajo have traditionally used to produce a rainbow of dyes for their textiles.", "With her wool now spun and dyed, the weaver picks up her weaving comb and begins.", "Navajo ancestors used trees as the sides of their looms.", "Today's weavers make looms from lumber or metal pipes.", "After stringing tight, vertical strands of wool called the warp, she uses a flat, handmade stick called a batten to pry a wide enough opening through which to pass her hand with the colored weaving wool.", "She weaves horizontally in and out between the warp first in one direction, then in the other.", "Then, she packs down the wool tightly with her comb so that the warp doesn't show.", "She mostly eyeballs the emerging unique pattern, occasionally counting vertical strands to calculate the symmetry, a signature feature of traditional navajo rugs.", "Crude oil, also called petroleum, is unprocessed oil found deep in the ground.", "It forms naturally from decomposed, prehistoric plants and animals.", "The color can range from clear to black, the consistency from very watery to very thick.", "Oil companies drill wells deep into the ground then install pumping units to draw up the fluid that contains crude oil and salty water.", "This oil field in central california has 6,000 producing wells.", "The pumping units can run 24 hours a day.", "However, a sensor triggers them to pump only when the fluid flow stops.", "Here's what goes on inside the well.", "With each downstroke, the pumping unit pushes a steel rod down the steel tube lining the well.", "With each upstroke, the rod rises, and the pressure difference between the fluid on the outside and fluid on the inside opens a ball-shaped valve plugging the bottom, letting the fluid flow up the tube.", "Another valve at the top releases the fluid out of the well.", "To drill a new well, workers first erect a drilling rig at the site then hoist a giant pipe with a drill bit on the end.", "They feed this drill pipe through the center of a spinning disk called a rotary table.", "As the table turns, the drill pipe turns, its weight bearing down and boring a hole through the ground.", "Once the drill pipe descends its full 30-foot length, they connect another pipe then keep repeating with subsequent drill pipes until they bore into the reservoir containing fluid.", "Throughout the drilling process, they pump a mud mixture down the drill pipe.", "It comes out the drill bit at the end, hits the bottom of the hole, then backs up to the top, bringing the drilled-out rock with it.", "After lining the well with a steel tube to keep the walls from collapsing inward, they mount the pumping unit and install the valves we saw in the model.", "The pumping unit pushes the rod up and down through the well head at the surface.", "As a safety measure, workers take readings to check the air for any hazardous underground gases that may be exiting the well.", "Once they determine the area is safe, they draw a sample of fluid to test the well's water-to-oil ratio.", "The typical ratio is 90% water to 10% oil.", "The fluid from each well exits via a pipe, and the pipes from all the wells feed a main line leading to a gas-removal vessel.", "The fluid contains carbon dioxide, hydrogen sulfide, and natural gas.", "They naturally rise to the top of the vessel and exit via a pipe which runs to the company's gas-treatment plant.", "There, equipment removes and treats the hydrogen sulfide, transforming it into sulfur, which a local farm buys to use as fertilizer.", "The natural gas and co2, meanwhile, are piped to another area, where they fuel the company's steam generator.", "The generator boils the water extracted from the fluid to produce steam.", "The company injects steam into the wells to heat the fluid, thinning it so that it flows faster.", "Once gasless, the fluid is piped to the treatment plant that extracts the salty water.", "In this big tank, appropriately called the free-water knockout, the separation of oil and water happens naturally, the oil floating to the top.", "However, to hasten that natural process, they add a chemical called an emulsion breaker.", "The extracted water exits via a pipe leading to the steam generator.", "The oil goes to a clarification tank in which a chemical process filters out sand, which the fluid brought up from the reservoir.", "The emulsion breaker added in the previous tank continues to extract water.", "By the end, when the ratio is 98% oil to 2% water or better, the crude oil is ready to sell.", "Built-in meters give instantaneous water-content readings.", "As an additional quality-control measure, however, the company also draws samples for analysis in its onsite lab.", "In fact, there's testing throughout production to ensure sufficient water is being extracted at each phase of processing.", "Refineries buy crude oil as a raw material for producing gasoline, asphalt, plastics, and many other products.", "Invented in the early 19th century by a scottish scientist studying light, the kaleidoscope can still compete when it comes to producing stunning visual effects.", "Peer inside and witness dazzling geometric images produced as mirrors multiply objects.", "The images are spectacular and fleeting, each one lasting just seconds before the next appears.", "Many years after its invention, the kaleidoscope is still worth looking into.", "To make a kaleidoscope, this craftsman starts with a mirror sheet that has adhesive backing.", "He scores it to create long and narrow rectangles and gently breaks it along the scored lines.", "The mirror's reflective coating is on the front instead of the underside.", "A mirror like this produces sharper reflections than a regular household mirror.", "He slices the adhesive backing to separate the mirrored rectangles.", "He snaps off the scored ends, creating perfectly linear edges.", "Next, he peels backing from a strip of black-out felt paper and wraps it around a glass rectangle.", "This felt-wrapped glass will be the third wall of a two-mirror system-- one with a triangular configuration.", "He removes the adhesive film from the mirrors then builds the triangles with the mirrors' reflective surfaces facing inward towards the felt-wrapped rectangle.", "This arrangement will reflect objects to create a circular image known as a mandala.", "He aims the mirror system at a light box with a two-line drawing in it.", "One line is curved, and the other is straight.", "Peering into it, he adjusts the alignment of the mirrors until the lines morph into a five-point star.", "This means the corners of the mirror triangle are precisely 36 degrees and it is multiplying images correctly.", "He hot-glues the mirrors to the opaque part and applies metal tape to the top seam to complete the kaleidoscope mirror system.", "Over in the art department, the artist assembles decorative objects against a black background in an acrylic cell.", "With every placement, she checks the effect through the triangular mirror system.", "She glues dichroic glass onto the backdrop.", "It's a kind of glass that's been treated with metal oxides, and it appears to have different hues.", "Other objects include jewelry parts, colored wire, buttons, and even paper clips.", "She follows no specific design but works freestyle.", "While she glues some down, she leaves others loose to simply tumble around.", "A sprinkle of tiny beads completes the grouping.", "As the mirror system multiplies these objects, they will create the mandalas.", "These are photographs of actual mandalas, and they'll be used to decorate the outside of the kaleidoscope.", "The other member of the team now applies an acrylic adhesive to the rim of the cell and presses a clear lid onto it.", "The lid fuses to the cell body.", "But it's not yet completely sealed.", "There's a tiny hole in the side of the cell through which he now dispenses heavy mineral oil.", "Submerged in mineral oil, the objects will float and move through the cell for greater effect.", "He plugs the hole with an acrylic adhesive and screw.", "He is now ready to assemble all the parts of the kaleidoscope.", "He slides the mirror system into a heavy cardboard tube decorated by the mandala photos.", "He cushions the mirror system with foam, and this stabilizes it.", "He installs a metal eyepiece and glass lens on one end of the kaleidoscope tube.", "He slides the object cell into a protective metal cage that rotates.", "He places a transparent glass disk over the cell.", "He applies adhesive to the cage and inserts the assembly into the other end of the kaleidoscope tube.", "This kaleidoscope is now ready for a viewing.", "Light passes through the object cell, illuminating the trinkets.", "Reflections bounce off the mirrors to create one spectacular illusion after another.", "Two centuries after its invention, the view through the kaleidoscope still fascinates.", "The ancient mayans hammered seashells into their jaws to replace missing teeth.", "Those seashells were likely the first dental implants.", "Today, titanium tooth implants fill the gaps nicely, and, usually, the patient's jawbone will actually bond to them.", "In the middle of the 20th century, it was discovered that titanium is a metal that bonds with bone.", "It revolutionized restorative dentistry, making enduring tooth implants possible.", "To make these implants, they start with a solid titanium rod.", "This 13-foot rod will be used to make more than 200 implants.", "The technician inserts the rod in a long tubular device that keeps it straight as it feeds to a lathe system.", "The titanium rod spins as computerized tools slim it down and cut threads into it.", "These threads will help anchor the implants in the patient's jaw.", "The lathe pushes the rod out and then pulls it back in repeatedly to facilitate the shaping process.", "A tool now grips the implant while another cuts it to length.", "Then, a computerized drill hollows out the implant and carves threads inside for attaching the ceramic tooth.", "In minutes, a solid, metal cylinder becomes a hollowed and threaded implant.", "A robot now retrieves the implant from the clutches of another one.", "It transfers it to a cleaning station and then over to what's known as a vision measuring system.", "Here, a camera takes pictures of the implant from all angles and sends the images to a computer for analysis.", "The computer confirms the dimensions are exactly right.", "Then, the robot collects the implant and places it into a slot in a tray.", "Once filled with implants, a technician screws a mesh lid on the tray and slides it into a metal basket.", "The basket positions them for cleaning in a special washing machine known as a vapor degreaser.", "Inside, solvent vapors envelop the parts to clean off residual lubricant oils used during the cutting process.", "A robot transfers an implant to a holding device.", "The device secures the implant for the next robot to press a plastic collar onto it.", "This collar is temporary.", "It will serve as a mask to protect the outside of the implant as the top undergoes a process of colorization.", "A robot places the implant upside down in a mild acid.", "They apply an electrical charge.", "Different colors will appear at different voltages to color-code the part and indicate the diameter.", "The process is called anodizing.", "A robot now pulls off the masking collar.", "It transfers the implants to another tray and screws them onto it.", "This keeps them from falling off as machinery turns the tray upside down to immerse the implants in acid and anodize the exterior.", "This time, the anodizing serves another purpose.", "It changes the surface to make it more porous.", "This will improve the bonding of the patient's jawbone to the implant.", "The implant sparkles in the solution as it undergoes a transformation.", "Here's the new porous surface magnified by a microscope.", "A robot transfers the dental implants to another tray.", "They're now ready for a final cleaning.", "A technician puts a lid on the tray and lowers it into a tank full of hot, purified water.", "A generator sends high-frequency sound waves into the water, creating bubbles and waves that gently scrub the implants.", "After sterilization, these titanium dental implants are ready to take root in human jaws.", "The clinician screws the implant into the patient's jawbone and then secures a made-to-match ceramic tooth to it.", "Over time, bone will fuse to this artificial tooth, providing a long-lasting tooth replacement and giving the patient a reason to smile." ]

{ "things": [ "Digital Dentistry", "Nail Clippers", "Poster Restoration", "Canola Oil" ] }

[ "Digital technology is revolutionizing dental treatment.", "3-d cameras and computers can now be used to produce crowns and other prosthetic restorations on site, eliminating the need to send the work to an outside lab.", "For the patient, it means one appointment instead of two and less time in the dentist's chair.", "With computer-driven tools, custom restorations take shape in a matter of minutes while the patient waits.", "After donning dark safety glasses, the patient is ready for her close-up.", "The dental assistant inserts a small video camera in her mouth to examine the problem area.", "She then inserts a strip of carbon paper between the patient's teeth and instructs her to clench her teeth.", "This leaves markings that indicate her bite profile.", "The dentist meets the patient and reviews her case.", "They agree to replace the silver filling with a ceramic inlay that will strengthen the tooth for much longer than a regular filling would.", "He anesthetizes the tooth and the gums that surround it.", "He then stretches a rubber dam across her mouth and exposes the area to be treated through a slit.", "This keeps filling fragments out of the patient's mouth as he drills.", "He switches to a smaller drill bit to excavate the remaining filling particles and to remove decay.", "Each cavity must be completely clear before the restorative work can begin.", "The dental assistant then scrubs an antimicrobial solution into the tooth.", "Then she brushes an acidic conditioner into the cavity.", "The dentist activates the conditioner with a halogen light.", "He points a high-resolution l.e.d. camera at the tooth and downloads the image onto a computer, which converts it to 3-d.", "Next, the dentist fills the cavity with the silicone putty.", "When her teeth come together, they leave an impression in the putty that indicates her bite profile.", "Once the putty hardens, the dentist and his assistant chip off the excess.", "He downloads the image of the bite impression and then superimposes the images as he designs a custom dental inlay digitally.", "The dental assistant selects a glass ceramic block of the appropriate size and color.", "She anchors the block in a milling chamber and shuts the lid.", "Two computerized drills now sculpt the block into the dental inlay, guided by the digitally produced design.", "This process takes less than 10 minutes.", "The dentist then pulls the ceramic inlay from the base.", "This leaves a small nub that he then grinds away.", "Next, using rubber wheels and diamond-impregnated brushes, he polishes the entire restoration to a high gloss.", "He conditions the inlay with hydrofluoric acid to prepare it for adhesion to the tooth.", "He dips the filling in water, and the hardened solution flakes off.", "He then thoroughly dries the inlay.", "Next, he adds a drop of silane that will promote the bonding of the inlay to the tooth.", "The dentist injects tooth-colored resin cement into the cavity.", "He presses the digitally designed and milled inlay into the cement, then scrapes away the overflow.", "Halogen light on the dental work hardens the cement.", "He takes another impression of the patient's bite to confirm the new inlay is perfect.", "Finally, the dentist polishes the contours of the ceramic inlay.", "And it's time for the reveal.", "He uses the camera to magnify the new dental work for the patient's scrutiny.", "It's taken just an hour and a quarter for her custom restoration to be designed, milled, and installed, all thanks to digital dentistry.", "The nail clipper was invented in 1896 in the united states, and soon it was at everyone's fingertips.", "By 1902 it, ads marketed it as the \"gem,\" and it was sold by the dozen for $2.", "As an alternative to scissors, it was the idea that just clicked.", "More than a century after its invention, the nail clipper is still behind many a well-groomed hand.", "Its popularity numbers in the millions, and no manicure set would be complete without one.", "Production begins with this elaborate dye.", "It's about a yard in length and has 12 different-shaped openings.", "Hydraulic machinery repeatedly forces a steel sheet through the various openings as the sheet moves forward.", "With each stroke, the parts look more like nail-clipper jaws.", "The clipping edge starts out straight and blunt and gradually becomes concave.", "The machinery also cuts and shapes the holes for assembling the nail clippers.", "In just one minute, a total of 80 strokes generate a dozen nail-clipper jaws.", "Here, the clipper jaws vibrate with abrasive stones and organic acid for up to 20 hours.", "This gentle polishing makes the parts gleam, but doesn't ruin the edges and contours.", "At the next station, a worker aligns pairs of clipper jaws for assembly.", "Using a mechanical press, he drives a rivet into the hole at the gripping end of the jaws.", "He flips the assembled clipper jaws over, inserts the other half of the rivet, and then presses the two tightly together.", "The rivet locks the gripping end of the nail clippers together so that the two jaws can't be twisted apart.", "Next, a worker smoothes the edges of the clipper's gripping end against an abrasive wheel.", "This grinding evens out any irregularities and makes the two clipper jaws appear as one at the gripping end.", "Attention now turns to the cutting end of the clippers.", "After locking them in a device, a worker grinds the concave edges until they match up.", "These nail-clipper jaws are now ready for the lever, but the lever itself still needs some work.", "Using a little press, they make a whole and an indentation between its two prongs, allowing the lever to sit more comfortably on the clipper.", "Levers are then fed one at a time to a set of drills that carve little holes into the prongs of the fork.", "The holes are just big enough for a pin that's 0.05 of an inch in diameter.", "Here's the view from the side before and after drilling.", "A worker now inserts a bolt in the cutting end of the clipper jaws.", "This bolt has a little hole in the end of it.", "He presses the jaws together, and it's now time to attach the lever.", "He inserts the pin in the holes in the lever and the bolt.", "He pinches the pin with pliers to secure it, and the lever now pivots freely on the cutting jaws.", "All the pieces of the nail clipper have come together, but the assembly processes have left oil and other residues on this tool.", "It's time for a cleaning in a special tub.", "Sound waves keep the water moving to distribute the soap and scrub them clean.", "Once they dry, a worker uses a combination of acid and positive electrodes to etch the company name and item number onto the nail clipper.", "The next employee sands the cutting edges to sharpen them.", "It takes skill and practice to get them just right.", "He holds the nail clipper to a light and scrutinizes the alignment of the jaws as he opens and closes them.", "This cardboard test confirms that these nail clippers are up to the job.", "From a blunt clipper on the left to a really sharp tool on the right, what a difference the sanding has made.", "The lever swivels for various clipping angles and then folds down neatly when not in use.", "It takes 11 people to manufacture 100 of these clippers an hour, and that means they've been working at a very fast clip.", "Long before the internet and electronic media, the poster was an important means of communication.", "These lithographed notices were used to sell everything from soap to political propaganda.", "Today they're being painstakingly restored to preserve both the artistry and history behind them.", "These are the signs of a different time.", "And decades later, the bold artistry of these poster lithographs is still an attention grabber.", "Some vintage posters can be worth tens of thousands of dollars, which makes them worth restoring and preserving.", "Posters often become brittle and break along the fold lines.", "So first, this restoration specialist reassembles the torn sections and examines them to determine if this poster can be saved.", "He decides to proceed.", "He loosens old tape with solvent and carefully peels it away.", "Next, he separates the poster sections with plastic mesh-- to keep them from sticking together-- in a bleach bath.", "The bleach gently removes dirt and mildew to reveal the vintage poster's original colors.", "He presses out air pockets between the layers to maximize its effect.", "While the pieces of this poster dry, he prepares a paste of water, wheat, and calcium.", "The calcium will counteract the acid in the vintage paper, preventing further deterioration.", "He rolls the wheat paste onto a big sheet of acid-free paper.", "And he spreads more paste on a piece of linen-textured cotton.", "He then presses the paper to the fabric, and they adhere.", "He now has a big piece of fabric-backed paper.", "He rolls out the air bubbles and excess paste for a more even surface.", "He now reconstructs the poster on the fabric-backed paper, which is now saturated with glue.", "He works carefully and quickly to put the pieces together before the glue dries.", "One false move and he could make a real mess of things.", "But experience pays off.", "He aligns the four sections perfectly.", "The glue dries, giving the vintage poster a solid backing.", "He flips through a collection of paper scraps in search of one that's similar in texture and thickness to the posters.", "He'll now use it to repair the poster's ripped corner.", "He traces the outline of the tear onto transparent paper.", "He cuts the scrap paper along the traced line, producing a new corner for the poster-- one with exactly the right profile.", "He sands the edge a bit to give it a more gradual slope.", "He brushes vegetable-based glue onto the cutout.", "He aligns it with the torn edge and glues it in place, then flattens the new corner to make it level with the rest of the poster.", "It's now time to complete the picture by repairing the torn images.", "The tricky part is mixing the paint to match the poster's vintage colors.", "It sometimes takes a few tries to get it right and make the repair blend in.", "Even the white on the border has to match.", "No detail is overlooked as he restores the corner of this poster to its original condition.", "He touches up the rest of the artwork with watercolor pencils, applying color heavily or lightly where needed.", "And with a practiced hand, he makes all the flaws and fold lines disappear.", "By the time he's done, the vintage poster will look good enough to frame.", "With all the details now covered, he trims the poster on all sides and examines his work for imperfections.", "The repairs have to both look and feel real.", "From a tattered relic of the past to one that looks fresh off the press, a restored vintage poster is an important piece of history, now preserved for future generations.", "Canola oil is a commonly used type of cooking oil.", "It's derived from the seed of the canola plant, which north american farmers have been growing for about 30 years now.", "The plant blooms in the summer, producing bright yellow flowers.", "Farmers harvest the seeds from pods which form after those flowers die off.", "Canola oil is one of the healthiest cooking oils.", "Compared to olive, sunflower, and soybean oils, it has the lowest level of saturated fat-- 7%.", "It also contains more healthy omega-3 fatty acids and is high in monounsaturated fat, which lowers cholesterol.", "When the canola seed arrives at the processing factory, it contains foreign material-- mostly plant pieces.", "So the first step is to clean the seeds in a vibrating sieve.", "The seeds-- smaller than the openings in the sieve's mesh-- fall through to a conveyor below.", "The foreign material remains on top.", "A conveyor moves it to a storage bin, where it's collected for sale as cattle feed.", "The seeds pass by a magnet.", "It removes any metal that may have fallen in during the journey from field to factory.", "Next, the seeds enter a roller mill.", "They pass between two steel rollers, which crush them into thin flakes.", "A conveyor then feeds the flakes into a screw press.", "It has a large revolving screw-shaped shaft enclosed within a slotted cage.", "As the shaft turns, its threads squeeze the flakes with high pressure, forcing out the oil, which then drains out through the slots.", "42% of canola seed is oil.", "This group press extracts nearly 3/4 of that.", "The remainder is still trapped in the pressed flakes, now referred to as canola cake.", "The cake exits the other end of the press and moves on to a second extraction, this one a 70-minute wash with a solvent.", "This chemical-extraction process removes all but a trace of oil.", "The factory then grinds the cake into protein-rich meal that it sells as animal feed.", "The extracted oil, stored in large tanks, now enters the refining phase.", "First, they wash the oil for 20 minutes with sodium hydroxide.", "During this wash cycle, they spin the oil at high speed so that the centrifugal force separates the natural impurities, which the factory later sells to soap manufacturers.", "After this cleaning process, the canola oil is visibly clearer.", "However, it still contains natural waxes, which makes it look cloudy.", "So the next step is to cool the oil to 41 degrees fahrenheit.", "This thickens those waxes so that they can be filtered out.", "The waxes don't go to waste, either.", "The factory uses them to produce vegetable shortening.", "In the factory's lab, technicians recreate production on a small scale to ensure performance and quality.", "Meanwhile, back in the factory, after washing and filtering the oil, they bleach it to lighten the color, then use a steam-injection heating process to remove the canola odor.", "The oil is now fully refined and ready for bottling.", "The equipment first turns the plastic bottles upside down and injects filtered pressurized air to blow out any dust or dirt inside.", "Then it turns the bottles right side up again to position for filling.", "Just before a nozzle starts filling, it applies a vacuum.", "If there's no suction, indicating a leak in the bottle, the machine automatically ejects that bottle from the line.", "Each bottling machine in the factory fills 22,000 bottles per hour.", "The labeling machines work at the same speed.", "They spread glue on the back of each label, then apply the label's edge to the bottle.", "The bottle spins, wrapping the rest of the label around itself.", "As the bottles come off the labeler, a robot separates them into groups of 12.", "Then it picks up and deposits each dozen in a shipping box-- from field to factory to your pantry, where, once opened, canola oil has a shelf life of about a year." ]

{ "things": [ "Industrial Wire Ropes", "Living Walls", "Large Format Cameras", "Gemstones" ] }

[ "Industrial machines often have heavy loads to lift or pull.", "Whether it's a dragline excavator working in an open-pit mine, an oil-drilling rig, a construction crane, or farm machinery, the weight is borne by ultrastrong wire ropes.", "Industrial-wire ropes typically range from 8/10\" to 5\" in diameter.", "Besides machinery applications, they also serve as support cables for large static structures, such as bridges and stadium roofs.", "Manufacturing a wire rope begins with steel wire that's anywhere from 3/1,000\" to 3/10\" in diameter.", "The first step is to wind several of these wires together into a strand.", "How many wires per strand depends on the job the rope will perform, because different applications require different degrees of flexibility and strength.", "Each wire is spooled onto a steel bobbin and loaded onto a stranding machine, which is essentially a giant winder.", "There can be as many as 64 wires in a strand, although the typical range is between 19 and 36.", "The twisting wires converge in a die that forms them to the required diameter.", "Lubrication is critical, and not merely to help the wires move smoothly through the die.", "It also penetrates within to allow slight movement between the wires.", "This increases their life span and prevents the strand from seizing.", "The strand exits the machine saturated in lubricant.", "A large rubber band skims the excess off the surface.", "The strand now travels through a row of straighteners.", "These heavy rollers apply vertical pressure, effectively erasing the wire's memory of being spooled on a bobbin prior to stranding.", "This prevents the wires from unraveling.", "This cross-section shows all the wires inside the finished strand.", "The clothespin gives you a sense of its size.", "Wire strands are by themselves typically used as structural support cables.", "To make wire ropes used in machinery and for heavy lifting, they take several of these wire strands and wind them together on a far bigger and stronger machine called a closer.", "They make this particular rope from six wire strands.", "Before the strands converge in the die, rollers pre-shape them into a corkscrew-like form.", "The strands then enter the die, twisting together over a core, which is itself a small steel-wire rope.", "A core at the center of the cable provides additional strength.", "This cable's finished diameter is 3 1/2\".", "However, there are always small variations here and there, so now four calibration rollers, two compressing vertically, two horizontally, correct the cable to the right diameter all along its length.", "The finished cable winds onto a big steel reel, ready for shipping.", "The factory tests random samples in its quality-control lab.", "There, a machine measures the tensile strength-- how much pulling force the cable can withstand.", "The machine pulls the cable at both ends until it snaps.", "for this mega cable, the breaking point was 104 tons.", "To pass the test, a cable must exceed the tensile strength it's designed to withstand.", "For certain demanding applications, such as mining, wire ropes are double-coated in plastic to protect against wear and tear.", "To prepare the plastic, the factory mixes a recipe of clear and colored plastic pellets.", "An extrusion machine heats the pellets until they liquefy, then forces the molten plastic through a die, coating the rope as it passes through.", "As the rope exits the extrusion machine, it passes through water, which cools and hardens the hot plastic.", "The plastic not only jackets the rope's surface, it also provides cushioning when on the jobsite, the strands inside rub against each other as the rope moves.", "By reducing wear and tear on the steel both internally and externally, plastic coating can extend the life of a rope by up to 50%.", "A cable's internal construction determines its strength and flexibility.", "A structural one needs to be strong, immobile, and taut, so it's a single strand made of large wires, whereas a moving rope and large machinery contains many strands made of smaller wires.", "A living wall is a vertical structure covered with fully grown plants.", "This green screen serves many purposes, such as hiding an eyesore or shielding an area for privacy.", "Some are installed in the ground, while others are mounted on building facades and have integrated irrigation systems.", "Living walls are modular systems.", "Each module contains fully grown plants, so upon installation, the green-screen effect is immediate.", "The plants are hedera helix woerner, a variety of ivy that's highly resistant to cold and drought.", "In the manufacturer's greenhouses, horticulturalists take cuttings from the mother plants...", "Then cut off the foliage and separate the leaves, leaving each with a small stem.", "Then they plant the cuttings five leaves to a pot.", "The soil is a secret recipe of organic and nonorganic materials and feed.", "Over the next month to six weeks, each stem develops a good root system.", "Meanwhile, workers construct a welded frame out of high-strength carbon steel.", "The metal is galvanized so it's rust-proof.", "Once the frame is ready, they take a mat made from biodegradable, recycled coconut husks and fold it into a planter box, which fits inside the bottom of the frame.", "Two side wires hold the box securely in place.", "An automated machine fills the box with the same soil mix used for the cuttings.", "Then the horticulturalists plant 13 pots of plants.", "That's 65 ivies per box.", "They wrap the longer stems around the uprights of the frame.", "The frames now move to the greenhouse, where they're hooked up to an irrigation system.", "For the next 18 months or so, the plants grow, and as they do, the horticulturalists keep wrapping the ends around the uprights.", "This is called training the plants.", "As the plants thicken, the nursery workers prune them to promote upward growth.", "The factory produces these green-screen modules in 3 heights, ranging from about 3 to 7 feet.", "After installation, the plants can grow on-site to a total height of 13 feet.", "Each frame-- one module of the living-wall system-- is 4 feet wide, making it easily transportable.", "At shipping time, workers load the screens 10 to a pallet and truck them to the installation site.", "Each module of the system installs just like a fence.", "Workers embed a wooden post on either side of where each screen will go and dig a trench that's the width and depth of the planter box running in between.", "They sit the screen in the trench, then, with galvanized-steel brackets, clip it to the side posts at the top and bottom.", "Then they fill in the gaps with dirt.", "The screens have a 45-year life expectancy, and the leaves remain on them year-round.", "This variety is used on living walls in europe and warmer regions.", "In colder climates, the manufacturer uses a hardier species of ivy that stays green even throughout harsh, snowy winters.", "A large-format camera is essentially great-granddad's camera, the one with accordion-style bellows, the big film, and the curtain draped around the viewfinder-- 19th century technology with some modern refinements.", "For many serious photographers, the basic concept still clicks.", "In an age when cameras are miniaturized and digitized, the large-format camera might seem to be a relic.", "But for pros, it's a creative tool.", "The flexible bellows allow for a wide range of movements for incredible control of the image.", "Image quality is another attraction.", "This camera uses big sheet film, 4\" x 5\" and up, generating big negatives that don't need to be enlarged as much during printing, so the image has better resolution.", "At this factory, they mold many of the camera's parts out of plastic.", "They inject liquid plastic into molds, and the parts quickly solidify.", "Other parts are made of laser-cut aluminum and stainless steel.", "The camera maker assembles the base first, attaching rails that slide back and forth for focusing.", "The next parts allow for swing and shift action-- movements that come in handy when composing a shot.", "He attaches the camera's molded, plastic body to the swing and shift assembly.", "Next, he assembles the front part of the camera, which holds the lens and shutter.", "It has a swing and tilt mechanism for changing a shot's depth of field.", "He slides the lens holder into place and secures it.", "It can be raised and lowered when composing the shot.", "He inserts spirit levels into the slots in the front and rear sections of the camera.", "These levels will be used to check the angle of the shot.", "Moving now to the focusing screen, it's made of ground acrylic to diffuse light.", "He protects the acrylic from scratches with a glass plate and secures the assembly with stainless-steel clips.", "He snaps the completed focusing screen to the body of the camera, where it can be easily switched from portrait to landscape position.", "He tests the focus mechanism and confirms it's operational.", "He now folds and glues fabric in an accordion configuration to create expanding bellows that will link the front and rear parts of the camera.", "He applies double-sided tape around the inner lip of the folded bellows.", "He sticks more double-sided tape onto a plastic frame...", "And peels away the tape backing in strategic locations.", "He inserts the frame into the bellows and aligns it with the taped inner border.", "He then completely peels off the taped backing and presses the frame to the bellows' taped rim.", "This frame adds crucial rigidity to the bellows.", "Using more double-sided tape and adhesive, he secures the bellows' accordion to a larger fabric bag.", "Next, he glues plastic flanges to each end of the bellows.", "The flanges are connector pieces for attaching the bellows to the front and rear sections of the camera.", "There are two kinds of bellows.", "The one with the bag attached is usually used with a lens of short focal length.", "An accordion without the bag has a much longer range of extension to accommodate a bigger lens.", "He now connects the back of the camera to the front with the bellows.", "They are a flexible link between the two.", "By expanding or retracting the bellows, the photographer can adjust the distance between the lens and film to focus the shot.", "Finally, he attaches the lens to the front of the camera.", "It's now ready for a film test.", "He loads the film into the holder.", "Normally, this is done in complete darkness to prevent exposure of the film.", "But he's left the lights on for our camera.", "The film slides into the holder into the camera back.", "And while film still rules in large-format photography, there are now digital camera backs for photographers who want instant results with traditional focus movements of the bellows camera.", "It's all a matter of focus.", "Man has used gemstones since ancient times.", "Genuine gemstones come from nature-- minerals, rocks, or even certain organic materials.", "Shaped, cut, and polished to bring out their colors and brilliance, the rarest ones are classified as precious gems, the others as semiprecious.", "This semiprecious stone is called blue john.", "It's a variety of the mineral fluorite, also known as fluorspar.", "While common fluorspar is cream or white, blue john also has magnificent bands of purple, blue, and yellow.", "There's only one place in the world where blue john is found, and that's in the village of castleton, derbyshire, in central england.", "The stone comes from a cavern located some 55 yards deep in a hillside.", "The miners don't use explosives, because the stone is quite soft and brittle in its natural state, and blasting would simply shatter it.", "Instead, they use drills to carefully dislodge pieces of blue john from the rock wall.", "They carry the blue john to the surface to the mine's workshop, where stone processors manually wash off the clay.", "The stone is wet due to having been underground for some 240 million years, so they put it into an oven at low heat-- 176 degrees fahrenheit.", "When the stone comes out of the oven a couple of weeks later, all its moisture has evaporated.", "The dried stone, however, is still brittle, so they submerge it in a bowl of liquid resin, then place the bowl into a vacuum oven at 176 degrees fahrenheit.", "This process draws out all the air and forces the resin deep into the stone's pores.", "The stone then goes into another oven at 122 degrees fahrenheit for about 12 hours.", "This hardens the resin, stabilizing the stone so that it can be worked without crumbling.", "To create large items, such as goblets and bowls, the workshop's artisans turn the stone on a lathe.", "To avoid fracturing it, they must work the blue john slowly and with diamond-tipped tools.", "Diamond, being harder than all other rocks, cuts with less force and stress.", "To supply jewelry makers, the mine workshop saws stones into slices using a diamond-edged saw.", "At the jewelry workshop, a gemologist examines the slices on a light box to highlight the coloring and any flaws.", "This helps determine which parts of the slice will yield the most striking gemstones.", "Meanwhile, in another part of the workshop, a silversmith crafts the piece of jewelry-- in this case, a sterling-silver ring which will receive the blue john gemstone.", "She bends, then solders together the ends of the ring's shank, the part that encircles the finger.", "After grinding the solder seam flat, she fuses the top of the ring, called the setting, onto the shank.", "Then she polishes the ring and passes it onto the gemologist, who takes a slice of blue john and, with a diamond-edged lapidary saw, cuts out the gemstone's shape, making it slightly larger than the setting.", "Next, she glues on a backing cut from mother-of-pearl.", "Just like the white light on which the gemologist examined the blue john slices, this mother-of-pearl backing highlights the colors in the stone.", "Now, using a diamond-grit grinding wheel, she shapes the stone to perfectly fit in the setting.", "She applies glue to the setting and fits the gemstone snugly inside.", "Once the glue dries, she uses a diamond-grit sanding belt to smooth down the edges, gradually transforming the rough oval into a sleek dome.", "This gem shape is known as a cabochon.", "Finally, she polishes the entire ring's surface until the silver and richly hued blue john glisten.", "Whether it's one of several, the shape funky or traditional, a gemstone sure makes a piece of jewelry rock." ]

{ "things": [ "Nails and Staples", "Safety Glasses", "Fabrics", "Bicycles" ] }

[ "Today on \"how it's made\"...", "Nails and staples-- a fascinating manufacturing process.", "Safety glasses-- focused on protecting your eyesight.", "Fabrics-- we'll weave our way through a textile mill.", "And bicycles-- we gear up to see how they're made.", "If you've ever needed to attach two pieces of wood, you know there's no shortage of fasteners.", "You can choose from common nails, spiral nails, finishing nails, and even staples.", "And if you've ever wondered where these useful little items come from, well, we've got it all nailed down for you.", "There are hundreds of varieties of nails being made, and they're made of very durable carbon steel, all starting from steel wire.", "Rolled up on a drum, this steel wire weighs in at 5,500 pounds.", "The wire's diameter is a quarter of an inch.", "And that's too large, so they'll have to reduce its size.", "Using many drums, they're going to pull the wire successively to gradually thin it.", "Then they'll roll it up again.", "When full, this roll will contain almost 80,000 feet of wire weighing 2,500 pounds.", "The wire now has a diameter of 1/10 of an inch, so it will have to be reduced by half.", "Now they're going to cut the wire into little rods.", "The cut rods are gathered up with this electromagnet and dumped into a machine that will process them.", "Here, the rods are made into nails.", "The metal rods move along slowly, and a blade forms the nail points.", "These blades are changed every 600 hours.", "This machine forms nailheads by flattening them with great pressure on the rod ends.", "Nailheads are formed at a rate of 1,400 per minute.", "The manufacturing of nails is now finished.", "They fall into a chute, then into this collecting bin.", "Nails are sold by the pound or embedded in plastic rolls, as we see here.", "This machine inserts 167 nails into each roll.", "The plastic strip has teeth, and the nails hook into these.", "They handle the rolls with gloves, since the coating applied to the nails is not yet dry.", "This machine produces five rolls a minute for a total of 835 nails.", "Making spiral nails requires an extra processing step.", "This machine puts the spirals into the nails with these cylinders and welds them.", "It makes 1,200 nails a minute.", "Then the nails are put together into strips for use in pneumatic nailing guns.", "Each strip contains 30 spiral nails.", "To help them in place, the nails are coated with a resin that dries in four minutes.", "This is the nailing device that uses nails on a strip.", "It sets the nails in one strike with the user's trigger finger.", "Now we move on to the fabrication of staples.", "The staple press binds 80 iron wires, which have been well-lined up.", "The 80 small wires are placed side by side.", "The wires are glued together.", "Then the wires come out well-adhered to one another.", "The staple strips are fed into this machine.", "It cuts the staples to the desired length and folds them in one stroke of this press, which applies 40 tons of pressure.", "Staples are formed on this gauge, and the staple strips are then ready for packaging.", "Every day they produce a total of some 25 million nails here, which require the processing of 11,000 tons of metal annually.", "At work and at play, our precious vision can be at risk.", "For instance, we need to protect our eyes when we're using power tools and when we're playing squash.", "Thankfully, all we need to do is wear safety glasses.", "How do they make them so resistant?", "Let's have a look.", "Many sports and trades require the wearing of safety glasses.", "These glasses are made with plastic molding.", "Here we see the interior of a mold.", "The optical part of the lens is mirrored in order to be as transparent as possible without being deformed.", "The glasses are made by melting the primary material, a plastic resin called polycarbonate.", "The resin granules are poured into this machine.", "It becomes liquefied at a temperature of 450 degrees.", "The liquid plastic is injected into the mold under pressure over a 30- to 60-second period.", "The plastic hardens rapidly, and the glasses are then removed from the mold.", "They mold several glasses at a time.", "The glasses are separated by hand and then are given an initial visual inspection.", "The glasses are placed on this support.", "They're then taken to the laboratory, where they'll be given a surface treatment.", "But before beginning the treatment, they're washed to eliminate any impurities and to assure that the coating treatment adheres well to the lens.", "When they've been washed, the glasses are then rinsed in clear water.", "The glasses are now gently soaked in a chemical solution, which prevents misting and scratching of the lens.", "This coating now has to be cooked.", "They direct the glasses toward an oven heated to 480 degrees.", "The soaking and cooking processes vary between 30 minutes and 2 hours.", "Each pair of glasses is inspected to make sure there are no imperfections or distortions in the lenses.", "Then the glasses are placed on this support.", "This milling machine automatically removes the last piece of polycarbonate.", "This one was left in place so that they would be able to handle the glasses without having to touch the lenses.", "At this stage of the production of the glasses, the nosepiece is glued on.", "Certain pairs of glasses are selected from each production run.", "Here they evaluate the resistance of glasses to a racquetball hurled at them at 90 miles per hour.", "Here a hockey visor is tested against a puck traveling at 60 miles an hour.", "To conform to safety standards, the glasses must withstand these tests.", "It confirms that they're truly safe.", "They now proceed to final assembly steps in making the glasses.", "The last few pieces of the glasses, such as the plastic ear stems, are installed.", "Now completed, the glasses are placed in cases.", "It's the final step in their fabrication.", "They make several types of safety glasses here-- industrial, hockey and football visors, swimming goggles, and racquetball glasses.", "This facility turns out thousands of safety glasses every day, and the polycarbonate resin used to make those safety glasses could very well save your eyes one day.", "Early man relied on animal skins to protect himself against the elements.", "Eventually, fabrics were invented, giving us a bit more choice in the matter and eliminating the need to hunt or go naked.", "Today textile mills make fabrics in every conceivable pattern and color.", "Fabric is made from thousands of braided threads.", "This mill has 700 bobbins of polyester.", "Each bobbin contains 155 miles of thread.", "We begin by separating the threads.", "This warp unit takes the 700 strands and assembles them.", "Then this comb separates them.", "Other strands are added, and in total there will be 7,000 of them.", "One fabric is composed of threads braided at 90 degrees.", "The warp threads are assembled lengthwise, while the weft threads are joined transversely.", "To prevent the threads from tearing, they pass through a bin of glue.", "These rollers eliminate the surplus.", "The glue will be removed with water before dyeing the threads.", "The glued-together threads exit this machine.", "These large green cylinders are heated and dry the glue on the threads.", "Knitting will soon begin.", "The 700 strands are newly separated on this loom roller.", "Each thread must pass through a blade to produce a specific design.", "This machine takes the 7,000 strands of thread, one by one, and they pass through the blade.", "It's a highly precise operation.", "The threads pass through a blade, and the weaving finally begins.", "On this jacquard-type loom roller, the warped thread is inserted by a jet of air.", "The weaving machine assembles two loom rollers made of 7,000 strands.", "The fabric reaches a width of 12 feet.", "The dark threads are inserted into the weave.", "They insert 600 weft strands per minute.", "The blades remove the weft strands to insert the warp ones between the two.", "A comb pushes the weft.", "The plate of the breakage chain stops the machine if a thread should break.", "This bobbin contains 155 miles of thread.", "The weft thread is in the insertion nozzle.", "When a weft is inserted, an air jet nudges it in.", "The loom roller operates at full tilt.", "It makes 600 thread intersections a minute.", "Weaving is now over.", "We move on to the following steps-- washing and dyeing.", "Washing is done in a soapy solution at 175 degrees and at a speed of 195 feet of fabric a minute.", "The fabric is rinsed in clear water of about 85 degrees.", "Now it's on to dyeing.", "This is done with jets.", "Up to 7 1/2 miles of fabric is placed in clean water into which colorants have been added.", "The solution is heated, and the fabric soaks here for about six hours.", "Then it will be rinsed in lukewarm water.", "The fabric is placed in a bin.", "This machine is called an opener.", "It unfolds and stretches the material before rolling it up on an immense roller.", "And now the roll is almost full.", "We now move to thermosetting in a high-temperature oven that dries the fabric.", "The temperature is almost 400 degrees at the oven's entrance.", "The fabric circulates here for 45 seconds.", "The bobbin that we saw at the beginning has produced 15 miles of fabric.", "This finished roll weighs 3,300 pounds.", "Bicycles have come a long way from the original basic design.", "Now they feature multiple gears, high-tech materials like carbon-fiber frames and featherlight metal alloys.", "And they're made to tackle everything from quiet bike paths to the most rugged mountain trails.", "A french invention of 1790, the first bicycle resembled a 2-wheeled wooden horse without pedals or handlebars.", "In 1817, a german gave it direction control.", "The addition of pedals to the front wheels came from france in 1861.", "The british contributed as well, adding the large front wheel in 1870.", "By 1903, all countries participated in the first bicycle tour de france.", "A bicycle is a beautiful piece of engineering.", "The frames are made of steel or a chromium-molybdenum alloy known as chromoly.", "Fabrication begins with these hollow tubes.", "The tube cutter cuts the steel before sending it to the bender.", "The bender curves the tubes cold, exerting strong pressure against the bending jig.", "The tubes must now be machined-- that is, cut into lengths so that they correctly fit into one another.", "During this operation, cutting oil cools the tube.", "The tube is cut, taking into consideration the insertion angle of the other pieces.", "Tubes to be welded together are placed in this support.", "They insert a piece in an alloy of silver and bronze, which increases the strength and produces a better finish at the welding point.", "Welding now takes place.", "Welding of the frame requires about two minutes at a temperature of over 1,400 degrees.", "Once welded, the part takes four minutes to cool.", "They proceed in the same way with all the tubes that form the frame of the bicycle.", "At this stage, it's important to straighten the frame, which could have deformed during welding.", "They verify the alignment of the tubes and straighten it out cold with a tool that sets it to the right dimensions.", "Now they're going to paint the frames.", "Paint is applied with a spray gun and adheres to the frame by static contact.", "Then the paint will be baked in a natural-gas oven at 425 degrees for 15 minutes.", "The frame is now cooled, and we can begin the assembly.", "The labels are now applied.", "In another department, an employee assembles the handlebars.", "He installs the mechanism for the brakes and the gears.", "Now we move on to the wheel rims.", "The 36 stainless-steel spokes of each aluminum wheel are installed manually.", "The dexterity of these workers allows them to install spokes on 65 wheel rims in an hour.", "This spoke tool allows them to screw the spokes into the rim.", "This machine exerts a pressure on the spokes so that they'll have the desired tension.", "If there's too much or not enough tension, the rim will be crooked.", "This machine aligns the rims, essential for proper functioning of the bicycle.", "It automatically adjusts the spokes so that the wheel will be truly straight.", "Next step-- placing of the tubes and the tires on the wheel rims.", "Set upside down, the bicycle circulates from one workshop to another, where they will install the last mechanical parts.", "These accessories are not made here.", "The handlebars, the pedals, the fork, the brake, and chain mechanisms are all installed manually.", "Here they screw on the rear brake plate.", "Finally they inspect each bicycle to make sure that the bolts are well-tightened and that everything's working properly.", "Then it's on to packaging.", "This factory makes 2,500 bicycles each day.", "Assembled from various tubes of chromoly, each one weighs about 25 pounds and will run for thousands of miles." ]

{ "things": [ "3D Commercial Signs", "Hardwood Floors", "Corrugated Polyethylene Pipe", "Mattresses" ] }

[ "Today on \"how it's made\"...", "Three-dimensional commercial sighs...", "Hardwood floors...", "Corrugated polyethylene pipe...", "And mattresses.", "There's nothing like an eye-catching sign to attract customers.", "Many signs have three-dimensional lettering or decoration.", "Whether you hang a small plaque, an old-fashioned shingle, or a huge overhead sign, a business name in 3-d really stands out.", "These signs are made of high-density polyurethane foam-- a material that's waterproof and very durable.", "The sign starts out as a line drawing, which they render into three dimensions using specialized software.", "They send the file to a computer-controlled router that carves the design into a piece of foam.", "The router can be outfitted with various blades to get different effects, such as rounded edges or this faceted effect known as prismatic lettering.", "Once they've finished carving the design, they switch the router blade to an end mill-- a cutting tool that slices straight down through the foam.", "Guided once again by the computer, the router gradually detaches the design's components.", "After coating the pieces with primer, they spray them with two to three coats of polyurethane paint.", "It dries to a durable, hard-as-plastic finish.", "This design calls for gold and black lettering.", "They'll use gold leaf instead of gold paint because it lasts longer and has finer color and luster.", "First, they brush on a special glue for gold leaf called size.", "They wait 12 hours until it becomes tacky.", "Wet glue would merely absorb the gold, producing a dull finish.", "Gold leaf crumbles at the slightest touch, so it comes on a paper backing, making it easier to apply.", "Gold leaf is available in different qualities.", "The lower the karat level, the more alloy it contains.", "This is 23-karat leaf-- the closest you can get to pure gold.", "Because it contains no other metals, it won't oxidize, tarnish, or dull despite acid rain, road salt, or other harsh elements.", "Using silicone and screws, they mount the lettering onto a painted aluminum frame.", "Another option would be to mount them on a painted background plaque made of the same foam as the letters.", "Designs can also be engraved directly into a plaque and then highlighted using either paint or gold leaf.", "They use vinyl film to mask the parts that won't be decorated.", "This time they apply loose gold leaf because it's easier to brush into small areas.", "When the gold leafing is done, they carefully remove the film.", "This factory makes signs out of a variety of materials-- everything from wood to stainless steel to plexiglas.", "The material used is determined primarily by whether the sign will hang indoors or out.", "Besides lettering, signs often incorporate 3-d objects made of resin or fiberglass.", "The factory casts these components in molds, then paints and mounts them.", "They'll create this sign in various thicknesses of aluminum.", "The same computer-guided router does the cutting, but now they have to continually douse its blade with coolant to prevent the friction-generated heat from melting the metal.", "They coat the components with metal primer before applying polyurethane paint.", "Assembly is simple.", "They screw aluminum studs to the back of all the pieces, then bolt them onto the background plaque.", "Thanks to the wonders of computer technology, design possibilities are virtually endless-- a true sign of the times.", "There was a time when exposing your hardwood floors meant you couldn't afford wall-to-wall carpeting.", "Not anymore.", "Hardwood floors are definitely in, and today there are so many wood and stain color choices, hardwood floors can suit any decor.", "The types of wood commonly used for flooring include red oak...", "Beech...", "Maple...", "White oak...", "Walnut...", "Birch...", "And ash.", "As soon as the wood arrives from the sawmill, workers at the floor factory stack it on racks, then pile the racks floor to ceiling in a dryer that's the size of a large barn.", "There, large fans circulate hot air around the racks.", "The wood's moisture content is between 40% and 60%, depending on the season.", "When that drops to about 7%, the wood is ready to come out.", "This drying process takes anywhere from 10 days to a month.", "The length of time varies because some types of wood dry much slower than others.", "The wood is in random lengths and widths, so the first step after drying is to cut it to standard sizes.", "On the way to the ripsaw, the planks pass under an optical device called an optimizer.", "In mere seconds, it reads the dimensions of each plank and sends that information to a computer.", "The computer calculates the greatest number of standard-size pieces that can be cut from the plank, then guides the ripsaw to cut accordingly.", "This maximizes the yield and limits waste.", "Flooring is made from medium-quality rather than top-quality lumber to keep prices competitive.", "As the pieces exit the saw, workers manually cut out any large knots or other defects-- weak points at which a piece could potentially snap and jam up the equipment.", "The pieces now travel to a machine called the molder.", "Its revolving steel knives spin at a rate of 6,000 rotations per minute, carving a tongue down one side of each piece and a groove down the other.", "Workers do frequent spot checks to make sure the tongues and grooves fit together snugly.", "The next machine carves grooves on what will be the underside of the pieces.", "This is for air circulation and stability.", "Using crosscut saws, workers remove any faults in the wood and divide pieces that have noticeable color variations.", "This is the first step towards sorting the wood by grade.", "Now a machine called an end matcher carves a tongue and groove on the two ends.", "Here's the view from inside the machine.", "Workers check again for faults, then, assessing quality and color, sort each piece by grade.", "This will be prefinished flooring, so the pieces now run through a sander to prepare them to receive eight coats of varnish.", "For certain finishes, the first coat contains wood stain.", "All subsequent coats are colorless.", "Between each application, ultraviolet lamps dry the varnish in just seconds.", "As the flooring exits the last drying oven, it's ready for packaging.", "Unfinished hardwood flooring has to be sanded, stained, and varnished after it's installed.", "Prefinished flooring eliminates that extra work, sparing you the dust, the drying time, and the smell.", "Drainage pipes are vital to many industries.", "The pipes are generally made out of plastic, and they're an important component of municipal infrastructure.", "Cities use them to prevent streets from flooding in heavy rain.", "Forestry companies use them as culverts when building logging roads over streams.", "This corrugated pipe is made from a type of plastic called high-density polyethylene, or h.d.p.e.", "The pipe factory combines three varieties of h.d.p.e.", "Pellets-- plain pellets, recycled pellets, and pellets with a colorant that provides u.v. protection.", "The proportions vary depending on the pipe's intended use.", "The mixer transfers the pellets to a machine called the extruder.", "It first heats them to about 450 degrees fahrenheit.", "This melts them into a thick liquid.", "Then it assembles what's called the corrugator-- a mold whose cavity is the shape of a corrugated pipe.", "The extruder injects the liquefied h.d.p.e.", "Into the corrugator, applying vacuum pressure to spread it evenly into all the crevices.", "A built-in cooling system hardens the plastic just enough to set the shape, enabling them to extract the pipe from the mold.", "The pipe then passes through a cold-water shower, which hardens the plastic completely.", "The pipe now enters a machine called the perforator, which punches holes around the circumference.", "These holes, whose size varies by model, serve two purposes.", "First, they make the pipe lighter and therefore easier to transport and install.", "Second, they enable water to enter the pipe constantly at virtually any location, then flow to the end and drain out.", "It's crucial to prevent soil from clogging these holes, so this next machine wraps the pipe in a filter cloth made of polyester.", "They don't want this filter cloth to unravel, so the machine heat-seals it closed.", "This corrugated polyethylene pipe is finished and ready to be packaged and shipped.", "The packaging line is highly automated.", "Robotic equipment first coils the length of pipe that the customer ordered.", "Then it cuts the end.", "The robots tie the coil at several points so that it doesn't unravel.", "Workers now transfer the coiled pipe to a machine that covers it in plastic stretch wrap.", "This covering will protect the filter cloth from the damaging effects of dirt, moisture, and light.", "This factory also produces what's called double-wall pipe, which has a corrugated outside wall and a smooth inside wall.", "This type of pipe drains more efficiently because water flows faster over a flat surface than over the repeated peaks and valleys of a corrugated one.", "Making this type of pipe requires two extruders-- one to form each wall.", "Samples from every production run go through several quality-control tests.", "This compression strength test ensures the pipe won't buckle under the weight of the earth above it.", "High-density polyethylene pipe may be lightweight compared to cement pipe, but it's equally resistant to pressure, chemicals, and abrasion.", "Mattress anatomy 101.", "The comfort layer is the quilted fabric top and the underlying foam.", "The support layer is made up of the interior coils and heavy-gauge wire along the perimeter.", "The foundation, or box spring, is a separate bottom unit that acts like a giant shock absorber.", "For thousands of years, people slept on the floor on palettes stuffed with natural material such as straw, wool, or feathers.", "During the middle ages, family members would set down their palettes around the home's central fireplace.", "Only royalty and the wealthy had separate sleeping quarters and mattresses that sat off the floor on a wooden frame called a bedstead.", "Beds didn't become common in middle-class homes until the 1600s.", "The comfort layer, or quilt, starts with ticking-- a cover fabric made of polyester or cotton polyester.", "Under that are layers of polyester cloth, foam, and fiber.", "Luxury mattresses contain wool, silk, or cashmere fiber.", "The assembled layers go into an automated sewing machine.", "It's computer programmed to stitch one of several quilted designs.", "A roller compresses the thick pile to enable the 3-inch-long needles to pierce through all the layers.", "The two polyester sheets inside the quilt are essential.", "One is directly under the ticking.", "It acts as a barrier to prevent scratchy fibers from poking through the top of the mattress.", "The other is at the bottom of the quilt.", "It holds the stitches in place, preventing the thread from moving around inside and ripping the foam.", "A cutting wheel now trims the quilt to twin, double, queen, or king size, leaving an extra 2 inches all around.", "This surplus ensures the foam will reach all the way to the edge once the quilt's sewn up.", "The sewing table is air-cushioned, like an air hockey table.", "This floats the quilt, enabling the seamstress to maneuver it easily.", "As she stitches the quilt closed, she trims off the excess and sews a polyester band to the underside along the perimeter.", "Meanwhile, an automated sewing machine produces the mattress sides from the same ticking used for the quilt.", "It stitches the fabric to a foam sheet 4/10 of an inch thick, making a quilted design.", "Low-end mattresses have unquilted side fabric.", "Elsewhere in the factory, as we see here in slow motion, automated machines produce the guts of the mattress-- the coils.", "Low-end mattresses contain continuous coils-- rows of springs formed out of one long strip of steel wire.", "Better mattresses contain individual coils, each formed from a separate piece of wire.", "This machine is producing open coils-- a type of individual coil used in mid-quality mattresses.", "Open coils have an hourglass shape and are made of steel.", "Luxury mattresses contain pocket coils-- individual coils that are barrel-shaped and made of steel, manganese, and carbon-- a high-strength combination of metals.", "The coils are individually wrapped in cloth pockets to prevent them from tangling together.", "This machine is producing open coils.", "It first heats the wire with an electric current to make the metal flexible.", "Once it forms the coil, it curls the two ends of the wire like a pig's tail.", "This pigtail finishing prevents the sharp ends from poking through the mattress surface.", "They line up the open coils in rows, then feed them into a machine that connects them by running long strips of pigtailed wire along the tops and bottoms.", "Using pigtailed wire again, workers attach thick, steel edge wire along the top and bottom perimeters and steel brackets called edge guards at strategic points along the sides.", "These supports are what keep the mattress firm when you sit on the edge.", "Pocket coils are glued to each other at the center.", "This enables them to move independently so that motion on one side of the bed won't affect the other side.", "A reinforcement netting holds the coils in position.", "Workers attach the edge wires and edge guards to the outer coils with thick staples.", "The rest of the assembly process is the same for all types of mattresses.", "After adding two layers of foam, workers attach a quilt to the top and bottom by stapling the polyester band on the quilt's underside to the metal components.", "The final step is to attach the sides.", "A special machine called a mattress closer joins them to the quilts with a reinforcement strip made of durable fabric." ]

{ "things": [ "Footballs", "Electric Guitar Amplifiers", "Marbles", "Airplane Propellers" ] }

[ "Today, on \"how it's made\"...", "Footballs...", "Electric-guitar amplifiers...", "Marbles...", "And airplane propellers.", "In 1869, players in the first football game used a round ball, like in soccer.", "It was tough to carry and awkward to throw, so they changed it to look more like a watermelon.", "The current shape enables a better grip and passing on an arc that's unique to football.", "A lot of people handle a football before it ever gets to the field.", "They start with cowhide.", "Footballs are traditionally made of this leather because it wears well over time.", "With a die, a worker cuts out the four sections that make up the ball's skin.", "A stamping machine then brands the skin with the company logo.", "They may put other markings elsewhere on the ball, depending on the design of the model they're making.", "Each of the sections goes into a machine that trims the pieces' combined weight down to spec.", "To strengthen the skin, a seamstress sews cotton and vinyl linings onto all four sections.", "Then she places them in a die that positions them for another set of markings.", "These four white lines will form two stripes when the sections come together.", "This is purely aesthetic and varies according to the football model.", "Now it's time to sew the top sections together and then the bottom ones to each other.", "Exactly how many stitches this takes is this company's closely guarded secret.", "This press makes a hole in one of the top sections for the air valve.", "They make eight holes in the top sections for laces that will hold the skin tightly around an inflated bag called a bladder.", "To join the ball's top and bottom sections, the seamstress first cups them and then joins the edges together.", "She sews the leather inside out to make the stitches less visible.", "Later, workers will turn the skin right-side out by reaching through the opening between the lace holes.", "This is also where they'll insert the bladder.", "It's important to flatten the four seams.", "To do this, a worker places each one on a wheel, as a roller passes over the top.", "This keeps the ball from being bumpy when they stretch the skin over the bladder.", "A 15-second steam softens the leather and makes it easier to manipulate.", "A concave press flattens the seams at the tips.", "This will also keep the ball smooth when they inflate it.", "Time to turn the skin right-side out.", "The worker places it on a metal bar, then, reaching through the opening between the lace holes, he grabs the other side of the skin and pulls it through.", "Then he runs the bar along the inside to reshape the skin.", "The bladder is made of polyurethane, a type of plastic, with a vinyl patch reinforcing the lacing area.", "After squeezing the bladder inside the skin, a worker snips off the end of the air valve to keep it out of the way.", "Then she inflates the bladder a bit to make it rigid enough for lacing.", "After steadying the ball with clamps, she uses an awl to thread the lace through the holes-- just one vinyl lace, measuring four feet.", "It worms through both sides and then down the center and through all the holes once again.", "The lacing is spaced about a half inch apart-- wide enough to comfortably grip for that magic pass you've got in mind.", "Next, workers temporarily overinflate the balls.", "Steel molds surround them to ensure they'll assume the correct shape.", "After 90 seconds, the extra air seeps out.", "Finally, the factory inspects the balls to ensure they're up to standard.", "Fully inflated, a ball must weigh no more than 15 ounces.", "It should measure 21 1/2 inches through the middle and 28 inches around both ends.", "After a five-day manufacturing process, these balls are ready for the field.", "You have to plug an electrical guitar into an amplifier if you want it to be more than barely audible.", "A guitar amplifier is typically a boxed unit, containing an amp to boost the electronic signal and a loudspeaker.", "Some amplifiers use state-of-the-art silicon-chip circuitry, while others use traditional vacuum tubes.", "the amp's electronics are housed inside a metal chassis.", "This model's chassis is made from a sheet of metal that's less than .", "04 inches thick.", "A computer-guided machine called a turret punch cuts the contour and pierces a series of holes and slots for the controls.", "A worker then uses a computer-guided bender to shape the chassis cutout.", "Elsewhere in the factory, the amp's circuit board takes shape.", "It'll go inside the chassis.", "A computer-guided drill makes tiny holes in a laminate board that's coated with copper.", "The holes are for the board's various electronic components.", "An automated silk-screen printer now applies a diagram of the electrical circuitry in ammonia-resistant ink.", "Then the board goes into a machine called an etcher, which uses ammonia to dissolve the copper coating.", "Copper shielded by the ink diagram stays intact.", "The machine then rinses the board with sodium hydroxide to dissolve the ink, leaving behind just the circuitry diagram and copper.", "This copper configuration will conduct electricity to the circuit-board components.", "Automated machines insert the smaller components.", "Here's what that looks like in slow motion...", "And at actual speed.", "As a worker provides counterpressure, a machine folds over the leaves of some larger components to secure them to the board until they're soldered.", "Workers then install large, irregular parts by hand, among them-- the sockets that hold the tubes which power the amp...", "The ribbon connecters that join different areas of the circuit board...", "And the wires that connect external components to the board.", "The factory permanently affixes everything in one shot, using a process called wave soldering.", "The circuit board runs through a bath of molten tin and lead.", "In just a couple of seconds, the liquefied metal hardens, bonding the components securely.", "Back to that steel chassis we saw them bend into shape earlier.", "Since then, they've painted it black.", "With a silk screen printer, they apply the control markings, logos, and other information.", "They begin the final assembly.", "First, they screw the circuit board into the chassis.", "Then they plug the preamp tube into the appropriate socket on the board.", "This tube boosts the electrical signal coming from the guitar and feeds it to the output tubes, which up the voltage level, making the signal stronger and louder.", "After installing control knobs and covering the bottom of the chassis, workers insert and clamp the output tubes, the number of which usually varies according to how many watts of power the amp is designed to produce.", "The chassis housing the electronics goes into a box.", "This factory builds its boxes from high-grade baltic birch plywood, but other companies often use domestic plywood, mdf, or even plastic.", "After covering the box in leatherette and adding corner reinforcements, they install the two remaining components-- the spring reverb...", "And the speaker.", "As the guitar's electrical signals run through the amp, part of the electrical signal diverts to one end of the spring, vibrating it.", "The spring's other end picks up this vibration and sends it back through the amp as a delayed signal.", "That reverberation combines with the original signal to produce a bigger sound.", "people have been playing with small balls of stone, clay, or marble since ancient egyptian and roman times.", "Today's marbles are actually made of glass and used for industrial tasks as well as games.", "Glass is not only inexpensive and durable, but also quite beautiful.", "To make marbles, this company melts recycled glass with marbles made earlier but rejected for being the wrong size.", "All this goes into a kiln heated to 2,200 degrees fahrenheit.", "After 16 hours, they open a door at the bottom of the kiln, and the molten glass flows out.", "A shearing device cuts the stream every half a second, forming segments called slugs that become marbles.", "To make different-sized marbles, they adjust the device to cut at shorter or longer intervals.", "The slugs slide down chutes, landing between grooves on spinning cast-iron rolls.", "The spinning keeps the slugs from sticking.", "They'll need 72 hours to cool completely, but their final appearance is already set.", "That was determined back in the kiln, when the airflow drove the heat to melt the glass and mix the colors.", "These channels separate the good from the bad.", "Openings along the way weed out the ones that are too big or too small and collect the ones that are just right.", "More intricate marbles are handmade.", "This craftsman first preheats some clear glass in a small oven.", "Then he breaks off a piece of colored glass.", "After the clear glass has melted in the furnace overnight, he gathers some on a steel rod then picks up a chunk of preheated colored glass with it.", "He forms a knob and works the mass into a long string that's up to 16 1/2 feet long and thin as a noodle.", "He'll use them in various colors to decorate the clear glass cores of the marbles.", "He gathers a clump of melted clear glass on the rod and shapes it with wet newspaper, which won't stick to hot glass.", "After shaping the end, he rolls the clump on several preheated colored glass strings.", "Then it's back in the furnace.", "He repeats these steps up to three times and rolls the clump on a metal table to even out the surface between each trip to the furnace.", "Then he adds a layer of clear glass on top.", "With another tool now, he stretches the clump to about 1 1/2 feet long.", "He'll use this to make several cores.", "To make the second layer of the core, he rolls a 2-inch-long segment onto colored glass slivers called ribbons.", "After rolling them in the furnace to melt them, he flattens the ribbons with pliers and snips off the excess at the ends.", "He wraps the core and the ribbons in a layer of clear glass, then hand-shapes it.", "Now he rolls the core on more glass strings.", "Then it's back in the furnace to meld them.", "He adds one more clear glass layer, and the inside is finished.", "That's a total of six layers for this marble.", "Other models have fewer or more.", "The craftsman shapes the glass with several metal and wooden tools.", "He measures the diameter with metal calipers and gradually sculpts a sphere.", "He'll make up to five marbles from this segment, ranging up to the size of a golf ball.", "After scoring the glass with a knife, he places it in the open end of a pipe to hold it.", "Then he gently taps the rod, which breaks the glass and releases the sphere.", "He melts away the bump left at the spot where the glass broke.", "Next, the marble goes into an oven at 986 degrees fahrenheit.", "The oven slowly cools overnight to strengthen the glass.", "Clearly a cut above, this eye-catching, handcrafted marble is already an object of art.", "An airplane propeller usually has two, three, or four blades, the angles of which the pilot can adjust in response to airspeed and flight conditions.", "A propeller's main parts are made of aluminum because it's critical to keep it as lightweight as possible.", "The blades and hub are made of aerospace-grade aluminum that resist corrosion and metal fatigue.", "The propeller's blades attach to a hub.", "This piece of aluminum is on its way to becoming that hub.", "Like the starting pieces for all parts, it was forged beforehand into a rough version of the final shape.", "This sophisticated, computer-guided mill now machines the piece.", "40 minutes later, the hub is finished and ready for assembly to the engine.", "This roughly shaped piece is about to become one of the propeller's blades.", "A computer-guided lathe machines it to the final shape.", "Liquid lubricant washes away the metal shavings and cools the friction-generated heat.", "The lathe first forms the shank-- the end of the blade that fits into the hub.", "The next milling machine cuts the blade's shape.", "Now the finishing steps-- done manually because they require a keen eye.", "Workers use a rotary sander, then a belt sander to grind away the marks the machining process left behind.", "They buff the metal with a polishing wheel...", "Then clean the blades by dipping them in a strong detergent.", "This acidic solution eats away any dirt, oil, or grease on the surface of the metal.", "After that, they dip the blades in a bath of water and chromic acid.", "This seals the pores in the metal, fending off corrosion.", "The factory tests all critical parts for surface defects by dipping them in a fluorescent solution that leaches into any imperfections.", "After rinsing, an inspection under black light.", "A blue glow means the parts are a-okay.", "Any imperfections show up as bright, fluorescent green.", "The defective part is either repaired or rejected from the production line.", "Blades that make the cut move onto the paint shop-- a coat of black on the back side to prevent sun reflection into the pilot's eyes and stripes for safety, to make the spinning blades visible.", "Next comes a de-icing boot-- a rubber-encased electric heating element that prevents ice buildup.", "The rubber is highly durable, yet flexible enough to mold to the curve of the blade.", "Next, they lubricate a part of the blade shank with grease, then install a strong steel-ball-bearing system.", "This will hold the blade securely in the hub, yet still enable it to pivot to change its angle.", "The shanks of the three blades fit right into this steel part called the fork.", "It keeps all the blades at the same angle.", "Now for what's called the pitch change rod.", "The term \"pitch\" refers to the angle of the blades.", "Engine oil will exert hydraulic pressure on a piston that moves the pitch rod, which advances the fork, rotating the blades to the required angle.", "After removing the pitch change rod temporarily, they apply sealant to the top half of the hub and place it over the bottom half that contains the ball-bearing set.", "A rubber o-ring seal, then a sturdy spring to provide the required counterpressure.", "Workers thread and torque the piston and pitch change rod-- now attached to each other-- to the fork.", "Another rubber o-ring-- this one to prevent leaks out of the top of the cylinder that will contain the engine oil.", "They use a special tool to tightly torque the cylinder down against the hub.", "With assembly complete, this propeller is ready to be installed on today's airplanes." ]

{ "things": [ "Fur Coats", "Hearses", "Outdoor Lighting Fixtures", "Golf Tees" ] }

[ "Today on \"how it's made\"...", "Fur coats...", "Hearses...", "Outdoor lighting fixtures...", "And golf tees.", "Fur coats have been around through thick and thin.", "They used to be very bulky, but today's garment is much thinner because of new manufacturing techniques.", "The new lightweight fur coats are also cut closer to the body, but they still provide old-fashioned warmth.", "Today fur coats are made for a changing market that values less bulk and more texture.", "The beaver pelt now undergoes multiple transformations until it doesn't even resemble the original pelt.", "They steam the fur to fluff it up.", "Then they give it a static charge to make the hair stand on end.", "The pelt then goes under a row of little blades several times.", "This shears the fur so the hairs are uniform and the pelt less bulky.", "But because the downy undercoat is the most insulating part, this fur will still be warm.", "Grooving is a new technique that involves carving a pattern into the dyed fur.", "The blades cut a zigzag pattern down the length of the fur, giving the beaver pelt a unique look and feel.", "Now the furrier demonstrates a process called letting out.", "He feeds a pelt to a machine that slices it into diagonal ribbons.", "Yes, he's cutting it to shreds, but when this process is complete, they'll have a new and improved fur.", "They sew the diagonal strips together, arranging each a little lower than the last.", "They use a special fur-sewing machine.", "As the operator feeds the strips, he pushes the fur down so it doesn't get caught in the seam and ruin the look.", "It's something that takes skill and experience.", "The narrow strips of fur created by this letting-out process will run the full length of a coat.", "It's a more flowing look than simply sewing whole pelts together, but it also makes the fur a bit rippled.", "A process called blocking will correct that.", "They wet down the leather of the pelt.", "Then they split it a bit at the end to fit the pattern that's been traced onto a board underneath.", "They staple the fur onto the pattern.", "After leaving it to dry overnight, they trace the original pattern onto the leather side of the fur, now smoothed out from the stretching.", "They mark a spot for a pocket and trim the fur to the pattern so the dimensions are now exact.", "Specialized finishers sew a cloth pocket into the slit prepared for it.", "They stitch in the zipper and then cut out pieces of silk to line the coat.", "Before they sew in that lining, they build up the front edges of the garment by tacking lamb's wool on the inside edging.", "This will add structure and help the fur hold its form as they put it in the lining.", "Starch-cotton tape now goes into the hem of the coat to keep the fur from stretching.", "Handcraftsmanship has always been a key element of the fur industry.", "Every fur gets these hand-stitched finishing touches.", "Once the label goes on, this fur coat is ready for a night on the town.", "We all have to go sometime, and when it's our time, a hearse will likely be waiting to take us away in style.", "Hearses are all about luxury, because luxury says dignity and respect.", "From the plush custom interior to the stretched and streamlined design, it's nothing but the best for our dearly departed.", "It's the final journey, and the vehicle is custom-made for the occasion.", "They start with a cadillac chassis.", "It's been built without rear doors, rear windows, backseats, trunk, or rear bumper.", "They park in a master-framer jig and immediately slice it in two, using a reciprocating saw that cuts through metal like butter.", "The jig allows the two halves to be pulled apart so there's just under 31 inches between them.", "Then they weld rails to join the two halves.", "They encase each new frame rail with a support piece.", "The framework for a hearse has to be extremely solid because it will carry heavy loads for many years.", "The base cadillac also has more structural reinforcements than a regular vehicle, like stronger wheels and suspension.", "They hoist the steel rear cage and roof frame onto the car, and they build up the roof with steel rails.", "The framework for the casket-loading door goes on next.", "Once the rear cage and chassis extensions are in position, they mount the panels, which are made of a blend of fiberglass and space-age materials.", "Adhesive seals the panels to the steel skeleton...", "And they secure all the panels in place with screws.", "This is a made-to-measure job.", "The panels precisely fit to the welded cage.", "Meanwhile, over in the press room, they roll a nonstick coating onto a die, then place a sheet of steel over it.", "They also give the steel a coat of the nonstick agent.", "An 850-ton press then pushes the steel into the die to shape the door of the funeral coach.", "The nonstick coating allows them to remove the door easily without damaging it.", "They attach the door to the back of the hearse using superstrong hinges because they'll have to stand up to a lot of wear.", "This door is high and wide and opens 135 degrees to allow for easy loading of the casket.", "After smoothing out the seams in the body and giving it a high-gloss paint job, they cover the roof with a foam pad.", "They place vinyl material over it and pull it snugly around the corners.", "They line the deck of the hearse with a heavy-duty laminate.", "Next they put up the head liner, the fabric that covers the ceiling of the hearse.", "They mount the hardware that will allow the casket to easily roll in and out of the coach.", "Finally, the \"custom built\" sign.", "From the lustrous paint job to the lush, curtained interior, the funeral coach has an ethereal look-- appropriate since it's designed to make an exit that's out of this world.", "Day or night, streetlights light up our lives.", "Typically standing as high as 26 feet above the sidewalk, they cast a warm glow in the darkness and continue to provide street decor during the day.", "This fixture, called a luminaire, starts as a technical drawing.", "To make certain parts of the luminaire, the factory uses a process called sand-casting.", "To create the internal features of the sand mold, workers take a wooden mold for the part and fill it with a mixture made of white sand.", "They insert a wire into the center to make an opening...", "Then inject carbon dioxide into the opening.", "This causes a chemical reaction that hardens the sand.", "They remove the white-sand piece, called the core, from the wooden mold.", "To cast the external parts of the luminaire, workers start with a mold made of aluminum.", "Inside it, they build another mold made of brown soil.", "They place a wood block on top and pack down the soil.", "They do the same on the other half of the mold.", "Now, with a copper pipe, they make holes in the soil mold-- one in which they pour molten aluminum, the other to vent air.", "They spray the inside with compressed air so no particles will stick to the cast piece.", "They position the core into the soil mold.", "Keys in the soil mold help them position it exactly.", "Then they pour molten aluminum into the mold.", "Aluminum is an ideal metal for streetlights because it's lightweight, rust-resistant, and it won't stick to the soil mold.", "After two to five minutes, they open the metal frame and shatter the mold.", "They use a drill to remove the white sand piece from the inside of the cast-aluminum part.", "Next they sand down the part to make it smooth.", "Automated drills then pierce pilot holes for various hardware.", "A welder places a bracket in a vise, then welds a decorative tube onto it.", "Next he welds an anchor plate onto a pole.", "The upper part of the pole is welded to a larger bottom part.", "All the poles, brackets, and luminaire parts go into a series of chemical baths to prepare them for painting.", "The model shown here comes with tempered-glass or polycarbonate lens finishes on all four sides.", "They install the lighting system.", "First they position the bowl-shaped aluminum piece.", "Then the lamp socket is mounted with the electrical components inside the aluminum bowl.", "Finally they install a reflector inside the hood to project the light toward the street.", "They apply labels with product and maintenance information into the fixture's hood.", "Now they can close up the luminaire and mount it on a pole or bracket.", "And let there be light.", "Before golf tees became popular, players would tee up their ball on a little mound of sand.", "The first peg-style tees were invented more than a century ago, but they didn't really catch on until the 1920s, when one company marketed them aggressively, using professional golfers to promote them.", "That wooden peg you stick in the ground to hold the ball is almost as important as your golf club.", "You use a tee on the first stroke of each hole to give your drive shot extra distance.", "At the sawmill, white birch logs are scaled at the small end.", "Just one 8-inch diameter log yields close to 3,000 golf tees.", "The logs go into what's called a step feeder.", "This conveyor transports them to a debarking machine.", "Then a slasher saws the log into shorter lengths.", "The thumper roll, a roller with steel teeth, secures each log to a sharp chain.", "This holds the log in place as it heads for the saws.", "Four saws work their magic, carving the 4-1/2-foot boards into shorter dowel boards, each measuring 18 inches.", "Then a series of chains lay down the dowel boards in a single file on what's called a molder-and-feed roll.", "The molder's two rotating heads transform the rectangular board into round dowels.", "An outfeed roll drops each dowel onto a belt for several quality-control checks.", "An inspector examines the dowels, removing defective pieces and setting aside dowels that need more cutting.", "A single inspector sorts close to 19,000 dowels per hour.", "They go into racks that hold 8,900 dowels each.", "Rack after rack now travels into a lathe.", "A blade whittles the dowel to a preliminary shape.", "This tool, called a trumpet, moves over the dowels, sculpting the tee's final shape.", "A blade simultaneously slices the tee from the dowel and forms the cup.", "The metamorphosis is almost complete from wooden boards...", "To dowels...", "To tees.", "Next the tees go for a tumble in a sanding drum.", "This cascading action has the tees sanding each other's surface until they're smooth.", "The slots on this machine separate the good tees from the bad ones and screen out the waste.", "Long, nail-like bumps on the machine divide the tees so that only one drops down at a time.", "The tee fits through only if it's perfectly shaped.", "The rejects and wood shavings roll across the top and land elsewhere.", "The good tees land in a big bin, called a tote.", "Golf tees come in a few different lengths, but your average one is 2 1/2 inches long and weighs .", "02 grams, so a tote typically holds some 100,000 tees.", "A tote dumper then dumps two totes of tees into a paint drum.", "Small steel flights inside the drum send the tees cascading in a uniform direction.", "With each turn, they pick up paint.", "It takes 2 hours and 10 gallons of water-based paint to fully coat the tees, then another two hours to dry the paint.", "A trapdoor releases the tees into a vibrating conveyor and into a tote.", "If these tees will have printing on them, there's still one more step.", "They get an extra coat of enamel paint to create a smooth surface for the ink.", "Shiny or mat, plain or printed, the golf tee has sure come a long way since the days of teeing off on a mound of sand." ]

{ "things": [ "Ceramic Grills", "Pneumatic Punchers", "Water Jet Fountains", "Hollow Wooden Surfboards" ] }

[ "Ceramic is one of the best insulation materials in the world.", "Grills made with ceramic bodies can bake, roast, smoke, and, of course, grill food.", "Ceramic grills retain more heat than metal ones, resulting in a juicier, more flavorful meal.", "Ceramic grills use natural-lump charcoal.", "Natural charcoal is made by carbonizing wood through a specialized heating process.", "Cooking with natural charcoal is just like cooking over a campfire.", "At this factory, they begin by making a slurry.", "The main ingredients are water, clay, feldspar, and other raw materials.", "When the slurry is fired at a high temperature, it hardens into ceramic material.", "Another team assembles the two-part plaster mold to cast the base of the grill.", "After cleaning off residue from the previous casting, they clamp the parts together.", "The mold has two funnels.", "One funnel pumps the slurry into the mold.", "The other allows air to exit as the slurry fills the gap between the two parts of the mold.", "They let the slurry set for several hours.", "The plaster mold absorbs 80% of the water, leaving a firm but damp casting.", "They remove the top part of the mold and trim off any excess material.", "They cut out a rectangular hull for the sliding draft door.", "The door allows cold air to enter the grill.", "Then a worker uses a vacuum attached to a hoist to remove the heavy grill base from the mold.", "They repeat this casting process for the other ceramic parts of the grill, including the top called the dome and the fire box, which sits inside the base and holds the charcoal.", "After each casting, they scrape and sand away the excess material.", "They roll the cast parts into a dryer to remove the remaining moisture.", "For the next 30 hours, blowers circulate air that's heated to 180 degrees fahrenheit.", "After the parts cool, the base and dome undergo a final touch up to perfect their exterior surfaces.", "Next, the parts are taken to an automated glazing station.", "A conveyor spins the parts under a shower of ceramic glaze.", "A worker checks the coverage and sprays a touch up where required.", "The glaze dries in about 20 seconds.", "Workers vacuum up the excess...", "Then temporarily assemble the grill for firing.", "They place the fire box inside the base, the base plate at the bottom of the fire box, and the dome on top of the base.", "They fire the grills in a huge kiln for 24 hours.", "They gradually increase the temperature to more than 2,300 degrees fahrenheit, hold it there for a set time, then gradually cool it down.", "This firing process triggers a chemical reaction that transforms the clay-based slurry into hard, heat-resistant ceramic.", "It also turns the glaze on the surface into black glass.", "After firing, they attach the stainless steel draft door to the base.", "They spread adhesive on the top edge of the base...", "And apply a gasket made of heat-resistant material.", "This creates an air seal between the base and the dome.", "Then they attach the two parts with a hinge.", "They insert the fire box and stamp it.", "Then they glue a gasket around the neck of the dome and install the top vent.", "They place the cast-iron grate that holds the charcoal and the porcelain-coated cooking grates inside the grill.", "The cast-iron grate holds the charcoal.", "The porcelain-coated grate is for cooking.", "Finally, they install the thermometer.", "After lighting the charcoal, grillers can adjust the air flow with the draft door and top vent.", "The draft door and top vent must be fully closed to shut off the grill.", "This cuts off the air supply and extinguishes the fire.", "Many factories use punching machines to make the parts they need.", "Older punching machines consisted of a large press powered by a separate hydraulic or pneumatic system.", "Today's smaller punching machines contain both of these components in a single device.", "These punching machines are used in factories that make aluminum window and door frames.", "A factory worker inserts a strip of extruded aluminum in the machine and presses a foot pedal.", "The punch strikes the die, making the required cut.", "They construct the machine out of steel and aluminum, both of which arrive at the factory as solid bars.", "First they saw the bars into smaller pieces so they can make the machine's various components.", "They place the aluminum pieces in a computer-guided milling machine.", "It uses a series of tools to shape the metal into a specific component.", "This piece is called a punch guide.", "Its job is to align the punch tool so that it strikes the die correctly.", "A worker grinds the edges of the part until they're smooth.", "A different milling machine cuts more resilient parts out of steel bars.", "It, too, is computer guided and follows technical specifications.", "This steel component is the punch tool.", "It strikes through a steel die manufactured the same way.", "Every machine part undergoes a meticulous quality-control inspection.", "This computer-guided sensor checks each piece.", "Once all the parts have passed testing, workers begin assembling.", "The machine's base houses the air cylinder.", "They position the die on top of the base and screw it in place.", "Then they install the punch, carefully centering it over the die.", "A worker hooks up hoses to the air cylinder.", "He tests everything to make sure it's properly aligned with the die, then he fastens it with screws.", "They install the floor of the machine's second level.", "A machine can hold up to three different dies on three separate levels.", "They position the second die on the guide pins, then install the ceiling of the second level.", "They glue the punches to the ceiling.", "This level has several punches, allowing the machine to make different cuts using the same die.", "The cuts can be simultaneous or continuous.", "They install a punch selector which allows users to activate or deactivate each punch.", "Once installation is complete, they test the alignment of the punches.", "Then they mount safety covers on the machine.", "They prevent workers' hands from accidentally getting caught between a punch and die.", "Next, they make the pneumatic system that powers the machine.", "First, they attach air hoses to the foot pedal.", "The operator will step on the pedal to punch out the metal.", "Then they hook up the other end of the hoses to the compressed air-supply line.", "Now the pneumatic punching machine is ready to be used at the window-and-door factory.", "A worker inserts a strip of extruded aluminum into the first die to notch the end, then into the second die to punch three holes to join the window-frame parts.", "Finally, the third die punches three screw holes on the opposite side.", "The machine saves time because they don't have to switch dies between each cut.", "Water is essential to life on earth.", "We need it to survive, but we also use it for entertainment.", "Water-jet fountains captivate audiences with incredible displays.", "Some even use lights to change the appearance of the water's color.", "These water-jet fountains send spiraling ribbons of color into the air.", "The effect is magical.", "Production starts with this cast-bronze part.", "Computerized tools transform it it into a flange that will be installed on-site.", "The flange is designed to prevent leaks where the pipe meets the concrete pool.", "The next part is a stainless-steel faceplate for the fountain.", "An employee places it on a template, closes a u.v.-light shield, and activates a laser.", "The laser etches product information into the steel.", "This branding is permanent and won't wear off.", "Next, a technician assembles the colored l.e.d. lights.", "He connects the circuitry to a cable, then slides the bulb and its housing on to the circuitry.", "He screws a metal ring on to the base to keep the light watertight.", "He immerses the light in a clear water tank to test it.", "He switches on a vacuum to suck air out of the tank, simulating underwater pressure.", "He checks for bubbles around the light, which would indicate a leak.", "He programs the light for the water show so that different colors flash on cue.", "The next employee prepares an epoxy sealant.", "He pours the epoxy into the solenoid controller for the water-fountain jets.", "It takes two hours to dry.", "Once solidified, it will protect the components from water damage.", "Then he assembles the carriage for the fountain jets.", "He places the carriage on a spring-loaded slide and secures it with long-threaded rods.", "The worker applies sealant to the ends of the rods and screws on the nuts.", "He installs a plastic nozzle cup.", "He secures it to the carriage with a center pin that has a swiveling mechanism.", "He transfers the carriage assembly to a water-distribution manifold and screws it in place.", "He tests the carriage and confirms that it slides freely on the springs.", "Then he runs plastic tubing from the water-distribution manifold to the spouts of the nozzle cups.", "The worker secures the joints with plastic zip ties.", "Then he trims the ties using a special gun.", "He attaches the solenoid controller to the carriage and connects the controller to the various air tubes that lead to the waterspouts.", "He places the water-jet assembly on the back of a steel mounting plate and secures it with screws.", "He inserts two l.e.d. lights in specially designed slots, then screws them in place.", "This water-jet fountain is now complete.", "He hooks it up to a compressed air source for a dry-bench test.", "He confirms that the compressed air moves the carriage correctly in the programmed sequence.", "He also connects the water jet to a mechanical sequencer to verify that it's functional.", "After it passes the tests, he seals the perimeter of the jet with a rubber gasket and the faceplate.", "This water-jet fountain is ready for installation.", "When combined with other fountains, it will put on quite a show.", "Onlookers will be so engaged, they won't mind getting a little wet.", "People have been surfing on wooden boards for thousands of years.", "These early surfboards were heavy because they were made of solid wood.", "Today, surfers are taking this classic material and giving it a modern twist, creating beautiful, lightweight boards from sustainable resources.", "When most people think of surfboards, they picture brightly colored boards made of foam and fiberglass.", "But wooden surfboards are making a not-so-surprising comeback.", "Every waterborne vessel was originally made from trees because, no matter what, wood floats.", "They start by gluing two planks of poplar to a strip of oak.", "Using a template, a craftsman draws the shape he wants for the surfboard.", "He uses a japanese pull saw to cut the shape out by hand.", "This is the basic outline of the surfboard.", "A cnc router quickly and accurately cuts the inner support framework from poplar plywood.", "The builder sources wood from suppliers who use sustainable forestry practices.", "Using his pull saw, the craftsman carefully frees the pieces of the support framework.", "Then he smoothes the edges with a block sander.", "He begins fitting the pieces together to form the framework.", "For the spine, the builder uses fast-drying superglue.", "It bonds powerfully and quickly, allowing him to work fast.", "After completing the spine, he starts gluing and inserting the ribs.", "The finished frame resembles the skeleton of a large fish.", "Once the support structure has dried, the craftsman places it on the bottom skin of the surfboard.", "He positions it carefully and securely clamps it in place on a purpose-built jig.", "Then he traces the lines of the frame on to the skin.", "He measures and marks a set distance from the end of each rib.", "He squeezes a bead of epoxy-based glue over the network of lines before lifting the frame into position on the skin.", "He clamps everything down and lets it dry overnight.", "The sides of the surfboard, called the rails, consist of 12 strips of wood glued and clamped together.", "The rails take several days to make.", "After that process is complete, the builder lays a bead of polyurethane glue on the frame and rails.", "Then he lowers the surfboard's top skin into position and secures it with dozens of clamps.", "He lets the fully assembled board dry overnight.", "Now the board is ready for the last phase of production.", "First, the craftsman shapes and smoothes the wood to give the object its final shape.", "He trims the excess wood off the sides using the rails as a cutting guide.", "He rounds the top edges of the board with a small, japanese-made wood plane.", "The builder also uses a special tool called a saw rasp to finish the edges.", "He uses a square to make sure the bottom and top are even when shaping the nose and tail.", "The saw rasp allows him to quickly and efficiently bring the board to its final shape.", "Next, the craftsman uses a sanding block with increasingly finer grits of sandpaper to create a smooth surface.", "He signs the bottom of the board with a pencil, then burns it into the wood with a tool called a pyrography pen.", "He adds a layer of fiberglass and epoxy to give the wood a tough outer shell.", "Customers can choose to have a fin box with a removable fin or they can opt for a permanent wooden one.", "Traditional material plus an innovative design results in wooden surfboards that are built to last." ]

{ "things": [ "Whips", "Automated Pizza Makers", "Incense Cones", "Model Jet Engines" ] }

[ "In the old days, ranchers used the sound of the whip to move cattle.", "Today, collectors buy different types as functional works of art while others practice the sport of whip cracking, training to compete in competitions.", "There are even entertainers who perform eye-popping tricks with whips.", "In the world of whip-cracking, the best whips are made of kangaroo leather because it's 10 times stronger than cowhide of equal thickness.", "Modern whips have four main parts-- the handle, the thong, which is the flexible, braided portion, the fall, a replaceable strip of leather, and the cracker, the thin string which amplifies the sound of the crack.", "After carefully selecting the hide to be used for the specific whip, they begin by trimming away the ragged edges of the kangaroo hide with a razor-sharp knife.", "This leaves a smooth edge with which to work.", "They now begin cutting out all the whip's leather components, most of which have strands which they'll later braid.", "The internal construction of the whip is made of two layers of braiding called plaited bellies.", "Separating each braided layer is a solid piece of leather called a bolster.", "It encircles the braided belly layer under it.", "Then, covering everything is a final outer layer of braiding called the overlay.", "They cut the strands for the bellies and overlay by hand using a tapering cutter that's specially designed for whip-making.", "The finished overlay and bellies have a flat portion at the top called the yoke and strands tapering continuously along their entire length.", "They stretch each strand as much as possible to ensure the braid will be tight and uniform.", "Then, they resize each strand and bevel its edges.", "This helps the strands fit into each other snugly and create a smoother, gapless braid.", "Then, using a tool called a hand splitter, they shave the backside of each strand to a uniform thickness.", "This prevents lumps in the taper of the finished whip.", "Next, they take waxed cord and tightly bind a tapered strip of leather around a handle foundation.", "The leather strip called the core will extend into the center of the thong.", "They attach the first belly yoke over the handle and core, then braid the strands to begin forming the thong.", "This compresses the core into a solid, round center.", "Over the braided first belly, they wrap the first bolster, then attach and braid the second belly.", "Over that, they wrap the second bolster, each layer compressing the ones underneath.", "Then, at last, the final layer-- the overlay.", "First, they lubricate the strands with homemade animal-fat-based soap.", "This not only enables a tighter braid, the animal fat also conditions the leather.", "This particular whip has a 12-strand overlay, but more intricate overlays can have as many as 72 strands, forming complex patterns.", "While braiding, it's critical to see and align the inner layers and pull the strands tightly.", "When the thong reaches the finished length, they feed the end of the braiding through a slit in the next part of the whip, the fall.", "They tie the remaining strands in sequence around the fall, using what's known as a half-hitch knot.", "Then they seat the fall into place and trim the loose strands.", "This creates a secure connection between these two sections of the whip.", "Now they roll the thong between a hard surface and a block of marble.", "This compacts the braiding and rounds out the overall shape.", "Then they tie the cracker onto the tip of the fall.", "In the old days, they used horsehair for the cracker, also known as the popper.", "Nowadays, whip makers are more likely to use nylon string.", "They wrap a piece of leather to build a knot foundation at the base of the handle.", "For longer and thicker whips, they form the knot foundation with a piece of lead to properly balance the whip.", "They fold the yoke from the overlay over the foundation, then, with a separate strand of leather, cover the foundation with what's known as a turk's head knot.", "After trimming the knot strands, they shape the knot with a soft mallet, then more rolling.", "Lastly, they apply a coat of natural shellac to the entire whip.", "This protects the materials and produces a nice sheen.", "No whip leaves the shop without a round of hands-on testing to make absolutely sure it's all it's cracked up to be.", "if you have a craving for italian and there's no restaurant in sight, you can always buy a pizza from a vending machine-- not something pre-made and packaged that you have to reheat in the microwave but a fresh pizza, made from scratch right inside the machine and served to you piping hot.", "This automatic pizza-making machine produces a fresh pizza in less than three minutes.", "You simply insert money, then select one of four different pizza toppings.", "The machine then makes the dough, applies the toppings, and bakes the pizza right before your eyes.", "When it's ready, your made-to-order 10-inch round meal is ready for pickup at the exit slot.", "To build the machine, they first construct a three-section steel frame.", "Technicians install a refrigerator in the middle section.", "The fridge houses four dispensers, one for each of the four topping ingredients.", "The machine presses and dresses the pizza dough on a nonstick plate, around which they assemble a housing.", "A motorized tray moves the plate in and out of the housing to transfer the dough from one preparation stage to the next.", "Technicians install this assembled unit into the left section of the frame.", "Next, they install the dough mixer above it...", "And just below the mixer, a plastic cup that receives the kneaded dough, then drops it onto the press plate.", "Next, the flour dispenser.", "It holds enough flour to make dough for 100 pizzas.", "Still in the left section, behind the flour dispenser, they install and load the tomato-sauce dispenser and a bag of water.", "Then, in the right section, they install the oven and, below that, the pizza exit slot.", "Once everything's hooked up, a test run.", "The action begins in the left section.", "The flour dispenser releases a dose of flour, which is actually a mix of various flours, instant yeast, and salt.", "Then, the water bag releases a dose of water.", "The mixer blends and kneads all the ingredients.", "Once the wad of dough is ready, it drops from the mixer into the cup.", "A descending arm pushes it from the cup onto the press plate, forming a 4-inch disk.", "Then a large press flattens it out to 10 inches, the finished pizza size.", "Now the tomato-sauce dispenser rotates, squirting tomato sauce onto the dough in concentric circles.", "Next, the pizza travels through the middle section, passing beneath the refrigerator to receive the selected toppings-- in this case, cheese.", "Then, a large automated spatula, called a conveyor plate, moves the pizza to the right-side section into the machine's infrared oven.", "Infrared radiation works faster than traditional heating because it cooks food from the inside out rather than from the outside in, so the pizza bakes in just one minute.", "The conveyor plate returns, removes the hot pizza from the oven...", "And deposits it in a cardboard tray waiting in the exit slot...", "Cueing flashing lights, inviting you to come and get it.", "Once a test run produces a perfect pizza, the final step is to mount the doors on this self-service pizzeria.", "Buon appetito.", "Burning incense is a ritual as old as time itself.", "It likely began with the discovery that burning certain plants and tree barks generated pleasant aromas.", "Eventually, people began compressing those sweet smells into cone incense that burned slowly, giving the user more time to relax.", "Lighting an incense cone can instantly change the mood in a room.", "As the cone smolders, it releases a bouquet of scents from the powdered flowers, herbs, and other plants used to make it.", "The fragrances released create a soothing atmosphere.", "An incense cone starts with bins of aromatic raw materials, like dried flower petals, spruce-tree needles, and blossoms that have been ground to a fine powder to release their perfumes.", "Other ingredients in the bins include tree barks and tree resins.", "Everything comes from nature.", "The factory combines the ingredients in various formulations, depending on the incense-cone recipe.", "The exact amounts in each recipe are closely guarded company secrets.", "They follow each recipe to the letter, measuring all the ingredients with a traditional balance scale.", "There's no room for error.", "Otherwise, the product will smell off.", "This particular blend is called forest honey.", "The combination of ingredients includes berries and a pungent balsamic tree resin called olibanum.", "The batch should emit a sweet, woodsy aroma.", "They add buckets of the measured ingredients to a mixer and then turn the switch to activate the auger.", "The auger spirals to evenly distribute all the aromatic ingredients.", "While that's happening, a worker scoops up something that looks a lot like pastry flour but is actually a plant-based binding agent.", "He mixes it with cold water to liquefy the binder.", "Then, in a separate pot, he adds orange food coloring to boiling water, and an automated whisk mixes thoroughly.", "He pours the thick binder liquid into the orange-colored water.", "The whisk kneads it to a pudding-like consistency.", "It's thick and sticky, so it's ready to add to the dried fragrance mix.", "The auger works it into a cakey orange dough that's as malleable as putty.", "They'll now use this two-part die to shape the dough into cones.", "The worker manually presses the fragrant dough into the cavities of the die.", "He compacts the dough with this handy tool.", "This eliminates air pockets and ensures the dough takes the cone shape.", "He levels the bottoms of the incense cones and then opens the die carefully.", "The shapes are soft and delicate.", "One false move, and he could destroy some of the cones.", "The cautionary approach pays off, and the cones are intact.", "Now it's into the drying chamber.", "The temperature in here is around 100 degrees fahrenheit-- hot enough to toughen up these soft and crumbly cones.", "After four days in the drying chamber, the incense cones have hardened and solidified.", "The cones now bounce along a conveyor past an inspector who sorts out any defective ones.", "The good ones move forward and tumble down a chute.", "They land in a plastic bag, and a device moves in to heat-seal it.", "An automated counter overhead portions out the cones to ensure the correct number is deposited in each package.", "After a worker puts the bag in a box, an automated device folds down the lid.", "From start to finish, it takes about 14 days to produce a package of incense cones.", "All that hard work is about to go up in sweet-smelling smoke, which, of course, is the whole idea.", "The model jet engine is a scaled-down version of the real thing.", "It's essentially the same technology that lifts enormous aircraft off the ground and propels them through the sky.", "These engines were first developed for model aircraft in the 1980s, and they created an immediate sensation on the runway.", "For some model-aircraft enthusiasts, tiny turbines are now the only way to fly because they look and sound like a real turbo jet.", "It's a touch of authenticity that can allow the imagination to really take off.", "These mini jets start with the base plate.", "It's the piece that all the other turbine parts will be attached to.", "Automated tools transform a piece of aluminum into an aerodynamic shape.", "The little blades cut into the perimeter will act as air foils, contributing to lift and thrust.", "It takes just minutes to go from a metal disk the size of a hockey puck to a precision part.", "Next, a worker laser-welds the seams of a steal canister, creating what looks like a large can with holes.", "This is the jet engine's combustion chamber, where a mix of fuel and air will be ignited to drive the turbine.", "He now inserts a hollow cylinder into the base plate and then presses a fuel-distribution ring into the plate.", "With the parts correctly aligned, he places the assembly in a metal stand.", "He dips screws in a thread-locking compound and drives them into threaded slots in the base plate.", "This secures and cements the base-plate assembly.", "He now holds the base-plate unit above the combustion chamber while he inserts the tiny fuel-delivery tubes into the chamber.", "He flips the chamber around to slide the tubes further inside and complete the job.", "The stator vane, pressed onto the other end of the chamber, will redirect the flow of gases to the turbine wheel.", "And now the glow plug-- so named because it glows to ignite the fuel inside.", "He pops it into a threaded slot on the side of the combustion chamber, which is, by now, encased in an outer shell.", "Next, he installs the turbine and shaft, sliding the shaft into the center cylinder.", "He supports the shaft on both ends with thrust bearings and washers, pressing the parts into place.", "Next is the compressor wheel, which pressurizes air on its way into the chamber.", "Once installed, the compressor wheel spins at a blurring speed, and a computer analyzes it for the slightest vibration.", "Any vibration will signify an imbalance.", "The technician drills away tiny bits of metal to lighten the areas of imbalance.", "The exact spot was pinpointed by the computer.", "He gives the compressor wheel another spin.", "Again, the computer detects a small imbalance, and more material must be removed.", "The process is repeated several times until the compressor wheel is perfectly balanced and the computer gives it the green light.", "After that, he balances the turbine wheel on the other end of the shaft.", "This mini jet engine is now ready for the starter motor.", "He installs it on the shaft protruding from the compressor and anchors it with screws.", "Once in place, it will spin the shaft until enough compressed air is produced to ignite the fuel.", "This plastic tubing will deliver gas to the engine and oil for lubrication.", "He adds a little of the oil for the initial lubrication of the bearings.", "Next, he heats one end with a lighter.", "This makes the plastic supple so it easily fits onto the connector.", "He wires the starter to a battery and tests the motor.", "It works...", "So he snaps an aluminum cover onto the assembly.", "This model jet engine is ready for the final test.", "Locked down in a test box, they pump fuel into it and bring it up to full throttle.", "using computerized equipment, the technician monitors the output and confirms the engine is producing an adequate amount of thrust.", "That means it's ready to leave the factory and take flight.", "In total, it takes about six hours to make a model jet engine, but after that, the sky is the limit." ]

{ "things": [ "Motorcycles", "Clay Pipes", "Drum Sticks", "Whistles" ] }

[ "Today on \"how it's made\"...", "Motorcycles...", "Clay pipes...", "Drumsticks...", "And whistles.", "The invention of the motorcycle late in the 19th century was speed driven.", "People wanted to go places faster than they could on a bicycle.", "So they strapped an engine on a bike-- a simple concept.", "Today's motorbike is much more complex, and it leaves the earlier versions in the dust.", "These motorbikes are an engineering feat.", "They start by welding the frame out of lightweight aluminum, an advantage for speed and fuel efficiency.", "The frames are cleaned, powder-painted, then baked to cure the paint.", "They fit a crankshaft and pistons into the engine's left block.", "They tighten the bearings and caps, then slide in a u-shaped tool called a fork that orients the pistons in an upright position.", "Next, they compress the piston rings with another tool so that the pistons easily slide into place as they install the other half of the engine block.", "They place a gasket on the top of the block...", "And then install the cylinder head.", "Using torque-controlled electric tools, they tighten the bolts to attach the cylinder head to the block assembly.", "They install the camshaft in the cylinder head unit.", "The camshaft will drive the valves that bring in air and fuel and let out the exhaust.", "They rotate the crankshaft to fine-tune its action.", "Now it's time to give this engine a little test run.", "They fill the engine with coolant and fuel, then run through the gears.", "They check for leaks and overall function.", "When it passes inspection, they purge the coolant from the engine.", "A motorbike engine isn't only about function.", "It also has to look good, because it won't be totally hidden under a hood.", "Now they lower the 225-pound engine onto a cradle that sits on a conveyor.", "They mount the frame onto it.", "They attach the rear wheel assembly...", "And then the front wheel.", "They attach the handlebar using torque-controlled tools.", "And they tighten the brake assemblies.", "Next, they fill the radiator with antifreeze.", "Meanwhile, over in the paint department, robots are hard at work.", "They attach the painted pieces to the bike-- first the saddlebag body, then the lid, and finally, the trunk body.", "Then they assemble the instrumentation.", "The speedometer, fuel gauges, and many other things all go onto one unit.", "This part is called the front cowl, and it goes right in front of the instrumentation.", "They lower the front cowl with a meter panel onto the bike.", "And then they bolt everything to the frame.", "Finally, they install a cover for the exhaust pipe.", "They check everything to make sure it's solidly put together.", "And then they pull up to a dynamometer, a machine that measures mechanical power.", "They check the bike's speed, brakes, horn, navigation system, and the cruise control.", "Every motorbike undergoes this scrutiny, and if it passes, it's ready for life on the road.", "Clay pipes are part of a major underground network, one that's dedicated to proper drainage.", "We flush without thinking, but it may surprise you to learn that clay pipes have been serving us well for thousands of years, ever since the days of ancient babylonia.", "They're the sanitary sewer system's oldest secret.", "These pipes can take a lot of stress.", "They bear the weight of soil and structures overhead, and they won't corrode.", "They start with scrap clay from manufacturing, raw clay, and shale.", "After these materials have been roughly processed, a loader scoops the mix onto a conveyor that takes it to a mill for a finer grinding.", "At this point, the mix has about 10% natural moisture, but it's not enough for it to stick together, so they add more water as it falls into a mixer.", "The mixer evenly distributes the water in the mix, then moves it towards an extruder that pushes the clay through a pipe-shaped eye.", "The clay pipe that emerges is 7.8 inches in diameter, the size that typically serves a residential side street.", "It has a bell-shaped opening.", "It's the female part of a joint that will fit to the male end of another pipe.", "A rotating blade trims away the ragged edges.", "Then an automated system loads several pipes at a time onto a rack to await the next step.", "Over on another production line, they're making flue liners for chimneys.", "The clay is fairly soft at this point, so lettering wheels easily engrave information, and they can cut it to size using only a thin wire.", "An upender lift stacks it on a pallet to await further processing.", "Elsewhere in the plant, a main trunk sewer pipe is born.", "With a diameter of over 15 inches, it's big and needs a substantial trim job to get rid of the rough edges.", "It weighs well over 660 pounds, nearly five times that of the residential pipe.", "Once they're fabricated, every clay pipe goes into a big dryer for at least 24 hours.", "A trip through a kiln will toughen them up even more.", "They'll spend about 50 hours in here, exposed to very high temperatures.", "This step is called vitrification.", "It fuses the mineral particles together.", "They tap each pipe with a hammer to test it if it's solid...", "And perform a thorough visual inspection.", "To join lengths of pipe together, they pour polyester resin into the female joint molds that have been placed in the bell-shape pipes.", "The resin hardens, forming an o-ring, and the primer brushed on earlier helps the new resin joint adhere to the clay pipe.", "Next, they make a male joint by pouring resin around its spigot end.", "This will make for a joint with a tight seal.", "They test the joints by pumping water into the pipe.", "Then they raise it as they place a load on the joint.", "How much pressure will this joint take without failing?", "Over a ton, which more than meets industry requirements.", "Now they do another type of test on a basic clay pipe.", "A hydraulic jack applies pressure on the pipe.", "The number on the gauge far exceeds the burden of being buried underground.", "And so these pipes are now ready for civic duty down in the sewers.", "Drumsticks are designed for a life of hard knocks.", "They're usually made of hickory, which is heavier and sturdier than other woods.", "Hickory can also absorb a lot of shock, which means a drumstick made from it is easier on the hands and wrists, so the drummer doesn't have to suffer for his music.", "Hickory drumsticks also have good balance and feel, so it's easier to hit the right note.", "To make them, automated arms serve up hickory dowels to a three-bladed cutting device that moves on a rail.", "As the blades shape the spinning dowels, they form a round tip, a narrow shoulder, and a shaft that gradually widens.", "They spray each stick with a protective coating.", "These round blades lob off the stubs, the ends where the sticks were held during their initial machining.", "It's just a rough trim, and the ends need more work.", "So they feed them to spinning chucks with blades.", "The chucks are inside a protective metal housing because they spin very fast and the blades are extremely sharp.", "For a demonstration, the housing on one of the chucks has been removed, and they turn it by hand.", "The chuck usually rotates at 10,000 rpm, but at this slow speed, you can see just how it shaves an end into the desired shape.", "The stick comes out of the chuck with a nicely rounded tip.", "Now they test the sticks.", "Each one rolls down steel rails that have been specially aligned.", "If it rolls straight, it means the stick is straight.", "But if it wobbles, it isn't and would be impossible to play with.", "They reject those sticks.", "Next, a printer embosses the brand name and model number onto each of the drumsticks.", "Now they sort each drumstick by weight.", "Even if two sticks have been made exactly the same shape and size, their weight can vary because wood has different densities, and that's something that affects the stick's feel and tone.", "For example, this drumstick weighs 53 grams.", "But the next one comes in at 55.", "Over at another work station, they're making a different kind of drumstick-- a felt-tip mount that will have a softer sound.", "They press a wooden shaft into the glue-filled hole of the felt ball.", "The hole is a bit smaller than the shaft, resulting in a tight bond between the stick and felt head.", "They do a sound check on the other sticks.", "Even though they've been sorted by weight, there are still subtle differences in tone.", "A computer analyzes their sound and matches pairs.", "It's a bit like a dating game.", "The unmated sticks go back into the mix, and they try to match them up again.", "This matching process is critical.", "If one stick has a different pitch, the sound will be off-balance.", "They assign a numerical value to each pair of drumsticks.", "A cardboard sleeve holds each matched pair together.", "From a rough wooden dowel to a sleek drumstick, a process that's designed for impact.", "When you blow into a whistle, part of the air stream exits the slot in a swirling motion, generating sound.", "The rest of the air stream travels through the whistle chamber, then exits the slot, reinforcing the sound.", "The little ball rolling inside puts the trill in the whistle blast.", "Quality whistles are made of solid brass because nothing beats its resonance.", "production begins with a narrow brass sheet not quite 4/100 of an inch thick.", "A punch press slices through the sheet, cutting a square connected to two circles.", "The factory calls these pieces the mickey mouse ears.", "One by one they go into a second press that folds the circles inward to form the sides of the whistle's barrel and bends the edges of the square inward to form the top and sides of the mouthpiece.", "At the same time, it strikes the mouthpiece against a die that embosses the company logo into the metal.", "Another brass sheet feeds a third press.", "This machine punches out and partially shapes the part that forms the rest of the whistle.", "It notches the tapered end, which will be the underside of the mouthpiece, giving your teeth something to grip.", "Now a fourth press finishes shaping these pieces.", "It bends the other end into a circle to form the barrel.", "The two main parts of the whistle are now ready.", "A worker snaps them together with pliers.", "Note that on the bottom piece the barrel stops short of meeting the top of the mouthpiece.", "This creates the whistle's air slot.", "This press cuts and folds a brass sheet into the third and final part of the whistle, called the tip.", "It's a piece on the back that holds a ring for hanging the whistle.", "The tips go into a bowl feeder.", "The vibration orients them in the same direction so that a robotic arm can pick them up and put them in a holder.", "Tin and silver solder is applied to each tip.", "This will bond it to the whistle.", "To fuse all the parts together, solder is applied in six different spots.", "The solder liquifies as a gas flame heats it to about 1,100 degrees fahrenheit.", "It flows around all the seams, filling them in a matter of seconds.", "A blast of cold air solidifies the solder.", "Even then, it's still steaming as the whistle comes off the machine.", "The ball that goes inside the barrel is about a half inch in diameter and made of synthetic cork, which doesn't absorb moisture, so the ball never gets soggy and stuck.", "A worker holds each whistle, now plated with nickel, against the insertion machine.", "The device works like these pliers, squeezing a ball through the whistle's air slot.", "With one side of the barrel cut away, you can see how the ball regains its shape as soon as it clears the slot.", "The last step is to hook a steel ring onto each tip.", "The factory packages its whistles with a nylon cord called a lanyard.", "A hook on one end attaches to the whistle's ring.", "Another accessory in the package is a rubber cover for the mouthpiece.", "It makes holding the whistle in your mouth for a long time more comfortable.", "This factory also makes customized whistles.", "You can order them with your own logo.", "Or to really blow someone away, you can present them with a 24-karat gold-plated award whistle." ]

{ "things": [ "Winter Jackets", "Animation", "Mushrooms", "Gold Rings" ] }

[ "Today on \"how it's made\"...", "Winter jackets, animation, mushrooms, and gold rings.", "As anyone who's shivered through a cold winter knows, you've got your run-of-the-mill winter jackets and then, those really warm winter jackets that can run up to $1,000.", "The difference is what they're made of and how they're made.", "A top-of-the-line winter jacket gives you the warmth without the weight.", "It's waterproof and comfortable-- no bulky stuffing or constrictive styling.", "The designer draws a pattern by computer.", "A software program then adapts the pattern to different sizes.", "A giant printer puts it to paper.", "The tailor spreads out several layers of each of the fabrics that'll make up the jacket.", "He lays out the pattern...", "Then pins it in place.", "Next, he cuts through several layers of fabric at a time with electric scissors.", "These scissors maneuver much like a jigsaw around the lines and curves of the pattern pieces.", "The finished jacket will actually be made up of two jackets sewn together-- an insulation jacket on the inside and a windbreaker on the outside.", "The inner insulation jacket begins with a nylon lining.", "Then they layer the key components-- a film to stabilize and protect the insulation, then the thick polyester insulation itself.", "At this point, the insulation layer is larger than the lining.", "This ensures that every inch of the jacket will have insulation.", "Working with one piece at a time, they stitch the layers together.", "Each line of stitching is tacked at the beginning and at the end for added strength.", "They cut off the excess insulation, then sew an overlock around each piece to hold the remaining insulation solidly in place.", "Once they've completed each piece of the insulation jacket, they sew it all together.", "Next step-- the windbreaker.", "The outer fabric is heavy nylon.", "The lining is a special fabric with tiny holes, large enough to let humidity escape, but small enough to stop water droplets and wind from penetrating.", "This is what will allow the jacket to breath, while at the same time, making it windproof and waterproof.", "Finally, it's time to put the two jacket components together.", "Using two separate strong threads, they sew seams made of knotted stitches.", "No seams go through the jacket because that would break the insulation barrier and let in cold air.", "They join the two jackets together only where they have to-- at the collar, the cuffs, the hem, and along the zipper.", "And this isn't any ordinary zipper.", "It's made of corrosion-resistant nylon with a nickel-plated slider that lasts seven times longer than a normal slider.", "Until now, they've been sewing the jacket turned inside out.", "Now they turn it right-side in for finishing.", "These heavy-duty snaps have sturdy grips that anchor themselves between the fibers in the material so they won't tear the fabric with repeated use.", "Some jackets have decorative embroidery.", "Designers use a computer program to prepare the pattern.", "The automatic machine embroiders five jackets at once.", "This intricate owl pattern takes 1 1/4 hours to complete.", "The final result is a stylish jacket whose secret weapon is that hidden layer of insulation.", "It traps air inside your body, then heats it up, creating a cushion of warmth against the cold of winter.", "What is biophotonics?", "Well, bio is short for biology.", "Photonics is the physics of light.", "Biophotonics uses sophisticated imaging and other sensitive optical instruments to conduct biomedical research.", "Biophotonics has a range of uses from medical diagnosis to drug screening.", "In the golden years of animated film, teams of animators would draw every single illustration by hand.", "Today, they do much of their work by computer, but that doesn't mean it's any less artistic.", "It all starts with a screenplay-- a script containing not just dialogue, but also physical descriptions of the characters and background scenery.", "The art director begins creating the characters.", "He draws in pencil.", "When he's finished, he traces the drawing in felt pen.", "Then he erases the pencil marks.", "He adds shadowing to create relief.", "Once he's drawn all the characters, he starts the backgrounds...", "And then the objects that appear in the backgrounds.", "The storyboard artist blocks out the film on paper, drawing by drawing.", "The production team will follow this storyboard the way a dressmaker follows a pattern.", "They blow up the drawings, scan them into the computer, then play them back in chronological order.", "This creates what's called an \"animatic\"-- a two-dimensional version of the film, minus the animation.", "Should the director now decide to change, say, a ground-level view of the street to an aerial view, he has the artist redraw the street from that new angle.", "Meanwhile, the animators work on bringing the characters to life.", "Using specialized software, they build a skeleton to fit inside the character's body.", "When they move the skeleton, the software makes the body move with it.", "They make the characters three-dimensional using a technique called wireframe animation.", "First, they build the shape of the character using a wire structure.", "Then they add color and clothing.", "They further refine the character by modifying facial features, by adding texture, and by shadowing.", "They use specialized software to synchronize the character's mouth with the dialogue.", "The technician works syllable by syllable, picking the mouth movement that matches each sound.", "It's a painstaking process that takes many months.", "Another animator applies the lighting effects.", "Lighting is as important in an animated cartoon as it is in a movie with real people.", "It creates relief, making everything look more realistic.", "The animators cut and paste the characters and objects onto the backgrounds.", "With the characters' movements programmed into the computer, the animators turn a two-dimensional still version of the film into a three-dimensional animation, essentially a rough cut of the film.", "Meanwhile, in the studio, the soundtrack takes shape.", "Actors record the characters' dialogue.", "The sound technician weaves together the voices, the music, and the sound effects using specially designed software.", "They sync the soundtrack to the rough cut of the film.", "Then they refine the rough cut, playing with colors and textures and smoothing out the characters' movements.", "After a full year's work and more than 42,000 drawings, this 24-minute computer-animated film is finally finished.", "Have you ever dined on fungus?", "Well, if you've eaten mushrooms, you have.", "We like to think of those tasty little umbrella-shaped things as vegetables, but technically, they're fungi.", "Fungus omelette, anyone?", "Mushrooms grow in compost, and preparing that compost is a science in itself.", "It starts with horse manure and straw.", "The correct balance of moisture and air is critical, because mushrooms need both to grow, so mushroom farmers have to turn the pile frequently to air it out, and they water it daily for about a week.", "This kicks up plenty of chemical and biological activity.", "Ammonia forms, and microorganisms grow and reproduce, releasing heat.", "Good compost requires a nitrogen content of about 2%, so farmers add a nitrogen supplement-- chicken manure.", "They also add gypsum-- a mineral that improves the structure of the compost and neutralizes its acidity.", "At the week to two-week mark, depending on how the compost is progressing, it goes into the composter, which waters, aerates, and blends it.", "The compost comes out chocolate brown, smelling of ammonia.", "Next, they pasteurize it, to kill off any insects or insect eggs.", "They heat the compost at 136 degrees for eight hours, then at 113 degrees for five days.", "Then, over several more days, they gradually cool it to 77 degrees as microorganisms turn the ammonia into a nitrogen protein-- a mushroom nutrient.", "The compost is finally ready.", "The farmer sows grains of wheat inoculated with mushroom mycelium-- fine threads of fungi that act as the mushrooms' roots.", "A layer of soil and peat moss goes on top of the compost.", "The mycelium draws water from the soil and nutrients from the compost.", "After about two weeks, tiny mushrooms begin to develop.", "They grow fast, doubling their size every 24 hours, and this in relative darkness.", "Green plants need sunlight for photosynthesis but mushrooms don't.", "What mushrooms do need is air, because they breathe in oxygen and breathe out carbon dioxide.", "Green plants do the opposite.", "Another three days, and the tiny mushrooms are fully grown and ready for harvesting.", "Pickers have to be careful not to remove the roots because left intact, they'll sprout a new batch of mushrooms every three to five days for about three weeks.", "They put the harvested mushrooms in a refrigerator just above freezing temperature, for about a half-hour, to stop the growing process.", "On the packaging line, they weigh the mushrooms and arrange them in a container, buttons up.", "A machine perforates the plastic covering to let the mushrooms breathe.", "This ensures a longer shelf life.", "The mushrooms stay in a fridge until they leave for the store the following day.", "It's taken about 12 weeks from the start of composting to your supermarket shelf.", "Gold jewelry has been a symbol of wealth and status throughout the ages.", "Today, though, it isn't just for the rich.", "Even ordinary people are likely to have a gold ring or necklace, just a little less diamond-studded.", "As early as 2,000 b.c., egyptian kings and queens adorned themselves in golden jewelry encrusted with precious gems.", "When the spanish sailed to the new world in 1492, they discovered mayan and aztec masterpieces of colored stones and pure gold.", "Today, elaborate gold jewelry and precious gems are well beyond the reach of the average person, except for the diamond ring-- still the customary symbol of engagements.", "The client and the jewelry designer first decide how the ring will look.", "The designer then measures the client's finger to determine her ring size.", "He then sketches out the design they've agreed upon-- a grooved band with three diamonds.", "The model maker works with a special carving wax.", "Using a compass, he measures and marks the width of the band, then carefully saws it off.", "He takes his gauge and puts it on a stick with ring-size markings, called a mandrel.", "He adjusts his compass to the ring size, then scores the finger hole on the block of wax.", "He then takes his drill and carefully carves out the hole he scored.", "Then he grinds off the wax on the outside of the band.", "Using the compass again, he scores the middle of the band, where he'll make the groove.", "Then, using a fine drill bit, he carves out the groove.", "With a file, he then refines the groove and shapes the curves of the ring according to the design.", "After putting wax prongs on the band, he attaches a wax stem to the model.", "He then positions the stem into the base of the cylinder that the jeweler will use to cast the ring.", "The base goes onto the platform of a vacuum machine.", "The jeweler puts a cylinder on top of the base, then pours in a special plaster.", "The vacuum sucks all the air out of the plaster.", "This is a key part of the process, because if any air bubbles remain, the finished ring will be out of shape.", "In less than a minute, the vacuuming is done, and the cylinder goes into the furnace at 1,350 degrees fahrenheit.", "The wax model evaporates, leaving a void the exact shape of the ring in the hardened plaster.", "Next, they melt the gold.", "The gold content of jewelry is measured by karat.", "The lower the karat, the less gold and the more alloy, or cheaper metals such as nickel, silver, and copper.", "After five hours, the cylinder comes out of the furnace and goes into the casting machine.", "The machine spins for about a minute.", "The centrifugal force shoots the liquefied gold into the plaster mold that's inside the cylinder.", "The jeweler then immerses the cylinder in cold water.", "This cools the gold and makes the plaster disintegrate.", "What's left is the cast gold ring, but its surface is rough, so on to the finishing process.", "The jeweler saws off the stem and gets to work.", "He files and grinds the ring until the surface is smooth.", "Then he stamps on his trademark and the karat marking.", "Then he hammers the ring on the mandrel to make it perfectly round.", "The jeweler then hands it off to a specialist in polishing.", "The polisher runs the ring against a series of buffing wheels until it's bright and shiny.", "The polisher then hands it off to a specialist in setting gemstones.", "The setter straightens the prongs that'll hold the diamonds.", "Then, with a delicate drill bit, he carefully carves out the inside of the prongs.", "The edges of the diamonds will fit directly into these slots.", "He readjusts the prongs, then sets the diamonds, making sure the prongs hold them down securely.", "That's a 1-carat diamond in the middle, a 1/2-carat diamond on each side.", "The jeweler then immerses the finished ring into the ultrasonic machine.", "The vibrations in the water penetrate every nook and cranny, washing the ring.", "Finally, he puts the ring under a jet of hot steam to blast away any remaining residue.", "And voilà.", "With a ring like that, who wouldn't say \"i do\"?" ]

{ "things": [ "Ultra" ] }

[ "Today, on \"how it's made\"...", "Thinner than a human hair, ultrathin glass flexes like plastic.", "It can also have greater electrical sensitivity, making it useful for things like fingerprint scanning on smartphones.", "Manufacturers have only just begun to explore the potential of this new class of glass.", "When it comes to sheer flexibility, thin is in.", "Ultrathin glass bends like a sheet of paper and a chemical process ensures that it's extremely robust.", "To make ultrathin glass, manufacturers use standard materials, such as lime, sand, soda, and potash.", "They store the ingredients in separate silos, until it's time for production.", "Then, inside the factory, a long cable delivers electricity to power a weigh cart.", "As the dry ingredients flow out of the silos and down chutes, the cart moves forward to collect them.", "It weighs the ingredients until it has the correct amounts for the glass recipe and then closes the lid automatically.", "A worker measures the secondary, smaller, ingredients manually and adds them to the batch.", "These ingredients enhance qualities like optical clarity or electrical sensitivity.", "The cart transfers the batch to a mixer.", "As it blends everything together, they add bits of broken, or waste, glass to it for recycling purposes.", "Once it's been thoroughly mixed, a lift raises a funnel-shaped container up to the base of the mixer and the mixer releases the batch into it.", "A worker hauls the batch-laden funnel tank to the next station.", "There, a crane takes over and lowers the tank onto a feeder system just above a gas-and-electric furnace.", "A trapdoor opens at the funnel's base and the mixture flows into the feeder mechanism.", "It's a kind of shovel that slowly pushes the mixture into the furnace, which has been fired to a blazing 2,732° fahrenheit.", "The shovel continuously adds more ingredients to keep production flowing.", "Glass production runs 24/7.", "The melting glass reaches the consistency of honey.", "The molten glass flows out through a narrow slit and this slit establishes the ultrathin dimensions of the glass.", "Cooling the glass slowly relieves internal stresses as the glass solidifies.", "Ultrathin glass can be just 25 microns thick.", "That's finer than a hair.", "And it's this thinness that makes it so flexible.", "The glass bends to loop down and up across rollers as it journeys forward in a continuous, nearly 2-foot-wide sheet and, unlike ordinary glass, it doesn't crack.", "It then travels past tiny cameras and laser sensors that look for defects, like bubbles.", "A computer maps any flaws, so they can be avoided when the glass is cut into smaller pieces.", "A revolving spool rolls up the glass, along with a plastic liner, which keeps the glass layers from sticking to one another.", "Once 546 yards of thin glass has been wound onto the spool, an automated system cuts the glass and slides the spool partway off the core and onto a rack.", "The operator gives it a push to complete the transfer and then rolls the rack to the next station.", "A lab technician slices off a fragment of the glass and inserts it in a micrometer.", "It gauges the thickness of the specimen and confirms that it's superthin.", "Another lab worker places a bigger segment of the glass under a cutter.", "He aligns it correctly and then activates the cutter.", "It scribes the glass, so it can be broken on this line, creating small screens for smartphones and smartwatches.", "A lab technician examines the glass for scratches under a bright light and confirms that it's undamaged.", "With that out of the way, it's time to have a little fun with a strip of this ultrathin glass.", "A worker bends it into a circle and ties it.", "It's hard to believe this is glass.", "Later, a chemical treatment will further strengthen the ultrathin glass, so that the chance of cracks or breaks will be very thin.", "When wooden shipping pallets break and need repair, or outlive their usefulness, they can be taken apart by pallet-dismantling machines, which saw through the nails to separate the wood blocks and planks.", "Salvageable pieces become new pallets, while broken pieces go into a wood chipper.", "With its powerful band saw, this pallet-dismantling machine slices through the nails that fasten the pallet's wood blocks to its transversal planks.", "The machine's shell, the equivalent of the body panels on a car, is made of steel sheets.", "A computer-guided laser cutter cuts them to the required shape.", "Then, workers bend the ends on a brake press to make edges with perfectly formed corners.", "Once shaped, the shell parts go to a paint shop.", "Workers build the structure of the machine out of heavy-duty steel tubes.", "After sawing them to the length required, they smooth the rough-cut edge with a hand-grinder.", "Workers mark where they have to make openings for various parts and drill the holes.", "They weld the tubes together to assemble the structure.", "They clean the surface with acid to remove traces of lubricant.", "Then, they spray paint the structure.", "The workers assemble the mechanical parts to the structure.", "They bolt on a plate to support the machine's electric engine.", "Then, on each side, they install a wheel.", "Next, workers install the motor reducer.", "To that, they bolt the machine's 2,800-rpm engine.", "The motor reducer decreases the speed of the engine to the sawing speed required to dismantle the pallet.", "Just above the tires on both sides, they bolt a blade guide to the structure.", "They install the front of the machine's shell and lower the machine's heavy, steel worktable.", "Now, the band-saw blade, which has a safety cover over its sharp teeth until the machine is operational.", "On each side of the worktable, workers align the blade with a tire and insert it between the wheels of the blade guide.", "The blade is steel, with carbide tips for added strength and resistance to wear.", "They turn this bolt to adjust the tension.", "They enclose the tire and blade guides in the side sections of the machine's shell.", "Then, workers install two pneumatic cylinders for raising and lowering a safety cage that goes over the worktable to protect the machine operator.", "Next, another pneumatic cylinder, this one, at the rear for the machine's guide arm.", "The guide arm, installed next, helps move the pallet around while the machine's band-saw blade cuts it apart.", "They install the safety cage over the worktable, then hook up the cables that feed compressed air to the pneumatic cylinders.", "They install another safety cage over the back of the machine, then, a pressure regulator for pneumatic cylinders.", "They mount the machine's control panel on the shell.", "It's wired to the engine and pneumatic system, as well as a set of foot pedals that moves the table up and down and another pedal that moves the guide arm.", "The operator places the pallet on the worktable and lowers the safety cage.", "With the foot pedal, he moves the arm to the right to angle the pallet against the blade.", "This lets it slice through multiple nails holding the wood planks and blocks together.", "Often frosted and adorned with sprinkles, a cupcake is a sugary indulgence that you don't have to share.", "We don't really know who invented them, but cupcakes have been around for a century or more, much to the satisfaction of those who want a little cake all to themselves.", "These minicupcakes are the sweetest little things and there's plenty for everyone because they're mass-produced in a factory.", "The dairy and nut-free recipe starts with canola oil.", "A worker pours a measured amount into a huger mixer bowl.", "A blend of baking power, sea salt, and other microingredients is next.", "He then adds a big bag of sugar.", "They'll be making 15,000 minicupcakes in this batch.", "Pastry flour flows into the mixer from a silo nearby.", "He adds cocoa, for chocolate flavoring, then, activates the mixer, to blend it all together.", "Next are the eggs.", "They'll act as a binding agent for the chocolate batter and will have a leavening effect during baking.", "A quick mix folds the eggs into the chocolatey blend.", "A pump now transfers the batter to the next station.", "The bakery's temperature is critical during pumping.", "Too warm, and the mixture will be too thin to pump.", "Too cool, and it will be too thick.", "The pump delivers the batter to a hopper.", "Down the line a bit, a conveyor moves baking trays forward.", "A machine uses suctioning devices to pick up paper liners, flip them right-side-up, and insert them in the baking trays.", "Valves open and dispense the batter in the hopper into the cupcake liners in the pans.", "The system controls the flow of batter, so it only fills the liners one-third of the way.", "This leaves room for the cake to rise during baking.", "The pans move through different levels, with a range of temperature zones over a period of 25 minutes, finally emerging from the other side.", "During baking, the cupcakes have risen above the liners.", "They now head into a cooling chamber.", "They stay in here for 20 minutes, while fans blow air onto them to cool them down.", "The cooling firms up the cakes.", "A robot plunges pinlike tentacles into the cupcakes to lift them out of the pans with the paper liners attached.", "It transfers them to the packaging conveyor line.", "Workers pack them in clamshell plastic containers, a dozen to each one.", "They leave the containers open because they still need to decorate these cupcakes.", "Ahead, fluffy chocolate icing flows out of a hopper into applicators.", "They deposit the icing in a swirl onto the cupcakes, adding nearly an inch of height and a lot more sweetness.", "Down the line, workers load sugary sprinkles into another hopper.", "A feeder dispenses a few more of the sprinkles onto each of the frosted cupcakes.", "The containers then ride by a rail that folds the lids over.", "A pusher device presses down on the lids to close them tightly.", "The containers of minicupcakes then meet up with a roller that applies the adhesive-backed labeling.", "Before the cupcakes can leave the factory, a technician tests a sample from the production line.", "He crumbles some of the cake into pods and places them in a machine.", "The machine probes the water content at a microscopic level to determine if the cupcake is moist enough.", "Another test evaluates the cupcake's texture.", "When the samples pass this technological scrutiny, the cupcakes are ready for human taste buds.", "As a component of mechanical equipment, seamless tube is stronger, and therefore more resistant to pressure and tension, than tube with a welded seam.", "That's because seamless tube is manufactured from a solid bar of stainless steel, rather than from a strip of stainless that's rolled and welded into a tube.", "Seamless stainless-steel tube is used when reliability is critical; for example, in aerospace engines, nuclear equipment, and medical devices.", "The manufacturer purchases stainless-steel tubes in a range of lengths, diameters, and thicknesses.", "Workers select the right starting size for the specific tube the customer has ordered.", "They check the length with a measuring tape, then use a large micrometer to measure the outside diameter.", "They switch to a smaller micrometer to measure the wall thickness.", "Then, they weigh the tubes.", "If the raw material meets all the specs, production can begin.", "They insert one end of each tube into this rotary swager.", "It shapes the end to a point, to enable it to fit through a die with a smaller diameter.", "Workers spread lubricant into a steel bar, insert it into the other end of the tube, then insert the pointed end through a draw die.", "This carriage then grabs the protruding point and draws the full length of the tube through the die and over the steel bar.", "The die reduces the tube to a smaller outside diameter, while the bar sets the desired inside diameter.", "The tube walls thin out and the tube elongates in the process.", "The next machine's two rollers apply pressure to the outside of the tube as it passes.", "This expands the tube slightly, creating a slight gap between the tube walls and the bar inside.", "This enables the next machine to extract the bar.", "Finally, workers saw the point off the tube.", "They place several tubes at a time in a degreasing unit, which uses a cleaning solution to remove all traces of lubricant the tubes picked up during the draw process.", "Workers then transfer the tubes to drying tanks, positioning them at a slight downward angle.", "As air blows through the tubes for about a half hour, all of the cleaning solution either drains or evaporates.", "To further clean the inside of the tubes, workers insert a felt wad into each one, then squirt in some cleaning solvent.", "They shoot in compressed air to force the wad down the tube.", "As the wad travels the length of the tube, it wipes the inside wall with the cleaning solvent.", "Next, workers strap the tubes to a belt that takes them on a 30-minute trip through a furnace.", "The temperature inside is more than 1,800° fahrenheit.", "This intense heat softens the steel, which had hardened as a result of having been pulled through the draw die earlier.", "This process is called annealing and it slightly warps the tubes, so, next, they pass through a straightening machine.", "Then, the entire cycle repeats, until it's reduced to precisely the diameter and wall thickness the customer ordered.", "The finished tube can be up to 40 times its original starting length.", "To ensure the structural integrity of each tube, workers run an electrical current around the circumference.", "A break in the current indicates a defect, which workers then cut out with a saw before cutting the tube into the specific lengths the customer ordered.", "The saw cuts leave burns, rough edges, so workers insert the cut ends in a deburring machine which grinds the edges smooth.", "The last step is to submerge the tubes in an acid solution, to remove any iron particles picked up from the processing.", "This prevents the tubes from rusting.", "In addition to inspecting every tube that leaves the factory, quality-control testing of random samples ensures the product meets all technical specifications." ]

{ "things": [ "Baseball Gloves", "Medical Electrodes", "Stetson Hats" ] }

[ "A baseball glove is an extraordinary thing.", "Each and every one starts out brand spanking new and ends up fitting its owner like a second skin.", "Before long, the player and his glove are inseparable.", "The glove helps him live his dreams and fills his imagination with lifelong memories.", "Baseball gloves have evolved from hard, leather mitts to the sophisticated design players depend on today.", "It all starts with a hydraulic press that punches out the felt padding that will cushion the fingers and thumb.", "The holes will be used to lace the glove.", "Another press cuts out the palm section of the glove from a side of leather.", "The palm section also has lacing holes cut into it.", "The hydraulic press then cuts out the web, or pocket, of the glove, preparing it for lacing, as well.", "Meanwhile, a machine heat embosses the palm section with the company logo.", "Embossing also helps identify different leathers and glove styles.", "Another worker hand-weaves the front and back pieces of the pocket.", "This special basket-weave web gives the glove additional flexibility and control.", "Pockets first appeared in gloves in the 1930s.", "She stitches the pocket together.", "Then, she applies glue to secure the tail ends, closes the flap, and stitches the web shut.", "Another worker then sews the palm lining and the finger lining together.", "By stitching the palm and finger linings together, she completes the interior piece of the glove that touches a player's hand.", "She then sews the felt finger pads to the lining.", "These pads give the glove extra comfort and control.", "To build the outer shell of the glove, she sews welting leather between the fingers.", "This makes the seam stronger.", "Then, she sews the fingers and the palm piece together to complete the back part of the outer shell.", "Some leather softener helps prevent tearing as she stitches the back and the front parts of the outer shell together.", "She also uses welting leather to add strength and rigidity to the outer shell.", "A worker mounts the finished outer shell on to a finger form, heated to about 248 degrees fahrenheit.", "It takes heat and leather softener to allow the worker to manipulate the shell without damaging the leather.", "The worker then transfers the softened outer shell on to a stationary turning stick in order to turn the outer shell inside out.", "He works the outer shell one finger at a time so he doesn't spoil the leather or the stitching.", "He makes sure all is perfect.", "Another worker slips the interior lining on to a mounting support, then covers the lining with the outer shell.", "He works the leather to make sure the lining and the shell fit together properly.", "Then he applies a special paste that makes the palm more flexible.", "He inserts a felt pad into the thumb...", "Then another cushioning pad into the pinky finger, using a metal rod to fully insert both pads.", "He then starts lacing the glove with a long strip of leather.", "Lacing the glove is a labor-intensive skill that can take up to an hour.", "No machine can do this.", "He makes sure the lacing gets the right tension and the attractive side of the leather faces upwards.", "Using special knots and loops, he laces the entire glove by hand.", "A worker inserts wooden dowels and mounts the glove on more hot fingers to open up the fingers and thumb.", "This helps the player's hand fit into the glove more easily.", "Now this truly looks and fits like a glove.", "Today's baseball gloves come in all different colors and styles.", "They are so finely hand-crafted, they could be called works of art.", "Medical electrodes can help your doctor find out what's going on with your health in a heartbeat.", "These little sensors detect electrical currents in the heart, brain, and other parts of the body, and they're wired to monitoring equipment that records it.", "They're inexpensive, disposable, and essential to healthcare.", "When the nurse says this won't hurt a bit, you can trust her, if the test she's about to give you involves medical electrodes.", "These electrodes stick to the skin and probe beneath the surface without actually piercing it.", "They send information to monitoring equipment so specialists can assess it.", "These electrodes start with a roll of foam.", "The foam is coated with medical-grade adhesive and has a paper backing to keep the layers from sticking together.", "Machinery pulls the foam over a punch cutter which make small holes in it.", "But first, razors slit the paper, and equipment pulls it away from the thumb to expose the adhesive.", "The process leaves strips of paper along the edge.", "The thumb moves forward, sticky side up, as plastic elements and metal snaps cascade into a feeder system.", "They're cueing up to be installed in the holes punched in the foam earlier.", "Vacuum heads picked up the elements and insert them into those holes.", "The elements are coated with silver chloride, which makes them electrically conductive so they'll help pick up electrical activity in the body.", "Next, pneumatic equipment press-fits the metal snaps onto the elements.", "These snaps are also electrically conductive.", "Down the line, a blade slices through gel that's sandwiched between two thin plastic liners.", "Machinery pulls those liners away from the gel.", "This gel is water-based and contains salt, which will seep into the skin to help establish electrical contact.", "Another blade cuts the gel into small rectangles, and they land on a thicker plastic liner.", "The gel liner and foam with its elements and snaps come together, and the gels land directly on the elements.", "Rollers press everything together in a tight sandwich.", "Equipment pushes that sandwich forward into a cutting station.", "That's protective padding you see around the cutters.", "It protects the blades from the adhesive on the foam as they punch out electrode shapes.", "Blades now lightly perforate the plastic liner around the electrodes, while below, equipment pulls away the scrap.", "The perforations will allow the electrodes to be torn into individual units later, and it also makes it easier to fold up for packaging.", "Remember that paper left along the edge of the foam early on?", "It serves as pull tabs on some of the electrodes.", "The tab makes it easier to apply the electrode to the patient and then remove it.", "They package the electrodes in a special material made of plastic, aluminum, and paper.", "Hot metal plates melt and seal the material to form an airtight pouch.", "Finally, a long blade cuts the pouches into individual units.", "It has taken less than a minute to make this package of medical electrodes.", "They'll use many of them in just one test.", "With the gel side of the electrode pressed against the skin, they wire it to the monitoring equipment.", "And within minutes, these electrodes can signal problems, and that could save a life.", "After the test, the electrodes will be discarded-- disposable and yet indispensable in the world of medicine.", "The cowboy hat was made popular in 1865 by the stetson hat company and its founder, john b. stetson.", "Part of its attractiveness in the american old west was the wide brim that protected the cowboy from the elements, a high crown that kept a pocket of warm air on his head, and the ability to carry water if he needed to.", "All models of stetson hats are made from blends of pretreated fur, including beaver, rabbit, and wild hare.", "First, a worker gathers the mixture of different fur and deposits it into a picker machine that begins blending the fur together.", "The picker roller, which dates from the 1890s, sends the fur into a mixer.", "Inside the mixer, compressed air blows the fur around.", "This settles and removes any dust and dirt that may be trapped in the fur.", "After about an hour, the blended fur settles into a collection box.", "A worker puts it through a rotating loader machine that sends the fur into a multichambered blower.", "A look inside the blower reveals a series of picker rollers.", "These rollers, along with blowing air, allow the lighter fur to flow through the chambers while the heavier hair and the impurities fall to the bottom.", "At the back of the blower, the worker gathers and weighs the amount of fur needed to make just one hat.", "That amount varies depending on the size and style.", "The proper amount of fur then moves by conveyor belt into a forming machine.", "Here, a vacuum sucks the fur onto a cone form.", "The fur builds up like a fragile blanket of dust that must be held down by wet cotton mesh.", "For extra protection, a worker wraps burlap onto the cone and puts a metal cover over it.", "He weighs it down and gives the fur cone a good soaking in a vat of hot, soapy water to make the fur fibers curl up and lock together.", "Shortly after, the worker peels the newly formed felted fur blanket off the cone.", "At this stage, the interlocked fur fibers are still very fragile, so a worker protects the cones from damage by wrapping them in cloth.", "Then, she puts them through a hardening process which consists of a series of massaging rollers and hot-water baths.", "The rollers in the hot-water baths increasingly shrink and tighten the fur fibers together.", "The final and most aggressive massage makes the fibers felt together even tighter, and the cone is now strong enough to manipulate by hand.", "But the cones must be even stronger than this, so she puts them through a final hardening stage that shrinks and tightens the fur fibers to the maximum.", "At last, the fragile cone that came out of the forming machine becomes the desired hat size.", "Tearing the felt by hand is now impossible.", "After the cones are dyed, they're placed on a crown machine.", "Here he works the top of the cone and makes the felt more flexible.", "Another machine softens the brim.", "Together, the machines form the cone into more of a hat shape.", "After soaking the cone again, a worker puts it on a wet blocker machine.", "Its brass fingers secure and stretch out the felt while it forces a crown shape into the hat body.", "Then he puts the hat body into a hat sucker or vacuum that sucks out most of the water.", "He then sets the hat bodies aside to dry for 24 hours.", "Up next, we'll see how these hat bodies are transformed into classic stetson hats.", "Making a stetson hat takes almost as much work now as it did since the early 1900s.", "Every hat made is still handled from start to finish by hand.", "Even some of the machines used are the same as in the past.", "The stetson hat is an icon of the american cowboy lifestyle.", "A worker steams a hat body to make it supple.", "He puts it into a blocker machine with brass fingers that secure it in place.", "He steams it again, then inserts a wooden block and presses it into the crown.", "This gives the hat a specific head size.", "He puts another hat into the blocker, this time making another hat size.", "This is called blocking a hat.", "Blocking transforms the brim diameter and the crown from an almost shapeless cut of felt into a more solid body and precise hat size.", "A worker puts the blocked hat on a brim stiffener which applies shellack.", "This shellack gives the brim extra firmness, making it easier to shape and style.", "He completes the brim-stiffening operation and readies the correct number of hats to fill an order.", "A worker hangs up the hats for a natural air dry.", "Two days later, a worker inserts blocks into the hat, which are color-coded for size.", "The blocks fit the hat on a pouncing machine that gently spins and sands the felt.", "This unsanded felt gets buffed until the hat ends up with the smoothest finish possible.", "Then a worker puts the hat onto a hydraulic crown press.", "Inside it, he places a piece of ink transfer paper and a heated aluminum mold.", "He lowers the press and applies the exact amount of pressure needed to mold a specific shape into the crown.", "On this particular hat, the press imprints the logo inside.", "Now the crown has a distinct shape.", "A worker then puts the hat on a brim cutter and holds it down flat with a cutting guide.", "She cuts the brim to the required dimension and removes the excess felt and the guide.", "A worker then puts the hat into a brim flanger-- an aluminum mold that heats and shapes the brim.", "He then puts the hat onto an identical wooden shape and covers it to keep its form while cooling.", "Once cooled, this hat will keep its symmetrical curves that will make it so distinctively western.", "A worker then marks the center of the hat.", "She lines up a leather sweatband with the chalk mark and sews it in along the bottom edge of the crown.", "She then folds the sweat band in and makes sure the hat is perfect.", "She ties the classic ribbon band into a knot and secures it around the outside of the hat.", "She trims the ribbon to the appropriate size, which completes the work on the exterior of the hat.", "Then another worker puts it into a holder and peels up the sweatband.", "She places a lining inside the hat, applying drops of glue all the way around to keep it in place.", "She then puts the hat inside a box for shipping anywhere in the world.", "Authentic stetson hats.", "Looking good, partner!" ]

{ "things": [ "Toothpicks", "Acrylic Bathtubs", "Helicopters", "Beer" ] }

[ "Today on \"how it's made\"...", "Toothpicks...", "Acrylic bathtubs...", "Helicopters...", "And beer.", "Some people use them to hold hors d'oeuvres together.", "Kids make scale models of famous buildings and bridges out of them.", "And some people actually use them for their primary purpose-- to remove food caught between their teeth.", "What are we talking about?", "Why, the humble toothpick, of course.", "Logs-- lots of birch logs are delivered to this factory.", "They're the raw material from which toothpicks will be made.", "The heavy logs are lifted by grippers and placed into a debarker.", "Bark isn't part of the toothpick-fabrication process and is recovered by this machine.", "But the bark isn't thrown away.", "It's sold to a neighboring factory where it will be used as fuel.", "The debarker works in two steps.", "With two passes, it produces a log roll that's perfectly cylindrical and easier to mill.", "This log is being transported to the next processing stage.", "This unraveling machine unravels the log as if it were a roll of paper, cutting it with 12 fine blades each .", "04 of an inch thick and 2 1/2 inches wide.", "These same blades will be used later to cut toothpicks.", "Then these 12 blades, positioned side by side on the unraveling machine, will form rolls of strips called \"billets\".", "These tiny cutters are used to trim the ends of the toothpicks.", "Knives placed here and there on the machine thin the ends of the toothpicks.", "The roller rolls up the cut strips, forming a billet.", "Completed strips, or billets, are taken out manually.", "Each billet weighs 4 pounds.", "The billets are carried to the puncher, the flat-toothpick puncher cuts the billet strips into small, equal-sized pieces.", "The cut pieces come out at this end of the machine.", "The punch works very rapidly.", "Knives come down 2,000 times per minute to cut a total of 8,000 toothpicks in just 60 seconds.", "Cut toothpicks fall into this chute, then into a container.", "At this stage, they're soft.", "They have to be hardened in a dryer for four hours at 250 degrees fahrenheit.", "Then the toothpicks are transferred to the polisher.", "Talcum powder and friction help make the toothpicks perfectly smooth.", "This operation takes four hours.", "Toothpicks exit the polisher and pass through this sifter, which filters out broken ones.", "Those in good condition continue on to an air-blower system.", "Damaged ones are rejected.", "Perfect toothpicks are placed onto two conveyers by an air-blowing system.", "Drums at the end of the conveyors assure quantity distribution, then they're carried to the automatic packagers.", "This machine counts the toothpicks.", "Boxes are made up, ready for filling.", "The number of toothpicks included in each box matters.", "The packager is calibrated to place 650 toothpicks in each container, and it produces about 1,150 boxes an hour.", "It handles 747,500 toothpicks an hour.", "Some toothpicks are individually wrapped for distribution to restaurants and airlines.", "This machine wraps 1,200 toothpicks per minute.", "It automatically wraps, glues, and cuts the paper.", "This facility can manufacture more than 20 million toothpicks every day.", "And it all started from several birch logs.", "Bathing daily is a relatively new phenomenon, historically speaking.", "People used to take baths only when necessary.", "Today whiling away the afternoon in the tub is more than a way to wash our bodies.", "With bubbles and bath oils, it can be an experience in luxury.", "Modern bathtubs look nothing like tubs of the middle ages or those wooden tubs we see in western films.", "To achieve supreme comfort, the designer explores new shapes via computer and design software, tools which make for a speedy review of various shapes.", "Then a model is produced.", "This one, produced on a 1/6 scale, is made of cardboard.", "But other models can be made of clay, polystyrene, or by stereolithography.", "Manufacturing begins with an acrylic sheet.", "It is heated to about 390 degrees fahrenheit with ceramic elements.", "The sheet becomes soft and malleable.", "So that it takes the form of the mold, thousands of tiny holes in the shell suction the sheet by vacuum.", "The mold must cool before it can be opened.", "Powerful ventilators blow air directly onto the mold, lowering the temperature to 170 degrees in 4 to 6 minutes.", "The ventilators are then withdrawn.", "Then the shell is easily removed from the mold.", "It weighs a mere 35 pounds.", "To make a tub in another shape, they change the mold.", "They put in another acrylic sheet.", "The sheet is heated on the ceramic and fiberglass mold, the little holes vacuum out air, and the job is done.", "The molded acrylic sheet is not sturdy enough to be filled with water, so it must be reinforced with fiberglass.", "This is the fiberglass.", "Mixed with resin, it is blown onto the mold by a robotic unit.", "Stored in reservoirs, the resin is carried to the robot by pumps.", "Here it produces a chemical reaction between the fiberglass and the resin, which produces a reinforced shell.", "Laminating is one of the most important steps.", "With brush and roller, they eliminate all air bubbles that could weaken the tub.", "This makes the fiberglass resin adhere perfectly to the acrylic shell.", "The process takes 75 minutes.", "The shell is then transported to the milling department.", "The shell is dry and hard.", "They can extract it manually, but here they use digitally controlled machines.", "The operation begins with the trimming of the edges of the bathtub.", "During this process, the robot will pierce openings for the drains, the whirlpool jets, and the air jets for the overflow and for ambient light.", "The bathtub, almost completed, is now sent to another workshop.", "They can now install the pump, the piping, and the blower.", "These last operations are done manually.", "The pump is installed for the whirlpool system, as well as the pvc pipes, whose joints have been hermetically sealed to prevent any leaks.", "Finally, to make sure that everything is functioning well, each bathtub undergoes a water test.", "The tub is finally ready.", "After 13 steps and anywhere from three to five hours of work, depending on the type of tub.", "It almost invites you to climb in.", "In the world of aeronautics, the helicopter is the ideal go-anywhere machine.", "Unlike airplanes, choppers can move in almost any direction and take off and land straight up and down.", "Now that we've \"coptered\" your attention, let's see what goes into building these whirlybirds.", "Man has always wanted to fly.", "And the versatility of the helicopter has allowed him to reach unexpected heights.", "Plans for a helicopter are created with catia 3-d design-assisting computer software.", "It takes 700 hours of work between the drawing stage and the assembly of the pattern.", "The helicopter is made of carbon fiber, a composite material lighter and stronger than steel, protected by two layers of green plastic.", "The fiber is cut with a blade controlled by ultrasound.", "They lay on several thicknesses of fiber to make the rear fuselage.", "The green light of a laser helps position the parts.", "Then with a heat gun, they apply a beehive web which increases the solidity of the structure.", "But the carbon fiber is still soft.", "To harden, it must be baked under pressure for 10 hours in this autoclave oven at 350 degrees fahrenheit.", "The pieces exit the oven and head for machining.", "The door of the motor housing is kept in a cutting jig and is shaped with a manual shaper.", "Before installing the parts, they strike the carbon fiber with a resonance hammer to detect any faults.", "The electrical harness is mounted on a pattern before being installed in the aircraft.", "This particular helicopter has 2,570 yards of wiring, but others can have almost 6 miles.", "The wiring will be connected to the flight-instruments panel, the brain of the helicopter.", "This aircraft has 9,964 rivets fastened with a gun and a ram.", "They also apply a sealant to prevent corrosion-creating humidity.", "They now assemble the helicopter's rear fuselage.", "Piece by piece, the aircraft takes shape.", "They will install mechanical components later.", "The motor arrives.", "This one weighs 260 pounds and has to be carefully handled.", "Among the other parts to be installed is the circular plate on which the blades will be attached.", "Safety is primary.", "The screw-nut holes are perforated, allowing for the insertion of the brake cable.", "This tightly braided metal wire prevents the nut from loosening, due to strong vibrations.", "Now they bolt on the four blades, which makes the helicopter fly.", "Weighing 90 pounds each, they're made of composite materials and an aluminum alloy.", "They're attached to the main rotor.", "The dashboard is installed in the cockpit, and all the wires are hooked up.", "Contact is established, and all is functioning properly.", "The last step-- finishing the interior of the craft.", "They install seats, safety belts, the consoles, bulkheads, windows and doors, as well as the trimmings.", "The helicopter is almost completed, but it still has to be painted.", "When done, the helicopter is towed outside the assembly hangar.", "Flight tests are performed to make sure that mechanical and electrical components are functioning properly.", "It requires an average of 110 days to assemble the more than 3,000 parts of a helicopter like this one, and they turn out almost 185 units each year.", "These 3-ton engines are capable of reaching speeds of 140 knots and flying at a maximum altitude of 20,000 feet.", "Beer has been around for as long as civilization itself.", "Historical records show that ancient peoples made beer with barley, hops, water, and yeast.", "We still use the same ingredients, but as you'll see, today's production technology is far more complex.", "Beer has been drunk since 4,000 b.c. in mesopotamia.", "The sikaru made it as a sacred beverage from grains but without hops.", "The gauls and the celts drank a beverage made with barley, wheat, and rye.", "During the crusades, europeans discovered spices and flavored the beverage with cinnamon and laurel.", "In the 15th century, nordic peoples used hops as a spice, giving rise to the beer we know today.", "Beer is a fermented beverage made with cereals and water.", "The company has its own water-filtration plant.", "It will be refiltered before being used to eliminate chlorine.", "This materials tanks can hold 21,000 gallons of water.", "Between 11 and 16 tons of malt and another grain are added.", "They use dark malt, which has been heat-treated to a high temperature.", "The mixture will spend two hours here.", "An agitator prevents malt husks from settling to the bottom of the tank.", "Turbulence from the pumps during the transfer causes the formation of this protein foam.", "The wort is in the process of being extracted and will be boiled.", "About five hours have passed since the brewing process began.", "Here they draw off a sample.", "They will make other control tests at various stages of brewing.", "This is the draff, a solid residue extracted from the wort.", "It will be used as cattle feed.", "Here is a close-up view of the draff.", "Then the liquid is filtered.", "Here's the filtration tank where the wort is separated from the malt husks.", "A sample is withdrawn from the wort heater to verify the density of sugars and the quality of the wort.", "Now another ingredient-- the hops-- is added into the wort heater.", "The hops impart the bitterness and aroma particular to beer.", "The hops looks like this.", "They can now start the brewing.", "In the control room, an operator handles the data-control system of the brewing process.", "They add in the yeast, which starts off the fermentation.", "This process lasts between 7 and 10 days.", "This foam indicates that fermentation has begun, and sugars will now transform into alcohol.", "Each fermentation tank is computer-controlled to maintain a specific temperature.", "During fermentation, chemical reactions create the scum that we see.", "Now aged for three weeks, the beer is almost finished.", "We see here the bottling tanks.", "The beer has to be filtered once more.", "Exiting these filters, the wort is clarified, then rid of the components responsible for the cloudiness of the beer.", "Here's the beer filtered a second time...", "And finally finished, as a clear product.", "Used bottles are now washed.", "After their wash cycle, the bottles have become sterilized.", "Empty bottles arrive on this plate, ready to be filled.", "About 1,000 bottles a minute are filled while on the move.", "Then they pass to the capper before being sent to the pasteurizer.", "Only two steps remain.", "Labels are glued onto the bottles, then they're sent by conveyor to be put in cases.", "Made from water and cereal grains, the beer is now ready to be consumed and enjoyed." ]

{ "things": [ "Nail Nippers", "Jade Putters", "Ice Cider", "Water Skis" ] }

[ "And water skis.", "Whether it's a hangnail that needs fixing or it's simply time for a trim, a nail nipper is a good thing to have at your fingertips.", "A nipper is a precision tool, one that offers a bit more control than lever-style clippers.", "The result is usually a more manicured look.", "Heavy duty and made of stainless steel, the nipper nail cutter looks as if it belongs in a tool chest and it actually works like cutter pliers.", "Squeezing the handles brings the curved blades at the end together for a well-rounded trim job.", "The handles offer a bit moore maneuverability than the lever mechanism on a standard nail clipper.", "Production begins with these forged-steel blanks.", "They'll make two pairs of nail nippers from each one.", "They load the blanks onto a carriage that transports them into a furnace.", "Subjected to intense heat, the steel blanks become white-hot and malleable in minutes.", "The foundry worker transfers a blank to a die.", "He moves it across the die and flips it over as a hammer slams it into the shape of two nail-nipper shanks, each with a cutting head.", "It takes several strikes to create the right impression on both sides of the blank.", "The process transforms the narrow blank into a wider piece with two nail-nipper formations.", "This is the blank before forging and now.", "Once the two shanks have been separated and trimmed, a drill cuts a hole under the blade end.", "This is the area where the nipper shanks are to be joined.", "A milling tool shaves down the area for a neat and level joint.", "This is the nail-nipper shank before the joint work and after.", "They transfer the nipper shanks to a finishing machine.", "They bounce around in a stream of abrasive ceramic pebbles for a few hours.", "This rubs off the rough bits.", "A magnetized conveyor pulls out the steel shanks, leaving the ceramics behind and carries the shanks forward.", "An employee sands the entire surface of each shank until it looks completely smooth.", "He brushes oil onto a shank joint to prevent rust and abrasion.", "It's time to rivet the two nail-nipper shanks together.", "The rivets funnel into tooling above and below the nail-nipper shanks.", "The machinery drives the rivets into the holes in the shanks.", "Once joined, they cannot be pulled apart without completely destroying the nail nippers.", "At this point, the rivets protrude slightly and could snag on clothing or other things.", "An employee sands each rivet until it's on the same plane as the rest of the nipper joint.", "The vigorous sanding makes the rivet seem to almost disappear.", "He polishes the inside of the nipper blades to completely smooth the surfaces.", "An even surface can be more thoroughly cleaned and disinfected between manicures.", "The blades are still blunt at this point.", "The next member of the team files them on an angle to give them a cutting edge.", "Filing too little could hamper the clearance between the blades.", "Filing too much would ruin the nippers entirely.", "He tests them on paper.", "If the cutting edge slips, the blades may need more work.", "If they slice right through, they're just right.", "Next, he clamps the nail nippers onto a circular bench.", "It revolves to meet up with a laser that etches the company logo and other information onto the shanks.", "After that, they drill holes and attach a spring to make the nippers easier to open and close.", "For the professional who will be opening and closing these nail nippers a few hundred times a day, this is a nifty feature.", "They manufacture these nail nippers in batches of 300 or 400 over a period of about two weeks, so they're should always be plenty on hand.", "This putter is made of jade, a precious stone traditionally used in jewelry and sculpture.", "Long coveted for its beauty, jade is in demand on the putting green.", "As tough as steel with a feel that's distinctly different, a putter made of jade is definitely up to par.", "The jade putter is among a number of new clubs on the green...", "Along with crystal quartz and fossilized vegetation, known as petrified wood.", "To make a jade putter, they head for the hills-- specifically, a nephrite jade outcrop in wyoming.", "Here, the putter maker finds a 20-foot wide vein of nephrite.", "This stone has taken 2½ billion years to form and develop a very hard and fibrous crystalline structure.", "The carver selects slabs that are thick enough to shape into four or five putter heads.", "This one has weathered to a rusty color, but it should clean up nicely.", "The color of wyoming jade ranges from white to green to black.", "He strikes the slab with a sledgehammer a few times to break it down to a more manageable size.", "He slices through one of the cut pieces with a rock saw while flushing it with coolant to save the diamond blade.", "He makes 9 or 10 cuts to rough out the triangular mallet shape of the putter head.", "He slices off the ends to complete the basic shape.", "Next, he anchors the jade in a wooden jig and cuts on an angle to profile the sides of the putter head.", "He slices off a back section to give the putter clearance from the ground when swung.", "This putter has really taken shape.", "He removes material from the corners to center the mass behind the golf ball for more striking energy.", "He sands the edges to round and soften them.", "He's careful not to remove too much in one place because that would affect the symmetry.", "He then polishes the entire piece of jade against diamond-abrasive belts.", "It's an intensive process that takes about two hours.", "He aims a drill and cores into the putter head on a 20° angle to make a hole for inserting the putter shaft.", "A perpetual flow of water keeps the diamond core bit cool and also flushes out the little bits of filings.", "He gently taps the drilled core to jar it so it falls out of the putter head.", "A laser emblazons the product name onto the jade, swiftly etching it into the surface.", "The putters can be customized with a customer's name and logo.", "He swabs gold-colored paint into the laser etching to make the letters really stand out.", "The swabbing leaves a lot of residual paint around the letters, so he rubs it off.", "He sprays the putter with a wax-based gloss to seal the stone.", "He then buffs it against a felt belt to give the jade a satiny sheen.", "He mixes epoxy ingredients to attach the shaft to the jade putter's head.", "He deposits epoxy in the hole in the shaft.", "He inserts the steel shaft into the 20°-angle hole.", "The angle of the hole positions the putter shaft to match the golfer's upright stance.", "Once the pistol-style grip has been slipped on, he applies a metallic-look decal just below it.", "The decal displays company contact information in the event of a problem that doesn't have to do with the golfer's technique.", "After cleaning and inspection, this jade putter is ready for action.", "Putters carved from jade and other materials are crafty editions to the golf-club arsenal and could lead to some artful moves on the green.", "Ice cider is an alcoholic drink made from fermented, frozen apples or apple juice.", "It's also known as apple ice wine and is produced the same way as ice wine but with apples instead of grapes.", "It's typically served with food such as foie gras, cheese, fruit, and dark chocolate.", "There's a world of difference between ice cider and regular cider.", "Regular cider is made from fresh apples, whereas ice cider is made from frozen apples or frozen apple juice.", "And while cider can be a non-alcoholic beverage, ice cider is always alcoholic.", "There are two methods to making ice cider.", "One is to leave the apples on the tree to freeze over the winter, then pick them and press them.", "The other method, which we're about to see, is to harvest the apples in the fall when they're ripe, press them, then freeze the juice.", "The apples are always handpicked at perfect maturity and always right off the tree.", "An ice-cider producer never uses fallen apples because they often get damaged when they hit the ground and then pick up bacteria from lying there.", "This producer uses different varieties of apples to make several types of ice cider.", "The one we're about to see is made from empire, spartan, cortland, mcintosh, and golden russet.", "Straight from the orchard, the apples go onto a conveyor belt which feeds them into a multistage press.", "The first part of the press crushes the apples into what's known as pumice.", "A screw conveyor moves the pumice onto a mesh conveyor belt that transports it through five stainless-steel rollers.", "Each roller applies 275 pounds of pressure, progressively extracting the apple juice.", "The juice drains down through the mesh conveyor belt to a vat below.", "From the vat, the juice is pumped into a large container made of food-safe plastic.", "The container holds 264 gallons.", "However, they leave 13 to 26 gallons of air space to leave room for expansion when the juice freezes.", "At the end of december, they haul the containers outdoors.", "The juice stays outside from 40 to 50 days, during which time the water in it freezes, leaving unfrozen, concentrated juice at the bottom of the container.", "Workers measure the sugar content daily, and once it reaches a certain level, they pump the juice indoors into temperature-controlled, stainless-steel tanks.", "Then they add yeast to kick-start fermentation-- the conversion of those natural sugars to alcohol.", "Every day, they measure the sugar level to monitor the fermentation process.", "When they hit their target, which typically takes between 40 and 50 days, the juice has transformed into ice cider with an alcohol content of 10.5% to 11%.", "Ice cider is bottled just like wine.", "The corking machine automatically pops in a cork as soon as its sensor detects the presence of a bottle.", "The next machine slips a plastic seal over the mouth of the bottle, then heats the plastic to shrink the seal tightly around the cork.", "Finally, an automated labeling machine simultaneously applies self-sticking labels to the front and back.", "It isn't only the apple variety that determines the flavor.", "It's also the production method.", "The process we've just seen, called cryoconcentration, produces ice cider with a strong, fruity flavor.", "The other method, called cryoextraction-- letting apples freeze on the tree, then pressing them-- produces ice cider which tastes like baked apples.", "Water skiing was invented in 1922 by an american teenager named ralph samuelson.", "With his brother pulling him by motorboat, he experimented first with skis made of barrel staves, then with snow skis, then with skis he had made out of pine boards 94\" long.", "This type of water skiing is known as slalom, winding through a course on a single water ski, one foot behind the other, in boots mounted to the ski.", "The core of these top-of-the-line competition slalom skis is high-density pvc foam-- exceptionally strong, yet lightweight.", "A computer-guided machine cuts the ski shape, then pockets to receive various components.", "Workers flip the core upside down, and the machine shapes the bottom.", "Workers then turn the core right-side up again and fill the pockets with glue.", "They insert an alignment tab in the tail pocket to help correctly position the core in the mold.", "They install fiberglassed, reinforced nylon blocks in the others.", "These will anchor threaded inserts for mounting the boots and the ski's fin.", "Now they begin building up the water ski with multiple layers of carbon fiber, an ultra-strong fabric.", "They apply the first layer to the bottom, wrapping it around to the top.", "This will prevent the ski from twisting.", "After stapling down the carbon fiber and trimming off the excess, they saturate it with resin and apply carbon fiber to the top of the ski.", "Depending on the model and its performance specifications, they wrap the core in up to seven layers of resin-saturated carbon fiber, controlling the flex in select areas along the way with additional patches.", "Then they top the ski with a layer of woven, synthetic fabric to prime the surface for the decorative graphics.", "On the bottom of the ski, they apply a sheet of super-lightweight polymer.", "It creates a white background to highlight the printed polyester sheet of decorative graphics.", "They coat it with a special resin that cures into a hard, hydrodynamic surface that increase the ski's speed.", "The graphic design that decorates the top of the ski is printed on nylon.", "They mount it to the top part of a ski-shaped mold, then lay the wrapped core into the bottom part.", "A heated press closes the mold, compressing the contents under high pressure for nine minutes.", "This bonds the layers, forms contours in the ski, and adheres the graphics.", "The pressure squeezes out excess resin along the perimeter so once they remove the ski from the mold, they cut off the excess with a band saw.", "Then with a custom-made router bit, they precision-trim to exact specifications.", "Next, a three-phase filing of the ski's edge-- first with a large file, then a small file, then with either a razor blade or medium-grit sandpaper.", "Then with the help of a template, they drill 18 holes into those fiberglass-reinforced nylon blocks in the core.", "They screw a threaded insert into each hole, and it locks into the block.", "There are more inserts that are actually required for mounting the fin and attaching the ski boots.", "This gives the skier different positioning options.", "Now the last edge-sanding with fine-grit paper.", "After wiping down the entire ski with an alcohol-based cleaner, they install the final and most important component-- the fin.", "It's made of aluminum that's chemically treated to be corrosion-resistant and ultra-durable.", "The fin's position critically affects the ski's traction and stability, so they use a micrometer to measure to the millimeter, securing the fin precisely where the design engineer specified in the performance-maximization sweet spot.", "Nonetheless, competitive water-skiers typically readjust the fin to their own preferences in hopes of leaving competitors in their wake." ]

{ "things": [ "Motorcycle Engines", "Glass Enamel Sculptures", "Hand" ] }

[ "The v-twin motorcycle engine actually dates back more than a century.", "Talk about staying power.", "Central to the design are two cylinders that form a \"v\" around the crankshaft.", "This configuration is more compact than a straight-line engine, and its appeal is timeless.", "With its throttle cranked, the v-twin can take you on an exciting ride and leave sedans in its dust.", "To make one, a robot loads a cylinder into a machine equipped with cutting tools.", "The tools mill the cylinder's metal slats to highlight them.", "The slats are called cooling fins.", "They allow the engine's heat to dissipate.", "This cutting tool bores into the center of the cylinder, carving it to precise dimensions to allow engine components a perfect fit.", "Next, an operator assembles the crankshaft.", "He aligns connecting rods and slides them over bearings.", "He then assembles the rods and bearings to the crankshaft.", "A machine press-fits everything together.", "Next, a lift scoops up the crankshaft assembly and transfers it to the lower half of the crankcase.", "At the next station, an automated dispenser precisely applies sealant to the inner edge of the crankcase.", "They then arrange the upper half of the crankcase on the lower assembly and bolt the two together.", "It's now time to link the crankcase and shaft assembly to the transmission.", "This chrome-plated cover is the finishing touch.", "Next, they fit the camshaft into the crankcase.", "Its job is to maintain valve timing.", "They position the pistons on the connecting rods now installed in the crankcase.", "Remember those highlighted cylinders made earlier?", "Workers now slide them over the pistons.", "These are the cylinder-head castings.", "Technicians paint them and then machine them to fit on the cylinders.", "A robot bolts them together with just the right amount of torque.", "The operator then installs tubing that will house pushrods.", "He snaps them into the cylinder heads.", "Then he clips on metal covers to secure them.", "He now inserts the pushrods in the tubing.", "Up next is the electronic fuel-injection system, which controls the flow of fuel to the engine.", "They install it between the two cylinders.", "A special bracket holds the injection system in place.", "He bolts the rocker boxes to the cylinder heads, then tops off the assembly with more gleaming chrome covers.", "The operator now screws the oil filter onto the engine case and secures it with a special wrench.", "This is the electrical charging system.", "It goes on the crankshaft.", "Now it's time to pump oil into this v-twin engine and put it through its paces.", "Computerized testing equipment moves in and mates to the engine.", "The engine rotates, and they shift the transmission through all the gears.", "This allows the testing equipment to analyze every aspect of its performance.", "Next, they insert spark plugs into the cylinder heads.", "And these 1584cc motorcycle engines are now revved and ready for their wheels.", "Enameling is the process of fusing colored glass to metal with intense heat.", "This decorative art developed more than 3,000 years ago.", "The earliest enameled objects archeologists have found are pieces of jewelry made in ancient greece.", "Today, artisans most often produce glass enamel on copper.", "Artisans handcraft these magnificent sculptures by fusing vibrant colors of finely ground glass to solid copper.", "First, the artist draws the design, then chooses the glass colors from a palette of hundreds of shades.", "She takes one element at a time and makes multiple copies of it on a sheet of paper.", "She has a lab produce a film negative, which she lays in an exposure machine.", "On top, she lays a silk screen coated with a light-sensitive chemical.", "Then it exposes them to halogen light for 90 seconds.", "The film negative works like a stencil.", "Its dark parts block the light from hitting the screen while its clear parts allow light through.", "Where light penetrates, the light-sensitive chemical reacts and hardens.", "The unhardened chemical rinses away, leaving just the image behind.", "In the next department, they lay the screen in a silk-screen printer, apply chemical-resistant ink, then load a sheet of solid copper about half a millimeter thick.", "The machine automatically prints the images onto the copper.", "They cure the ink in an oven for 20 minutes, then repeat the entire exposure process for the back side of the sheet.", "Next, they feed the sheet into a two-step milling machine.", "It applies chemicals that eat away any copper that isn't coated with the chemical-resistant ink.", "This cuts out the shapes.", "Then it strips off the ink, which, by this point, has served its purpose.", "Now they have a blank shape, but it's completely flat.", "To give it dimension, they stamp it with a forming dye.", "Now the enameling process can finally begin.", "For each color grouping of the design, there's an aluminum stencil.", "They lay down the first one and sprinkle glass powder in the first base-coat color, which looks white now, but comes out clear.", "Then a second stencil for the second base-coat color-- white.", "The shape then goes into a kiln for about a minute to liquefy the glass powder and fuse it to the copper.", "Once the base coat cools, they create the detail work with additional stencils and colors.", "This is where the true artistry comes in.", "Each shake of powdered glass is like a painter's brushstroke.", "Too much, and the color will come out too dark.", "Too little, and it'll come out too light.", "It takes an experienced enameler to get it just right.", "They craft dimension by blending colors and by combining different types of glass in the design-- some transparent, some opaque, some opalescent.", "After every few powder applications, they return the piece to the kiln, where the intense heat-- 1,600 degrees fahrenheit-- liquefies and fuses the glass to the copper.", "Slowly but surely, they turn what was a blank copper shape into a vibrant work of art.", "Meanwhile, an artistic welder skillfully creates the sculpture's metal framework-- in this case, branches on which copper-enamel birds will perch.", "He's using steel, but frameworks can also be made of copper, bronze, or brass.", "Besides birds, this sculpture features copper-enameled leaves and flowers.", "Their stems are bronze because bronze fuses easily to steel.", "With the framework and background elements in place, it's just a matter of attaching the main design elements.", "Some industrial-strength hot glue does the trick.", "A modern twist on an ancient craft, these glass-enamel sculptures make a glistening impression.", "Today, most commercially made paper is made from wood pulp treated with chemicals and mechanically processed.", "Making paper by hand is a craft that involves techniques and materials that go back over 2,000 years in china.", "These techniques have evolved over time, but the main ingredient remains the same-- imagination.", "Handmade paper is a distinctive choice for a variety of uses, from fine stationery to limited-edition prints.", "Natural fibers, like linen or these cotton remnants, are the raw materials for handmade paper.", "Workers place the cotton rag and put it on a conveyer, which leads into a machine that chops it up into small pieces.", "It collects in a bin, ready for the next step, called beating the rag.", "Workers pour out the chopped-up rag into a tub called a hollander that is filling with water.", "This machine beats the material into a pulp.", "Its only moving part-- a large roll weighing several tons, equipped with metal blades.", "Workers fill the hollander with up to 800 pounds of rag.", "Once all the rag is in, the giant roll descends to begin the beating.", "Water pours down to soak the fabric, as workers push it toward the roll.", "They sometimes take paper from previous batches, known as broke, and add it to the mix.", "They may also add a little dye to adjust the color, depending on the desired effect.", "After eight hours of beating, workers feel the pulp's consistency.", "They will then take samples from this batch to make sure it doesn't contain any unbeaten rag or knots.", "Next, they add colorful scraps of paper to the pulp to create a decorative pattern.", "To make a sheet of paper, the vat man plunges a wooden mold into the pulp.", "As he lifts out the mold, he shakes it to even out the pulp.", "Water pours out, leaving only fibers caught on the mold's surface.", "He removes the mold's frame, known as the deckle, and lowers the corner of the mold to drain away more water.", "He places the mold facedown on a wet felt, then carefully lifts it away.", "A sheet of paper now lies on the felt, which he then covers with another wet felt.", "When pulp pours through the mold's metal screen, it traps the fiber and lets the water through.", "The vat man plunges the mold once again into the pulp and couches another sheet of this distinctive paper.", "At this point, the paper is 99% water.", "Workers bring a stack over to a hydraulic press to draw the water from the paper and link the fibers together.", "They press the papers with care so they don't burst right out of the felts.", "They brush any leftover pulp from the felts, leaving them clean and ready for the next batch of sheets.", "Now workers can handle the paper without it falling apart.", "They take the sheets from the felts and hang them to dry on plastic tubes.", "Once dry, they collect the sheets according to type and stack them for a final finishing press before they go on for shipment to customers around the world.", "The mold's frame leaves a feathery edge-- a distinctive feature of handmade paper.", "These papers are available in more than 30 colors in various finishes, from smooth to rugged.", "There's a paper for every project, whether it's etching...", "Watercolor...", "Drawing...", "Or even folding.", "Pole-vaulting began as a mode of transportation, not a sport.", "In europe, men would use poles to propel themselves across bridgeless canals.", "In the late 1800s, pole-vaulting caught on as a college sport.", "The athletes used bamboo poles to vault themselves over a horizontal bar.", "Today's poles are incredibly lightweight, yet strong enough to absorb the vaulter's energy, then throw it back to propel him over the bar.", "Some poles are made of carbon fiber, others out of thismaterial-- resin-impregnated fiberglass.", "The first step is to spread out the material and cut out the pole pattern.", "Meanwhile, a slitter machine cuts the same material into strips of a specific width.", "Then it winds each strip into its own roll.", "This spiral-wrap machine automatically unravels the strip and wraps it around a hollow steel tube called a mandrel.", "This first layer of fiberglass gives the pole its flexibility.", "They wrap a second layer in the opposite direction, employing a crisscross pattern to increase durability.", "The second layer fortifies the pole's circumference.", "For the next layers, they remove the mandrel and lay it on the table.", "Now it's time for those fiberglass patterns they cut earlier.", "They heat the edge of the first one with an iron, melting the resin in the fiberglass until it's tacky.", "They stick this edge to the mandrel, then slide the other end between heated rollers.", "The rollers wrap the rest of the material around the mandrel, the heat activating the resin in the process.", "The same procedure, now with the second pattern.", "This piece is critical, because the way it's cut controls the way the pole bends.", "The mandrel and its multilayer fiberglass coat now go into an oven.", "The heat, generated by steam, starts at 175 degrees fahrenheit.", "This liquefies the resin so that it re-saturates the fiberglass.", "Then the temperature gradually rises to nearly 300 degrees, solidifying the resin again, curing it.", "This entire process takes about 45 minutes from start to finish.", "And when it finishes, a pole extractor slides the mandrel out of what's now a fiberglass pole.", "The pole moves onto a flex machine.", "In part, this is a stress test.", "If there's any type of defect, the pole will crack or break.", "But the flexor also permanently puts a specific degree of curve in the pole, which helps the athlete vault higher.", "Now they make what's called the soft-side mark.", "This helps the pole vaulter locate the bend, in order to know where to grip the pole.", "Next, they apply a maximum-weight label, indicating how heavy the vaulter can be.", "To finish the surface now, they mount the pole on a spindle, then run a polishing pad over it.", "Then, using a solvent, they clean off the debris.", "Now that the surface is pristine, they wrap it in thin, lightweight tape.", "Different-colored tapes designate different pole styles.", "They cap the top of the pole with plastic, then, at the bottom, mallet on a molded tip made of hard rubber.", "The finishing touch is the manufacturer's decal.", "Vaulting poles come in various lengths, between 10 and 16 feet.", "A pole designed for a heavier vaulter has to be stiffer than one designed for a lighter vaulter because the pole has to propel more weight with the same degree of bending." ]

{ "things": [ "Gummies", "Aluminum Cans", "Fish Farming", "Bronze Sculptures" ] }

[ "Today on \"how it's made,\" gummies, aluminum cans, fish farming, and bronze sculptures.", "There's nothing kids love more than candies they can pull and stretch, which probably explains why gummy candies and licorice have always been stick-to-your-teeth favorites, except with parents who don't have a family dental plan.", "Everyone calls this red licorice, but there's actually no licorice root in it.", "The ingredients are wheat, sugar, and corn syrup, with red food dye and both artificial and natural strawberry flavoring.", "They cook the mixture for 2 hours at 216 degrees.", "This slowly forms a thick paste.", "They cool it down, then put it through extruders.", "The extruders work like icing nozzles, shaping the paste into a design such as the twirls we see here.", "A water-lubricated knife slices the continuous strips into 7- and 8-inch lengths.", "The water also rinses off any licorice buildup on the blade.", "The cut licorice goes on aluminum trays.", "The stacks of trays then go into an oven to dry for 8 hours at 140 degrees.", "As the excess moisture evaporates, the licorice shrivels.", "Workers weigh the correct amount of licorice for each package.", "To make gummy candies, they use what are called printing boards-- large sheets with raised shapes.", "To make gummy worms, for example, they mount the gummy-worm board on a stamping machine.", "The machine then stamps the worm shapes onto trays of cornstarch.", "This creates a series of cornstarch molds for the gummy worms.", "While that's going on, another machine mixes gelatin, sugar, corn syrup, color, and flavoring and cooks the mixture at 240 degrees.", "A machine called the depositor pours the mixture into the cornstarch worm molds.", "The molds then go into a refrigerated room.", "In 12 to 15 hours, the candies cool and solidify.", "A machine then flips the candies out of the trays.", "The cornstarch molds disintegrate.", "As they fall downward, the machine sifts out the lumps, then recycles the used cornstarch into new cornstarch trays for the next batch.", "The candies go through a cleaner.", "As they spin, air nozzles blast off the cornstarch.", "The next drum coats the candies with mineral oil to make them shiny.", "Children love gummy worms because they're gooey and slippery and wiggly, but it's not just kids who are hooked on them.", "Many fishermen actually use them for bait.", "Before packaging the candies, the workers weed out any that are stretched out or stuck together.", "Wonder if they get to eat the rejects?", "A prion is what causes killer neurological diseases such as mad cow in animals and creutzfeldt-jakob in humans.", "It's a protein normally found in the membranes of cells.", "Scientists are trying to determine what changes that protein to an abnormal form to cause these fatal brain diseases.", "The next time you buy a canned soft drink, consider this-- that aluminum can will always be recyclable.", "Unlike plastic, aluminum never deteriorates, no matter how often it's melted down and used again.", "Aluminum cans are so lightweight that it's hard to believe they're made from a huge roll of aluminum sheeting that weighs almost 10 tons.", "The sheet is about 5 feet wide and as thin as construction paper.", "A roll like this is long enough to make three-quarters of a million drink cans.", "The sheet feeds into a press that punches out round pieces that will be formed into cans.", "The punch press actually performs two operations.", "It punches out a disc 5 1/2 inches in diameter, then bends it into a cup.", "What's left of the sheet gets compacted and sent back to the aluminum factory, where it's recycled into new rolls.", "The cup goes into a machine called the draw-and-iron body maker.", "A tool draws out the aluminum, forming the body of the can.", "The tool is lubricated so it won't tear the aluminum while stretching it.", "The lubricant also acts as a coolant because the aluminum heats up as it's being worked.", "Once the body is formed, a trimmer cleans and straightens the edge.", "Now the cans move along upside down on the conveyer belt over to the washer.", "The washer performs a 6-stage cleaning.", "The first two washes are in hydrofluoric acid at 140 degrees.", "The last four washes are in deionized water, neutral water with no ph, also at 140 degrees.", "The cans come out of the washer and go under a hot-air dryer.", "They're now shiny because the hydrofluoric-acid wash removed a thin surface layer of aluminum.", "Next, a roller passes over the cans, coating the bottom rims with varnish.", "This varnish coating allows the cans to slide easily on the conveyer belts and into vending machines.", "It shows up as a blue ring under an ultraviolet light.", "The cans are now ready to be printed.", "This rotation printing system can apply up to five colors, one at a time.", "The machine then applies a layer of varnish to protect the ink.", "This is what the print and varnish process looks like in slow motion, and here's the actual speed-- 1,800 cans per minute.", "Next, the cans fly through an oven that instantly hardens the ink and dries the protective varnish.", "The next machine sprays a water-based varnish on the inside of the cans.", "This creates a barrier between the drink and the aluminum, so the drink won't end up tasting like metal.", "It also prevents the aluminum from being eaten away from the inside by the acid in carbonated drinks.", "Next, the cans go through a machine called the necker which forms a 2-inch neck on the can.", "This is done gradually in 11 steps, so as not to puncture the paper-thin aluminum.", "The next machine, called the flanger, forms a curved-over edge at the top of the can, which will later attach to the pull-tab cover.", "The cans pass through a sophisticated vision system that photographs the inside of each can.", "Any can that doesn't meet standards, that has a bump or ink inside, for example, is automatically removed from the production line.", "They strap the finished cans onto a pallet.", "From here, they're shipped to the drink company, which fills them and then attaches the pull-tab cover.", "Fish farming generates about 20% of the world's fish production.", "Some fish farms are very high tech, while others use more traditional methods.", "Fish farming began in 2000 b.c. if these rainbow trout are going to have the energy to make baby trout, they'll have to be well fed.", "On today's menu-- brown shrimp.", "The fish farmer gives the mating process a hand.", "He takes the female fish and presses on her belly to squeeze out her eggs.", "A 1-pound fish has about 1,000 eggs.", "It takes about a minute to get them out.", "Next, he takes the male fish and squeezes out his sperm.", "This also takes about a minute.", "The fertilization process is pretty low tech-- no microscopes, no test tubes.", "The farmer mixes the eggs and sperm by hand.", "He then rinses the eggs with clean water.", "He repeats this step seven or eight times until the water runs clear.", "The eggs that stay at the surface are duds, so they're discarded.", "The farmer transfers the good eggs to bottles, then fills the bottles to the top with water.", "The eggs incubate for about a month.", "By the 25-day mark, if an egg is alive, two little black dots appear-- fish eyes.", "After the incubation period, the farmer empties the bottles and spreads the eggs on a surface with slats.", "The eggs lie here underwater...", "Until they hatch 10 to 15 days later.", "The newly hatched trout swim down through the slats into the basin below.", "The baby trout feed off their placenta for the first 18 days.", "After that, they eat special trout food made of fish meal.", "The trout grow to about 8 inches long by the age of 8 months.", "At that point, the smaller trout swimming around them start looking pretty appetizing.", "So the farmer has to classify the fish by size and move them into separate basins.", "Trout reach adulthood at the age of a year and a half.", "Now the farmer transfers them into his man-made lake.", "From here, the fish will go to market.", "But before they leave, the farmer mates them, starting the cycle all over again.", "Bronze is the oldest metal alloy known to man.", "It is ideal for casting works of art because, when molten, it flows into even the tiniest crevices of a mold.", "This allows sculptors to achieve incredible detail in their work.", "Man first discovered how to cast metal around 3500 b.c., during the period known as the bronze age.", "Many civilizations honored their royalty and gods with bronze statues.", "When it comes to art, the late 19th-century french sculptor auguste rodin was the master.", "They say his bronzes were more lifelike than the subjects themselves.", "Bronze is also a popular medium for modern art.", "Sculptors first carve a replica of their sculpture from wood or shape it out of a plaster or clay.", "They coat it with a lubricant...", "Then with silicone rubber.", "When the rubber hardens about six hours later, the lubricated replica slips out easily, leaving a detailed rubber mold.", "Next, they pour hot wax into the mold.", "The wax cools in about 15 minutes, leaving an exact wax replica of the sculpture.", "Next, they attach what's called a sprew-- a wax channel that will funnel the molten bronze into the mold.", "They dip the wax replica into a ceramic material.", "Then coat it with powdered silicone, a common mineral, to strengthen the ceramic.", "Next stop-- an autoclave.", "In about 10 minutes, under the machine's hot steam pressure, the wax inside the ceramic shell melts away, leaving a hardened and hollow ceramic mold.", "That mold goes into a kiln at 1,560 degrees.", "After two hours, it's fired.", "This is the finished mold into which the bronze will be cast.", "At the foundry, they heat the bronze to 2,084 degrees...", "Then carefully pour it into the mold.", "The molten metal takes just a few minutes to solidify.", "Then they chisel off the ceramic casing to reveal the bronze statue inside.", "They sandblast the statue to remove the ceramic residue.", "Then, they saw off the sprew.", "They weld shut any holes or other imperfections...", "Then polish the statue using various abrasive heads.", "They heat the statue, then spray on an acid coating.", "This coating, called patina, gives the bronze its shimmer and richness of color.", "Finally, a coat of wax makes the statue shine." ]

{ "things": [ "Dragster Tires", "Icing", "Floating Docks", "Spiral Pipes" ] }

[ "A dragster's tires take quite a beating during the brief, but fast run down the racetrack.", "The tires have to face full-on acceleration right out of the starting gate, then heavy-duty braking after the finish line, with the car deploying a rear parachute and slowing to an eventual stop.", "A drag race is the ultimate automotive sprint, with rapid acceleration to speeds topping 310 miles per hour.", "Optimal tire traction can give a car the winning edge.", "Dragster tires, like most tires, are made from rubber, which hasn't been cured to a firm and permanent state.", "For most parts of the tire, they reinforce the rubber with nylon fabric.", "The machine heats and kneads rubber slabs until they melt, then coats both sides of the material with a molten rubber.", "When the fabric-reinforced sheet of rubber cools, the machine slices it into pieces of a specific length, making the cuts at a diagonal, called a bias angle.", "A skilled tire builder then joins the edges of the piece to form a band, sticks it to an identical band made of an opposite bias piece-- layering increases strength-- then stretches this two-ply band over a tire-building machine.", "Next, he applies the belts, two opposing bias pieces of fabric-reinforced rubber, which he lays diagonally onto the tread area of the tire.", "A laser guide marks the edges so that he can match the belts to each other.", "These belts help give the tire stiffness, strength, and stability.", "He uses a roller to press out any trapped air between the plies and belts.", "This helps ensure a thorough bond.", "After a stitcher wheel folds down the plies, he folds the ends of the material into the machine.", "Then, he applies a contact cement-type material to enhance the natural adhesion of uncured rubber.", "Meanwhile, an automated machine makes the tires' beads, the rigid hoops around both sides of the opening, which holds the tire firmly to the wheel.", "Each bead is made from a thick, steel wire.", "The machine first encapsulates it in rubber.", "Then, it winds the bead around a mandrill up to 50 times, forming a hoop.", "The machine forms four beads at a time.", "The next machine wraps the hoop in a piece of fabric-reinforced rubber.", "This additional layer will stiffen the sidewall, the non-treaded area of the tire.", "The builder uses a tool called a bead server to mount the finished bead.", "While the tire is spinning, he applies the contact cement-type material to help the rubber-to-rubber adhesion when he wraps the plies around the bead to secure it further.", "The stitcher wheel smoothes the plies flat and pushes out trapped air.", "Then, the tire builder applies a strip of fabric-reinforced rubber on top and rolls it flat.", "This strip will make the bead area more durable when the tire is mounted on a wheel.", "He applies a layer of non-reinforced rubber on the sidewall.", "This covers the edges of the plies and will help the tire retain air once it's inflated.", "This machine makes the tread by extruding molten rubber through a dye into a continuous strip, then applying it onto the spinning tire.", "The fully constructed tire now goes into a press to cure.", "Inside, a hot mold closes around the perimeter, while a bag inflates in the middle, pushing the tire outward against the walls of the mold.", "When the tire comes out, about half an hour later, the rubber is no longer soft and pliable, and its chemical structure is stabilized, locking in the final dimensions.", "Workers seal the wheel opening and inflate the tire to hold the shape until the rubber cools.", "Once the rubber has cooled to room temperature, which takes about an hour, the tire undergoes a series of quality-control checks.", "Here, a worker performs a visual inspection while trimming off excess rubber from the bead area.", "Before the decals go on, they also x-ray the tire, looking for any internal flaws.", "Life in the fast lane, while exciting, is short.", "Dragster tires need to be replaced every four to six trips down the drag strip.", "Icing dates back to 17th-century england.", "Early versions were poured directly onto cake.", "The cake was then put back in the oven until the topping cooked into an icelike glaze, hence the term icing.", "Hundreds of years later, success never tasted sweeter.", "Today, icing comes ready-made in cans and tubes.", "No need to make a sticky mess in the kitchen.", "Just press the nozzle to transform a plain cupcake into an elaborate dessert.", "It takes a dozen different ingredients to make icing, beginning with vegetable-oil shortening.", "They encapsulate food coloring in the block of shortening.", "This keeps the food coloring from becoming airborne, as a mixture creams the shortening with sugar, which they pipe directly into the mixer basin.", "Sugar is the main ingredient in icing.", "Corn syrup is the next ingredient.", "It adds more sweetness and liquidity to the mix.", "The mixer arm spirals around the basin for a few minutes to blend everything.", "Then, they add cornstarch, which will act as a thickening agent.", "They pour warm water into the mixture and beat until smooth.", "If the icing consistency is too thin, they thicken it with more sugar.", "This 1,000-pound batch of icing is done, and there's enough to fill 2,000 aluminum cans.", "A conveyor delivers the cans to fillers that inject half a pound of icing into each can.", "The system fills 3,600 cans an hour, and no one has to get their fingers sticky.", "Plastic nozzles now funnel toward the containers, and with perfect timing, a press seals one to each of the icing-filled cans.", "At the same time, a pump shoots air into a small hole in the bottom of the can.", "This pressurizes the icing so it can be pumped out when needed.", "The burst of air carries a tiny, rubber cap with it, and it plugs the hole to maintain the pressure.", "The cans move forward and meet up with the applicator tips.", "There are four tips per can, held together by little, plastic connectors.", "The four applicator clusters fall out of the feeder and land on the can nozzles.", "Clear caps then fall into place on the cans.", "A blade cuts a labeled plastic sleeve to the correct length.", "The sleeve drops onto the cans, draping them loosely for the moment.", "They ride by a spinning plastic disk that tucks the sleeves all the way down.", "Then, it's into a drier, where the heat shrinks the wrap to the cans, sealing the icing.", "It's a perfect fit.", "Next, they make icing for packaging in squeeze tubes.", "They blend together the same ingredients, but in different amounts and in a different order.", "This achieves a thicker consistency.", "Thicker icing can be more easily squeezed out of tubes.", "For ready-made icing, it really is all in the packaging.", "A mechanized arm picks up the squeeze tube and delivers it to the filling machine.", "A vacuum pump sucks out air and any contaminants.", "Another mechanism orients the tube for filling.", "Nozzles now inject thick, yellow icing into the tubes, but stop short at a complete fill-up, leaving space for the open ends to be closed and sealed by hot jaws.", "Once closed, the machine ejects the tubes.", "Each one contains four ounces of icing.", "It's about half as much as the can.", "To decorate with icing from a tube, the consumer squeezes it out of the bottom tip.", "To apply icing from a can, you pump it out of the top.", "No matter how you ice it, the result will be sweet.", "The egyptians built the earliest known docks on the shores of the red sea around 2500 bc.", "More than 4,000 years later, our lakes and rivers are dotted with floating structures where boaters can dock their crafts, go for a dip, or just lounge in the sun.", "Floating docks can be much more than just walkways where you tie up your boat.", "They can be waterborne buildings with slips, jet-ski ports, and even a rooftop deck.", "This facility has created its own computer-aided design software.", "With it, they can quickly design each component of a dock in 3-d.", "The program will even calculate how many floats are needed and where they should be placed to keep the dock level in the water.", "Thanks to its lightweight, rustproof strength, aluminum is the ideal material for building docks.", "All the aluminum here has been extruded in unique shapes according to the design requirements.", "The plans are printed, and workers consult them closely as they cut and form the material.", "The blades they use are specially designed for cutting aluminum.", "They use a variety of methods to form the shapes, including drill presses equipped with components called hole saws.", "Workers lay the material out on the factory floor in preparation for assembling the structure.", "The final assembly of the floating docks will happen on the water at the site.", "They tack-weld the parts to each other, then make sure everything is perfectly square before doing the final weld.", "Unlike steel, aluminum loses strength when it's welded.", "For this reason, the designers of these docks have created special aluminum sleeves for every major joint.", "That means there's extra metal supporting the weld and strengthening the structure.", "To make sure everything fits properly, the workers join the sections to each other with stainless-steel bolts and lock nuts.", "There is minimal reaction between the different metals, because there is so little stainless steel relative to the quantity of aluminum being used.", "Once the bottom section of the dock is assembled, workers build up from there.", "For this test phase, they use shortened, temporary roof poles to make the process easier.", "The blue material on the poles is polyethylene bushing, which prevents creaking when the dock is stressed in turbulent water.", "Because aluminum is so lightweight, there's no need for cranes in an aluminum dock facility.", "Manpower is enough.", "Workers attach a series of narrow, aluminum tubes, called purlins, to the roof and deck.", "Workers install the roofing by screwing it into the purlins.", "In most cases, the roof won't be installed until the dock is assembled on-site.", "Satisfied that everything assembles correctly, the workers take it all apart.", "They flip the lower sections over and attach the floats.", "These floats consist of roto-molded polyethylene shells.", "Styrofoam has been expanded in place to fit inside the shell perfectly.", "Even if the outer shell breaks, the dock will still float.", "This facility offers a range of decking options from aluminum to concrete to plastic composite to specialty woods like this one, which is called ipe.", "Like teak, ipe is incredibly durable and extremely stable.", "In other words, it won't rot, swell, or contract, despite extended exposure to a high-humidity environment.", "If the dock has an upper deck, it needs a railing.", "It's important to have something to lean against when you're sipping cocktails and watching the sunset after a long boat ride.", "Of course, it's also a crucial safety feature.", "There are 12 different components to assemble for just this one section, and there might be as many as 15 different sections of varying lengths for an entire dock.", "Customers can choose to add a range of accessories to floating docks made at this facility.", "To make things like safety railings and ladders, workers use a hydraulic bending machine to shape aluminum tubing to the required contours.", "All the aluminum these manufacturers use in their floating docks is a marine-grade alloy especially resistant to degradation when exposed to water.", "Finally, it's time to build the docks in place.", "Thanks to careful planning on the part of the manufacturers, assembly is a breeze.", "The crew doesn't need much more than a ratchet set to pull it all together.", "It's smooth sailing from here on out.", "In the modern world, steel pipes form an underground network to deliver necessities like drinking water or fuel.", "These pipes are often spirally welded and can be made in any size.", "In fact, longer pipe means fewer joints and less work to install them underground.", "Spirally welded pipes can be short, or they can go on and on.", "The potential length is limitless, because, unlike other kinds of pipes, spiral pipes don't have to conform to the size of a forming roll or the dimensions of a steel plate.", "They can spiral-weld these coils of steel sheets endlessly.", "But first they have to take the kink out of the coiled steel.", "A machine unwinds it and pushes it between rollers to completely flatten it.", "A fixed arm then presses the steel against rollers to round it to a precise diameter, and an automated system welds the formed pipe from the inside.", "A barely visible mantel of powdered flux protects the welding process.", "Copper-coated steel wire acts as both an electrode for the welding process and as filler material.", "With the inside weld complete, a second welder device works on the outside of the pipe to give it a double-welded seam.", "A plasma torch cuts the pipe to length cleanly by melting it.", "In this case, they're making a water pipe that's 6 feet in diameter and 50 feet in length.", "The pipe then rolls over to the next station.", "Here, a worker grinds both ends of the pipe to improve the profile.", "Then it's over to a die.", "It stretches one end of the pipe to create a slight flare, or bell.", "This will allow it to be connected to the narrower end of another pipe, forming what's known as a lap joint.", "Next, they cap the ends of the pipe and pump in water to a highly pressurized state.", "They look for leaks in the weld and confirm that it's watertight.", "Another worker installs rubber dams at both ends of the pipe.", "A cement fixture then flows into a long applicator with a nozzle.", "The nozzle applies the cement to the pipe's inner wall as the pipe spins and generates a centrifugal effect that's 70 times the force of gravity.", "This causes the cement to be distributed uniformly.", "The rubber dams contain the cement during this process.", "The spinning displaces water in the cement, and a blower forces that water out of the pipe.", "Next, a worker drapes plastic onto both ends of the pipe.", "He tacks it with magnets and then secures it tightly with an elastic cord.", "He pumps hot steam into the pipe.", "Over a period of 18 hours, the steam cures the cement.", "It's a slow cure for better structural integrity.", "For our camera, they open one end of the pipe for an inside look at the steaming action.", "18 hours later, they remove the rubber dams.", "The spiral-welded pipe now has a tough, protective inner liner.", "Next, the pipe moves into a blast chamber, where fine, steel shot bombards the outside of the pipe to clean it thoroughly.", "This prepares it for the next step.", "A sprayer applies a liquid adhesive.", "Over the adhesive, they wrap a polyethylene-backed tape.", "They apply a total of three layers of tape.", "The first one provides corrosion protection to the spirally welded steel.", "The other two layers protect the first.", "They give the spirally welded pipe a tough outer skin.", "The three tapes are color-coded.", "This will allow the depth of any damage to be quickly assessed on-site.", "They produce approximately 15 spirally welded water pipes per eight-hour shift at this factory.", "They should last for a century underground." ]

{ "things": [ "Spiral Stairs", "Pita Bread", "Exhaust Headers", "Molded Limestone Artwork" ] }

[ "spiral stairs were part of a strategy to defend the towers of medieval castles.", "Attackers had to climb single-file and couldn't storm the castle all at once.", "And at the top of the stairs, the guardsmen could more easily maneuver their swords, giving them the upper hand.", "Spiral stairs take people to the next level without taking up a lot of space.", "They're compact, and with their corkscrew curvature, they can also be architectural features.", "Production starts with the steel hubs cut to the desired riser height.", "A worker files the sharp edges smooth and drills a threaded hole which will be used to fasten the treads in place.", "A computer-driven plasma system cuts through a sheet of steel to produce the pie-shaped stair treads.", "A worker nestles a tread to the hub and clamps them in a weld fixture.", "He also clamps structural supports to the base of the tread.", "With everything in the right configuration, he welds the supports to the tread and the hub.", "He'll make 12 of these hub and tread assemblies.", "He chips off the weld slag for cleaner seams.", "A team slides the hub and tread assemblies on to the center pole and rotates them to the correct position.", "The design geometry dictates the rotation.", "Once rotated correctly, the workers fasten the hubs to the pole and add a platform for the top step.", "A baluster spins in a lathe, as tools cut it to length and round the end to the correct diameter.", "The operator measures the diameter.", "He inserts the rounded end in a dye that carves the thread into it.", "A worker welds a steel cup just above the threaded part of the baluster.", "This cup will support the baluster once it's been installed on the thread.", "He grinds the weld scale from the cup.", "He inserts the baluster through holes in a metal spacer in the tread.", "He screws a nut on to the end to secure it.", "Using rollers now, another worker twists long strips of metal into spiraling hand rails that match the rise of the stairs.", "He fits the rail to the top balusters and clamps it in place.", "He then welds the balusters to the rail.", "He adds more railing until it spirals all the way down to the first step.", "The team secures it to the platform.", "The spiral staircase's metal structure is now complete.", "It's ready for the wooden accents.", "A worker applies glue to pieces of red oak.", "He'll use two of them to make one stair tread.", "He clamps two tread sets in a fixture while the glue sets.", "He inserts a shim and tightens the clamp to apply downward pressure.", "Once the glue has cured, a planer shaves the tread perfectly flat and to the desired thickness.", "After refining the profile, a worker rounds the edge of the stair tread using a router.", "After gluing strips of wood together to create a curved railing, he sands the excess adhesive, and with a file, removes more of the glue.", "He turns the railing over and carves a groove in the wood.", "This will enable the railing to be installed over the metal rail support.", "He adds some detailing along the edge.", "A team then fits the wooden railing to the metal support structure.", "All of the rail sections fit together perfectly.", "After the pre-fit, they remove the railing and sculpt the edges to be rounder.", "The rounded edges complement the overall spiral design.", "A worker pre-fits the wooden treads to the metal structure and then disassembles the entire spiral staircase for painting and staining.", "The spiral stairs are then ready for reassembly in the building they were designed for.", "They'll definitely add a certain twist to the interior design.", "Originating in the middle east, pita bread has been around for thousands of years.", "Today, its popularity continues to grow around the globe.", "Part of its appeal is its versatility.", "People can stuff their pita's pockets, use it as a sandwich wrap, or slice it for dipping.", "Pita bread may be flat, but that doesn't mean it's boring.", "Anyone can use pita to make any number of interesting lunchtime combinations.", "Making pita bread starts with silos full of flour.", "A blower system delivers the flour to an automated sifter.", "The sifter shakes the flour through three levels of mesh to filter out impurities.", "Magnets extract any metal contaminants.", "Workers prepare a pre-mix of sugar, salt, yeast, and preservatives.", "They combine these ingredients with the sifted flour in a big mixer and add water.", "The mixer is equipped with numerous bars that rotate horizontally to blend the ingredients.", "The operator opens the mixer and spins it one more time to eject the dough into a bin.", "He rolls the bin to the next station.", "Here the pita dough goes into a hopper.", "And from there, it drops into a machine called a dough divider.", "This machine turns big chunks of dough into many small blobs.", "To do this, it forces the dough through a round hole, and a guillotine blade chops it to the correct thickness.", "The dough blobs ride a conveyor and pass under a roller that flattens them.", "Flour from an overhead sifter dusts the dough blobs to keep them from sticking to the machinery.", "Each one of these flattened dough blobs will eventually become a pita.", "The round pieces of dough now ride a conveyor up to a warm zone.", "Over a period of 15 minutes, the yeast ferments, causing the dough to rise.", "Out of the fermentation station, a roller flattens the pita dough segments again.", "They're now ready to be rolled very thin in a process known as sheeting.", "The next roller presses the pita dough much thinner.", "Rolling it in one direction makes the dough segments oval-shaped.", "The oval pitas ride by a pusher that now shoves them towards the final roller.", "It rolls the dough in the other direction to round out the shape and make it even thinner.", "Perfectly round and thin, the pitas now travel up to another fermentation operation.", "Inside, the temperature is toasty.", "It's warm enough to reawaken the yeast and cause the dough to rise again.", "Conveyors move in criss-cross directions to take the pitas back and forth.", "This zig-zagging journey lasts about 15 minutes.", "When the pitas emerge from the chamber, they have thickened up substantially.", "They head into an oven where the magic happens.", "The oven's temperature is between 750 and 930 degrees fahrenheit.", "They spend just 15 seconds in it.", "This flash-baking causes the water in the dough to turn to steam.", "The steam puffs the pitas, creating pockets inside.", "The pitas then travel on conveyors for a 20 minute cool down.", "As they cool, they deflate.", "The process has created pockets in the pitas.", "Once sliced open, the pockets can be stuffed to create sandwiches.", "Workers stack the pitas six high for packaging.", "The next conveyor delivers the stacks into the clutch of an automated arm.", "Just ahead, a burst of air opens a bag and the arm inserts the pitas into it.", "At the same time, it pushes the bag on to the next conveyor.", "Moving forward, another device automatically twists the open end of the bag.", "The device applies a plastic lock tab to the twisted end of the bag, sealing the pita breads inside.", "The bags pass by a metal detector, and then they're on their way to the supermarket.", "This pita bread has taken 45 minutes to make and package, but it should enable lunch to come together very quickly.", "Installing exhaust headers will add extra power from a car's engine.", "They bolt on to the engine, giving each cylinder its own exhaust pipe leading to the collector, which connects to the car's main exhaust pipe.", "That's more efficient than having all the cylinders exhaust into a common manifold.", "A header draws out significantly more spent exhaust gasses after combustion, leaving room for a greater amount of new gas and fresh air to enter the cylinder for the next combustion cycle.", "Headers are made of steel or stainless steel.", "A worker uses a roll cutter to slice tubes into nearly 6-inch-long pieces for the header's collector.", "A forming tool on a press stretches one side of the collector outward.", "Then the worker places the same side on an end-forming machine, which shapes it like a four-leaf clover.", "He slips a flange over the unshaped side and widens that side to create the ball portion of the gasketless ball and socket connection to the car's main exhaust pipe.", "Meanwhile, another worker roll cuts narrower tubes into 32-inch-long pieces to make the header's primary tubes, the ones that attach at the top to engine's cylinders.", "A worker slides a tube on to a mandrel, then the computer-guided mandrel bender bends the tube in four places.", "The mandrel fills the inside of the tube just up to the bend point, preventing the tube from compressing or collapsing under pressure.", "The header they're making here is for a four-cylinder engine, so it has four primary tubes.", "An eight-cylinder engine requires a pair of headers, whereas a six-cylinder engine requires a pair of three-tube headers.", "A worker trims the bent primary tubes to the required length with a bandsaw.", "The sawed edges of the tube are ragged, so the next step is to grind them smooth.", "After grinding, the edge no longer looks like this.", "Workers heat the top end of the tube with a torch to soften the steel.", "They place the end into an end-forming machine.", "The machine shapes the end to match the top profile of the cylinder, to which the tube will be mounted.", "Cylinder profiles vary from engine to engine, so workers simply change the forming tool on the machine.", "A worker clamps the header flange with its four exhaust ports on to an assembly jig and positions the top end of a primary tube in each port.", "He inserts the bottom ends into the four-leaf-clover-shaped collector.", "He then welds the top end of each tube to its exhaust port on the header flange.", "Then he welds a tag with the company name on to one of the tubes.", "Finally, he welds the bottom end of the tubes to the collector.", "The header's three sections-- flange, tubes, and collector-- are now fused.", "The worker grinds down the weld around the ports until it's nearly flush.", "The remaining bit of weld material encircling the port will act as a seal to prevent leakage.", "During the welding, some welding material drips into the header flange's openings, so a worker reams the bolt holes with a drill and grinds the edges of each port.", "He mounts the header on the corresponding engine's cylinder head to make sure bolt holes are sufficiently cleared.", "Then he runs a torch over all the joints to check the welds.", "The flame would shoot through any hole in a weld, alerting them to repair it.", "This factory applies one of two finishes on its exhaust headers.", "The basic one is a coat of black water-based paint sprayed on and air-dried.", "It prevents surface rust from forming while the part is warehoused.", "The higher-end finish is an aerospace-grade ceramic coating, available in black or silver.", "This baked-on finish protects the headers from rust for many years of high-performance driving.", "This may look like ivory, but it's actually limestone.", "It looks as though it's a sculpted work of art, but it's actually molded.", "How does one mold limestone?", "200 years ago, some people in france figured out how, and their descendents are still molding limestone artwork today.", "This unique art form exists because, two centuries ago, a family in france discovered springs amid volcanic rock, springs with water so rich in calcium carbonate that it petrified into stone.", "That is limestone.", "The family carved out caves, then invented a way to capture the calcium carbonate and mold sculptures with it.", "The descendents of the family continue that tradition today.", "The springwater contains two grams of calcium carbonate per liter and a lot of iron oxide, which makes the water orange.", "The original troughs direct the water on to a bed of wood shavings.", "The shavings trap the iron oxide, and the calcium carbonate floats to the surface.", "In the workshop, the owner of the company-- the seventh generation of the founding family-- makes the mold.", "He heats something called gutta-percha in a pot of water to soften it up.", "Gutta-percha is a natural latex made from the sap of the gutta tree.", "Once it's soft, he weighs out the required amount using the workshop's original scale.", "Then he kneads it to force out trapped air and make it more malleable.", "After forming it into a ball, he places it in an old press made my his great-grandfather.", "The press shapes the gutta-percha into a rectangle measuring 7-by-10 inches.", "After cooling in the press for 30 minutes, the gutta-percha has hardened just enough to maintain the rectangular shape.", "He removes it from the press and places a silicone-designed template on top.", "He cuts the gutta-percha to the shape of the template.", "He places the gutta-percha on top of a pattern created by an artist.", "He places the template on the gutta-percha, then a plank of wood on top of that.", "He puts the entire assembly under an old screw press.", "An hour later, he removes the assembly from the press and gently separates the layers.", "The artwork design is now transferred from the pattern to the gutta-percha.", "He sets it aside to cool to a hard state.", "When the work of art is either too wide or high to fit into the traditional screw press, the artisan then sculpts the pattern out of clay.", "Once the clay hardens, he coats it in silicone to make the mold.", "This modern mold-making technique is a bit trickier because silicone can't be reheated and reworked like gutta-percha.", "The silicone takes about 24 hours to harden into a flexible mold.", "A silicone mold can be used only once.", "And because it's so flexible, it has to sit on a support tray so that it doesn't buckle when filled or moved.", "Now it's time to mold the limestone.", "A craftsman positions the molds under these liquid limestone waterfalls.", "The carbonic gas in the liquid gradually evaporates, leaving accumulating deposits of calcium carbonate in the molds.", "An artisan moves every mold to a new position daily so that the dripping water hits all parts of it.", "Artwork just one 1/5 of an inch thick requires six months under the fountain.", "Artwork 4/5 of an inch thick requires two years.", "To extract the limestone artwork from a traditional mold, the artisan immerses it in hot water to soften the gutta-percha so that he can gently peel it off.", "Every intricate detail of the design in the gutta-percha is now replicated in limestone.", "This molded rock is as strong and hard as marble.", "To extra the artwork from a silicone mold, an artisan removes the support tray and lifts off the silicone.", "The company has more than 500 artwork patterns in stock dating back to 1821.", "Not all the molded limestone looks the same.", "The artisans can tailor the shade from white to ivory by controlling how much iron oxide they remove from the water." ]

{ "things": [ "Wheel Loaders", "Vegetable Oil", "Hand Tools", "Cotton Swabs" ] }

[ "Today, on \"how it's made\"...", "Wheel loaders...", "Vegetable oil...", "Hand tools...", "And cotton swabs.", "They're big, they're bulky, and boy, can they move stuff.", "Wheel loaders are drivable heavy machines.", "You see them on construction sites moving dirt, at landfill sites moving garbage, and in the winter, you see them all over, clearing large quantities of snow.", "They start by assembling the 100-odd steel components that make up the front frame.", "These parts are so heavy that workers have to use industrial-strength magnets to move them.", "Take note of those pieces with the holes in them.", "We'll come back to them later.", "Workers measure and mark exactly where they'll weld the front frame parts together.", "You might not think precision is all that important when it comes to building a 20-ton hunk of machinery, but it is.", "Being just a few hundredths of an inch off can cause major problems.", "The preliminary welding is done by hand.", "Workers tack the parts together.", "They do the same with the 100-plus steel parts that make up the loader's three other sections-- the rear frame, the driver's cab, and the moving arm at the front called the boom arm.", "Once the manual welding is completed, robots take over to do the major welding.", "They weld about 90% of the wheel loader.", "Now that the front frame is solidly fused, it undergoes a final machining.", "Remember those parts with the holes in them?", "They're what enable the boom arm to move.", "A computerized sensor now measures those holes and calculates how to cut them to the exact specifications of the engineering design.", "The computer then guides the machining tool to tailor the holes to spec.", "First, a preliminary cut.", "Then, after some oil lubrication, the final cut.", "When this operation's complete, the front frame will join the other sections at the paint shop.", "After painting, workers begin the final assembly.", "They position an axle under the front frame and another under the rear.", "Then, they affix the frames to the axles with heavy-duty bolts.", "They mount the diesel engine and transmission in the rear frame.", "After assembling the cab, they install it onto the rear frame...", "Then connect the wiring for the controls.", "Now comes the boom arm.", "Remember those front frame parts with the holes?", "Workers line them up with the holes on the boom arm, then insert giant steel pins.", "This creates a pivot mechanism, enabling the arm to move up and down.", "The moving parts must fit together snugly, but not so tightly as to restrict movement, which explains why welding and machining precision was so crucial.", "Once they've tested the boom arm's hydraulic lift system...", "Workers install the tires, which are almost 6 1/2 feet tall.", "Using a specially calibrated torque gun, they bolt the tires to the rim...", "32 bolts in all.", "The wheel loader is fully assembled.", "Now the boom arm can be equipped with a forklift, a broom, or a big shovel called a bucket.", "Vegetable oil is a fat extracted from the fruit or seeds of certain plants, such as corn, canola, cottonseed, safflower, sunflower, or soybean.", "There are various ways to extract the oil.", "The method we're about to see is called cold pressing.", "It all starts with seeds-- in this case, a dark variety of sunflower seeds.", "Cold pressing yields less oil than other methods, so it's usually just smaller specialty companies that use the process.", "The big vegetable-oil makers tend to use solvents and high-pressure, high-speed presses.", "That is much more productive.", "But it also generates heat, which darkens the oil and diminishes its flavor and nutritional value.", "These seeds, shells and all, will go through this low-pressure press.", "The temperature inside is kept below 104 degrees fahrenheit-- hence the term \"cold pressed\".", "The press operator has to carefully monitor and adjust the speed, pressure, and temperature...", "Because keeping a press cool is no easy task, given the heat that mashing seeds naturally generates.", "The pressing mechanism, the screw press, is made up of several sections.", "They can shorten or lengthen it according to the type of seeds they're pressing to allow for more or less room for the seeds within the chamber.", "220 pounds of seeds go through the press every hour, producing about 10 gallons of oil...", "Low volume, but high quality.", "The seed residue, called seed cakes, is later sold for animal feed.", "Now, though, they're the key to monitoring temperature.", "If the seed cakes are too warm, that means heat is building up and they have to open the exit wider to reduce the inside pressure and bring the temperature down.", "Once the oil is extracted, they pump it through a filtration system.", "These cloth filters allow the oil to pass through, but any remaining seed residue gets caught in the fibers.", "The oil runs through the filters repeatedly until it becomes clear.", "Mastering the art of cold pressing takes a lot of know-how and experience, but it results in oil that's healthier and tastier.", "Cold-pressed oils made from other seeds pose different production challenges.", "Flaxseed and hempseed are extremely sensitive to heat, so workers have to cool the press during the process to offset the heat that pressing generates.", "Canola, on the other hand, isn't particularly sensitive to heat, nor is sesame.", "All-natural, no-preservative vegetable oils like these have to be babied because exposure to air makes them prematurely spoil.", "Plastic isn't airtight, so they bottle these oils in glass-- dark glass to block the oil's other enemy, light.", "They seal the bottles with a flow-control cap.", "Without preservatives, sunflower, canola, and sesame oils have an 18-month shelf life.", "Flaxseed and hempseed oils have to be refrigerated.", "Even then, they go bad after just a few months.", "You don't have to be a do-it-yourselfer to own a few basic hand tools.", "Even the renovationally challenged are likely to posses a hammer, a screwdriver, maybe even a pair of pliers-- if not in a toolbox, then at least crammed into a messy drawer somewhere.", "Here's a look at how some hand tools are made.", "Every screwdriver and chisel has to have a handle.", "This factory makes handles from acetate, a synthetic resin.", "These acetate bars are 6 feet long and come in many colors and contours.", "They arrive here ready-made.", "Workers load the bars onto a machine that feeds them into a lathe.", "As the lathe spins, an automated knife cuts one handle after another, rounding off what will be the top of the handle.", "Then, it sculpts the other end.", "Then, a drill makes the hole into which they'll later insert the blade.", "All this takes just a few seconds.", "Now the handles travel to their next stop, the dipping machine.", "Acetate becomes dull and opaque when it's cut, so the machine dips them in acetone, a chemical solvent.", "This brings back their translucence and shine.", "It also removes any acetate shavings stuck to the ends.", "Here's what the handles look like before the acetone bath.", "And here's what they look like after.", "The handles air-dry on their way to the next stop on the production line-- printing.", "The hot-stamp printer works in conjunction with an ink ribbon.", "It applies about 55 pounds of pressure, engraving the product code and brand name, while the heat, about 160 degrees fahrenheit, transfers the ink from the ribbon into the engraved lettering.", "The handles are finished, and it's finally time to insert the blades-- in this case, phillips head screwdriver blades.", "Blades are made of carbon steel, an automated machine forces them into the handle with about 80 pounds of pressure.", "Workers insert chisel blades manually in order to protect their sharp edge.", "At the same time, they top the handle with a steel cap to give the chisel extra striking power.", "Another common hand tool is the drywall square, also known as a t-square.", "They cut two strips of aluminum, the first 4 1/2 feet long, the second 22 inches long.", "Then, they apply the markings by silk-screen printing.", "Next, they use a bending machine to hold over the top edge of the piece that will form the horizontal part of the \"t\".", "This will allow the tool to hook onto the edge of a drywall panel.", "Finally, they rivet the two pieces together.", "The drywall square is finished.", "Factories can alter the size of the tools they produce to meet their clients' specifications.", "Standard screwdrivers have handles measuring 3 1/2 to just over 4 inches long with blades that are 1 1/2 to almost 8 inches in length.", "Some screwdrivers, on the other hand, have extra-long blades, while stubby screwdrivers have short handles for getting into tight places.", "Then, there are those skinny pocket screwdrivers and precision screwdrivers for jewelers and electronic technicians...", "All of which proves there's a tool that's the right size for every job.", "We use them to apply and blend our makeup, we use them in a pinch to pry dirt out of tight crevices, and of course, we use them to clean our ears, though doctors say never to insert them into the ear canal.", "Cotton swabs are just one of those little things that are really handy to have around the house.", "Cotton swabs were invented in 1926 by leo gerstenzang, a polish-born american.", "He got the idea from watching his wife clean out their baby's ears using a flimsy toothpick stuck into a piece of cotton.", "Leo set out to design a safer device.", "He took a thicker wooden stick and wrapped the ends with cotton in such a way that it wouldn't come off and get stuck in the ear.", "The leo gerstenzang infant novelty company marketed this invention under the trade name baby gays.", "Many cotton-swab makers also produce cosmetic pads.", "Both start with bleached cotton.", "It arrives at the factory compressed in large bales.", "The cotton first goes into a machine called the feeder...", "From there, into a machine called the opener, which shreds the bales, pulling the cotton fibers apart.", "Next stop, the carding machine.", "Its large rollers comb the cotton fibers out.", "Then, guided by weight-detecting sensors, it produces a uniformly thick ribbon of cotton called a web.", "This web is now ready to be processed into either cotton swabs or cosmetic pads.", "To make pads, they layer several webs-- just how many, though, is a closely guarded company secret.", "And so is how much pressure they apply to those layers to compress them.", "This secret recipe of layers and pressure is what ultimately determines the weight of the pad.", "The heavier it is, the higher the quality because it's thicker.", "The now-compressed layers of web go through a machine called the slitter.", "It cuts the wide roll into several narrower rolls called header rolls.", "Each header roll then goes through a machine that stamps on a quilt-like pattern, purely for aesthetics.", "Finally, using a punching die, they cut the pads.", "On this production run, each pad weighs about 2/100 of an ounce, but the factory can produce whatever weight the client requests.", "The cosmetic pads are ready to be packaged.", "This client wants them in bags of 100.", "The blue light shows the workers the 100-pad cutoff point.", "To make cotton swabs, the initial web is divided into four narrower webs, each weighing about 5/100 of an ounce per yard.", "Each narrow web travels through a funnel, which transforms its shape from flat to round.", "Then, it coils into a barrel.", "The swab-making machine then takes cotton strands from two barrels at a time, feeding a line of cotton to each end of the stick.", "Like the cosmetic pads, the amount of cotton per stick varies according to the client's specifications.", "The stick feeder prepares the sticks.", "Then, as we see here in slow motion, the machine cuts the cotton strand and rolls a piece onto both ends of the stick simultaneously.", "Just prior, a heating device melted the tips of the plastic sticks so the cotton would adhere.", "With wood or cardboard sticks, they glue the cotton on.", "The finished swabs are sprayed with an antibacterial solution.", "Here's that action in slow motion.", "Now in real time-- 2,000 swabs per minute.", "Sensors detect any defective swabs and automatically toss them off the production line.", "If you look closely, every so often, you'll see one missing.", "Finally, a robotic arm grabs the exact number of swabs per box, again determined by the customer's specs, and packages them.", "The company's lab does spot checks on its swabs to ensure that the antibacterial solution is working...", "And that the products are germfree." ]

{ "things": [ "Solid State Drives", "Eye Shadow", "Limousines", "Dead Blow Hammers" ] }

[ "The drive in your computer saves and stores your data-- everything from documents to photos to software programs.", "The newer generation drives are solid state drives.", "They're gradually replacing traditional hard disk drives because they're compact, more durable, and process information much faster.", "Just like portable usb drives and camera memory cards, solid state drives store information on several memory chips installed on a circuit board.", "Each chip contains highly complex circuitry comprised of electrical pathways 2,000 times narrower than a human hair.", "To make those memory chips, they begin with a disk-shaped silicon wafer.", "Silicon is a non-metallic natural element that conducts electricity.", "It's highly susceptible to contamination, so the production area is virtually sterile to the point of being 1,000 times cleaner than the air in a hospital operating room.", "An automated robotic system moves the wafers through more than 800 operations, which take more than a month to complete.", "Each wafer receives layer after layer of materials-- some conductive, such as copper, some nonconductive, such as silicon dioxide.", "After applying each layer, the machine coats the wafer with a light-sensitive fluid then flashes u.v. light onto it through a glass stencil of the electrical circuitry pattern.", "In the areas where the fluid is exposed to the light, the chemicals break down and dissolve.", "Where the fluid was shielded from light by the stencil, the materials remain intact, effectively printing the circuitry pattern on the wafer.", "Chemical baths then wash away the exposed fluid and material.", "Each foot-wide wafer yields hundreds of microchips, which now have to be sliced apart.", "The robotic cutting machine covers the wafer with an adhesive film to hold the chips in place while they're being cut loose from each other.", "The next machine inserts each clip in a protective plastic housing.", "Meanwhile, six circuit boards at a time enter a machine which applies a thin layer of tin alloy solder paste onto the areas where the memory chips and other components will go.", "As the boards exit the machine, a robotic arm picks off the components required for each drive from feeder spools and deposits them at their respective locations on the circuit board.", "This particular model has 8 microchips, each able to store 64 gigabytes of data, giving the drive a capacity of 5,012 gigs.", "The circuit boards now enter a tunnel-shaped oven which melts the solder paste, fusing the components to the board.", "The brain of the solid state drive is now complete and ready for the first phase of quality-control testing.", "This machine performs an optical scan to verify that every component on the board is set in the right place.", "The next machine x-rays the board to verify that each component is securely soldered in the correct location.", "A later phase of quality-control testing will verify the drive's performance.", "Until now, six circuit boards have been attached to each other.", "An automated router now cuts them apart, and workers insert each board into a protective plastic housing.", "A slot on the outside of this housing reveals the board's connector by which the drive links to the computer.", "Solid state drives come in different sizes.", "This particular model is large enough to replace a traditional hard disk drive.", "However, many models are smaller, designed to fit where disk drives can't-- for example, in ultra-slim laptops.", "Every drive is labeled with its technical specs, model, and serial numbers and so on, along with a barcode for production tracking.", "Then they plug the drive's connector into a tester, which, after verifying that everything functions electronically, installs the drive's operating system.", "The drive moves to the next station, where it undergoes up to 60 hours of extensive performance testing to ensure that it stores and retrieves data correctly and at target speed.", "Packaging is twofold.", "First, a foil shield to prevent static electricity from damaging the drive, then a carton, and finally into a shipping box headed for a destination somewhere around the world.", "In ancient egypt, both men and women painted their eyes.", "It was thought that eye makeup made one less vulnerable to the evil eye, a gaze or stare meant to cause harm.", "Today, mostly women wear it.", "And of course, repelling evil is no longer a reason to wear eye shadow.", "With a palette of eye shadow, a woman can work a certain kind of magic.", "Skillful shading can add depth and drama to the eyes.", "This makeup can also create the illusion that the eyes are much larger than they really are.", "To make eye shadow, they follow specific recipes.", "A technician weighs the ingredients, beginning with mica, a mineral that acts as filler.", "The next ingredient is zinc stearate.", "It's a binder.", "A combination of pigments provides the desired color.", "These particular pigments are different shades of the mineral iron oxide.", "He transfers the measured ingredients to a big blender jar.", "As he pours the ingredients, they dust up, and a gas mask keeps him from breathing in the particles.", "He places the jar on the blender base, covers the top, and activates the blades.", "The blender mixes and grinds the powdered ingredients to a very fine state.", "Then it's into a very large mixer.", "He adds coconut oil-- just enough for the powdered ingredients to eventually coagulate into a cake form.", "More mica is next-- a lot more.", "Eye shadow is 80% mica.", "This mica is darker to add intensity to the color.", "It also has a bit of shimmer.", "He latches the lid to contain the ingredients and powers up this high-speed mixer.", "Inside, the mixing paddles swivel around for about 15 minutes to thoroughly mix the ingredients.", "The eye shadow mixture flows into a plastic bag.", "A technician examines it to confirm that the color has been evenly dispersed and that the powder is sufficiently moist.", "Another worker now pieces four eye shadow tins in pods on a metal platter.", "The platter rotates to deliver the tins to a mixing dispenser that's been filled with the eye shadow ingredients.", "The mixer pushes precise amounts through holes in the bottom and into the tins.", "A scraper levels off the tops.", "The next stop is a press with four circular heads.", "A ribbon of fabric keeps things hygienic as the press compresses the moist eye shadow powder and turns it into a cake-like form.", "Moving forward, the pods eject the tins, and an automated device pulls them off the machine.", "What a difference the compression has made.", "No longer a loose powder, the eye shadow ingredients have caked up nicely.", "The tins now move into a lane and come up against an abrasive belt that cleans the loose powder from the sides.", "A blast of air also gets rid of some of the residual powder.", "For one out of every 100 eye shadows produced, a technician does a drop test from a height of 18 inches.", "He checks for chipping or damage.", "And if he finds any, he'll add power to the press.", "For a color test, he brushes some eye shadow onto his arm, beginning with a laboratory standard.", "He then applies newly manufactured eye shadow to his arm and compares the two.", "It's a match.", "And with his approval, the batch is almost ready for retail.", "Another worker inserts the tins into more substantial plastic containers with magnets on the bottom to secure them.", "She screws the clear caps onto the jars, and the eye shadow is on its way to the cosmetic counter.", "They also manufacture entire palettes of eye shadow for a rainbow of choices.", "It takes about a day to manufacture eye shadow.", "And the result is truly a thing of beauty.", "The first stretch limousines, built around 1928, usually transported big bands and their musical equipment.", "Luxury sedans with an extended chassis are typically associated with special occasions such as weddings, proms, or a night on the town.", "It takes about 475 hours of work and painstaking detail to transform a luxury sedan into a stretch limo.", "Workers cut an ordinary-size car in half using cutting wheels.", "Before cutting begins, the inside of the car is stripped away, along with other components such as the gas tank and drive shaft.", "Workers cut away the inner support structure and cut across the floor of the car with a reciprocating saw.", "The car is now completely cut in half.", "Workers wheel the back half of the car away from the front half.", "They place the back half on the exact spot where the limousine will gradually be assembled.", "The construction department employees insert steel frame rails into the front half of the car.", "They insert the rails on both sides of the front half before inserting the rails into the back half of the car.", "They measure the length of the frame rails to make sure that the frame is square and that the two halves are the correct distance apart to build the limousine.", "A worker welds the rails to the frames of the front and back halves of the original car.", "They position the drive shaft tunnel, which houses the steel drive shaft and exhaust pipes, and weld it to the original vehicle tunnel.", "They position the floor, which is made of galvanized steel, and weld it to the frame rails and tunnel.", "They weld the steel roof rails into place.", "They connect the new rails to the roof rails in the original vehicle.", "A worked welds a vertical side post into place.", "With a level, he checks that the post of hardened steel is perfectly vertical before welding the base of the post to the floor frame.", "A roof panel made of galvanized steel is put in place.", "Workers install the limousine's bar.", "They've already installed the steel seat frames.", "Next, they install an outer body panel complete with a hardened steel crash bar.", "They screw the panel into place.", "The screws will be removed once the panel has bonded solidly to the limousine frame.", "A worker sprays on three coats of paint, then applies two coats of protective clear coating.", "Once the painting process is complete, workers install the laminated safety side glass.", "Another worker sprays contact cement on the roof of the limousine in preparation for the vinyl top.", "He stretches the vinyl across the roof and with his hand presses the fabric down into the crevices.", "Then he carefully trims off the excess.", "He presses a strip of chrome molding into place on the top of the vinyl.", "Workers in the interior department install the back of a leather seat...", "And the leather bench seat.", "After reupholstering the original rear seat to match, they return it to its original spot in the back of the limousine.", "A systems installer connects the electrical systems for the control center, located behind the driver's seat.", "A panel lists relays and fuses.", "The original center console is then reinstalled.", "A worker installs a video monitor in the limousine.", "Next, he rolls out the floor mats.", "The acrylic disco bar lighting system is tested.", "In just 21 days, the original car is transformed into a luxurious limousine.", "With test drives and quality-control checks complete, enjoy a ride in the lap of luxury.", "A hammer is one of the most useful tools out there.", "The only problem is you have to control the rebound.", "That is, unless you have a dead blow hammer.", "These tools are accurate and easy to use because this particular type absorbs the bounce.", "This facility makes a variety of dead blow hammers.", "Some are soft-faced and some are ball-peens, which are used by machinists.", "All in all, they come in handy everywhere from nascar racetracks to operating rooms.", "To first create the internal structure of the hammer, they drill through a short length of welded steel tubing with a drill press.", "The worker drills straight through the tube, creating a hole on both sides.", "This tube will become the internal head of the hammer.", "The head needs a handle.", "A worker places the tube on a jig and then positions a rod on the hole.", "A press forces the rod through the tube.", "At the next station, a worker places the internal hammer assemblage behind a pane of tinted glass to protect her eyes as she welds the head and handle together.", "She only welds the top of the tube so as not to alter the metal.", "A machine drills a set of small conical indents in the handle.", "Fitting a set of pins inside the mold, these indents will be crucial to the process.", "Because the internal handle is round, the urethane exterior could twist on it when the hammer is being used.", "To prevent this, a worker welds on a flat tab.", "The urethane will lock in place around the tab.", "Next, a worker crimps a metal cap on one end of the tube.", "This creates an open canister, which the worker partially fills with a crucial ingredient-- hardened steel shot.", "He then crimps a cap on the open end, sealing in the shot.", "With the head canister done, the core of the dead blow hammer is now complete.", "While the basic components are simple, workers must assemble every element with precision.", "The mold has a set of pins inside it.", "A worker aligns the indents on the metal handle with these pins.", "The pins ensure that the internal hammer hangs in a perfectly centered position inside the mold.", "Workers secure the mold in a support frame before placing it on a conveyor that will take it through a preheating oven.", "Ball-peen hammers are assembled differently.", "Instead of crimping a cap on, they screw the face of the hammer onto a threaded tube.", "The metal core of the ball-peen is placed in a mold that leaves the metal face and ball exposed.", "After the molds go through the preheater, they arrive at the filling station.", "A high-speed mix head blends urethane with hardeners and catalysts and pumps the mix through a flexible hose.", "A worker uses the hose to fill the molds to the brim with the orange fluid.", "She then sends them into the oven, where they'll spend 30 minutes curing at about 300 degrees fahrenheit.", "On the other side of the oven, a worker removes the molds from their frames and then releases the newly formed hammers.", "Thanks to a special release agent that was sprayed inside the mold, the hammers come out easily.", "At the finishing station, workers use a high-speed circular brush to remove the excess material, or flash, produced by the molding process.", "This is the most difficult operation in the making of dead blow hammers, and these workers are highly skilled.", "When molding ball-peen hammers, the front and back of the head are left exposed.", "For performance reasons, this steel is not stainless.", "Workers dip the exposed steel in hot wax.", "The wax coating will protect the hammer from rust until it's taken off the store shelf and put to use.", "Soft-faced ball-peens and sledges are among the 20 models of dead blow hammers manufactured here.", "A worker attaches a label which includes all the relevant information and warnings.", "The labeled hammers then go in a box ready for shipping.", "Dead blow hammers have many applications, from food processing plants to woodworking shops to the oil industry.", "Some surgeons even use them to drive artificial hips into place." ]

{ "things": [ "Engine Blocks", "Jawbreakers", "Drum Shells", "Drums" ] }

[ "Today on \"how it's made\"...", "Engine blocks...", "Jawbreakers...", "Drum shells...", "And drums.", "The engine block is the largest single piece of metal in a car and also one of the most intricate.", "It houses and links all the engine components, such as the cylinders and pistons, and it contains passages for circulating coolant.", "The engine block is where combustion converts into mechanical energy that drives the transmission, propelling the car.", "Engine blocks used to be made of iron.", "Today, most are made of lightweight aluminum alloy for fuel efficiency.", "An engine block is a one-piece component cast from a sand mold.", "To make the mold, the factory mixes glue...", "And a hardener...", "With zircon sand.", "This combination of materials can withstand the intense heat of molten metal, but only for one casting.", "Each mold is made up of sections called cores that fit together.", "To make each core, a machine blows the sand-and-glue mixture into a master mold made of iron.", "It injects a gas that activates the hardener, which solidifies the mixture.", "This is the base core to which other cores will attach.", "The base core travels down an assembly line to receive the other cores.", "The next core molds the engine-block cylinder bores, which will house the motor's pistons.", "A robot inserts iron liners into six holes in the core.", "They prevent the aluminum walls of the bores from wearing out from abrasion.", "The base core receives 17 other cores.", "The ones for engine-block areas through which oil will flow are coated with talcum powder.", "This keeps sand particles from sticking to the aluminum and getting into the oil.", "The machines glue certain cores so they'll stay intact when the robots flip them upside down and attach them to the rest.", "These are the last two cores.", "The mold is now fully assembled and ready for casting.", "Workers load aluminum ingots into a device called an elevator bucket.", "It positions them above the jet melter-- a gas-fired furnace.", "The bucket drops the ingots into the fire that's 1,500 degrees fahrenheit, liquefying the aluminum.", "Just before casting, they heat the cylinder-bore liners using high-frequency electric current.", "Aluminum will bond better to hot metal.", "They fill the molds from the bottom to avoid contaminating the metal with aluminum oxide.", "Oxide forms when molten aluminum comes into contact with the air.", "Pouring into the top of the mold would expose the metal to oxygen, and the pouring action itself would mix in the oxide.", "After the casting, the mold spends six hours in what's called a thermal sand reclaim oven.", "That breaks down the glue so the sand falls away.", "The heat also strengthens the metal.", "The cast aluminum engine blocks emerge, needing just some minor finishing.", "Robots turn them upside down to spill out loose sand.", "Machines saw off the risers-- extra metal that fed the mold cavity to compensate for the 7% shrinkage that occurs when liquid aluminum solidifies.", "Finally, computer-guided tooling equipment performs a rough machining of the metal.", "This brings the engine blocks to a near-finished state.", "The engine plant that buys them does the final machining before installing the engine parts.", "Every engine block this factory produces passes through an automated vision system that inspects the engine block to ensure they have no defects whatsoever.", "Jawbreakers, also known as gobstoppers, have preoccupied candy lovers for decades.", "You pop one in and slowly suck or chew through up to 10 layers of colors and flavors.", "Sometimes there's bubble gum in the middle for an even longer-lasting finish.", "The larger ones are just for show.", "Most jawbreakers are about the size of a golf ball.", "To make their bubble gum centers, a worker blends synthetic rubber with powdered resin, which will dissolve the rubber.", "He adds a thickener, a preservative, and an oil called soya palm stearin so the candy won't stick to your teeth.", "After mixing and steaming at 300 degrees fahrenheit for four hours, the batter pours into trays to cool.", "Sugar, coloring, and flavoring would deteriorate in the heat, so workers add those later.", "There's enough of this base to make gum centers for 450,000 small jawbreakers.", "After 24 hours, the batter is hard.", "Workers chop it up and blend it with corn syrup to make it softer and sweeter.", "They add just under 100 pounds of finished gum that didn't make it into jawbreakers before because it wasn't the right shape.", "Now they add natural and artificial flavors, which can include lemon, orange, strawberry, grape, even tutti-frutti.", "Then they add icing sugar.", "It makes the gum smoother to chew than regular sugar would.", "Workers dump the batch into an extruder that shapes two continuous streams of batter, called rope.", "Another extruder divides each rope into six hollow tubes.", "The cavity inside will become pockets of air inside the gum centers.", "The next machine slices the tubes into segments that are three feet, three inches long.", "A mechanical arm pushes the segments into the channel of a forming machine.", "Steel rolls then slice through the tubes and shape them into balls.", "The balls range in diameter, depending on the size of the jawbreakers being produced.", "Air blows through perforations in a cooling tunnel to cool and firm the centers.", "Then they fall into another forming machine, which restores their round shape.", "Other jawbreakers have hard candy in the center.", "The machine that makes them works like the presses drug companies use to make pills.", "It feeds candy powder into dies, then applies up to five tons of force to compress the powder into a solid candy.", "Now for the rest of the jawbreaker.", "First, they dump the candy centers into what's called a coating pan.", "They add a hot mixture of water, corn syrup, and food coloring...", "Then dextrose, a type of powdered sugar.", "The pan rotates for 20 minutes as warm air dries the ingredients over the centers.", "The factory repeats this step 10 times for each layer.", "Talk about a sweet ordeal-- making a jawbreaker takes four days.", "Workers give this batch special treatment.", "They speckle these jawbreakers with different colors, giving them what this company calls the psychedelic look.", "After letting the candies dry for 24 hours, a worker adds pinches of powdered carnauba wax.", "This gives the jawbreakers a shiny finish.", "Sliced open, you can see these jawbreakers have 10 layers of flavors and sugar surrounding either hard candy or bubble gum cores.", "They measure 2 1/4 inches in diameter-- as big as a billiard ball.", "And if you're counting calories, forget it.", "A jawbreaker is 90% sugar.", "Almost every culture has used drums in some way.", "Drums have been a part of different civilizations for thousands of years.", "The earliest drum shells were hollowed-out logs or gourds.", "Different sizes created different sounds.", "Today, drum shells are more sophisticated and consistent.", "To make drum shells, they slice an enormous rock maple log into several boards.", "Maple is ideal for making drum shells because its hardness allows sound to resonate fully.", "Each of these maple boards will be transformed into one drum shell.", "Workers feed the boards to a ripsaw, which cuts them to the correct width.", "This varies depending on the size of the drum being made.", "Then each board goes into a planer, which shaves it thinner.", "A worker aligns the board with markings on a saw table.", "This positions the board to be cut to the correct length.", "A radial arm saw does the job neatly.", "Now he sizes up each board in preparation for tapering.", "He places a board on an angle in a jig and then moves the end against a router cutter to taper it.", "It takes a few passes to get it just right.", "The taper needs to be about six inches long.", "He thins the other end of the board to the same dimension.", "These tapered ends will make it easier to bend the wood into a drum shape later.", "They'll also act as scarf joints which will fasten the ends of the board together when it's bent round.", "But first this board needs some softening up.", "An hour in the steam box does the trick.", "It's pliable enough to wind around a hot cylindrical form.", "Steel banding secures the board to the bending form, where it will spend 10 to 15 minutes.", "A worker pries apart the ends...", "And applies a generous amount of glue between the tapered tips.", "Then he removes the shim that was holding the ends apart, so that they stick together.", "He places a wooden guard over the glued joint.", "This nylon mesh band is a clamp.", "He wraps it around the drum shell and turns a screw to pull the band tightly around the wood until it reaches 14 inches in diameter.", "Then he fastens over a dozen steel clamps onto the joint.", "All these clamps will prevent any gaps from occurring in the joint as the glue sets overnight.", "With the joint sealed, the drum shell now spins while a cutter shaves down the edges to make it a true round shell.", "Then they bring in another cutter.", "It bores into the shell, making a smooth edge and rounding the inside.", "He turns the drum shell around to cut it from another angle.", "As the shell spins, a high-speed cutter shaves the outside from top to bottom.", "This makes the surface very smooth.", "It takes about a week to make a drum shell from solid wood, and it will be able to stand up to some loud playing.", "There's more than one way to beat a drum, and there's more than one way to make one.", "Earlier, we showed you how they create a drum shell from a maple plank.", "But a newer technique involves layering multiple plies of wood.", "This process is called laminating, and you can hear the difference.", "The laminated drum is an instrument of change.", "Its sound is crisper than a drum crafted from a single piece of wood.", "To make one, they layer 11 sheets of maple.", "Here, a worker glues on the final ply using a special adhesive.", "This outer layer is a luxurious bird's-eye maple.", "Rollers press all the layers together to ensure they stick without any gaps.", "Then they cut through the overlap to create a perfect seam.", "A robotic drill now takes over.", "It drills holes of various diameters.", "The small ones will hold hardware.", "This larger one is an air vent.", "A computerized router then cuts the bearing edges to a 45-degree angle, and a worker sands it smooth.", "He uses a level surface to ensure that all the edges are perfect.", "If they're not, the drumheads won't fit properly.", "He applies an adhesive to the air hole and inserts a plastic vent.", "Next, he inserts brackets, called lugs, into the other holes and screws them in.", "There are 10 lugs, spaced 36 degrees apart.", "They'll hold the rods that will attach the heads to the drum shell and also enable the drummer to adjust the tension on the heads.", "Here he attaches a lever to control wires, called snares, that are to be strung across the bottom head.", "It's called a snare strainer.", "Then he fits a plastic drumhead over the bottom of the shell.", "The counter hoop goes on next.", "It has little tabs which he aligns with each lug.", "He slides tension rods into the holes in the tabs.", "Using a drum key, he tightens the head to an even tension across the shell.", "Now he blasts it with a heat gun to shrink the plastic and remove any wrinkles.", "Now he places another plastic head on the top bearing edge.", "Since this head is the one that gets played, it's twice as thick as the bottom one.", "He places the chrome rim on it and tightens the tension rods.", "These brass brackets will hold the snare wires.", "He slides them under the snares that are stretched tightly across a jig, putting one at each end.", "He measures the length, then solders the snare wires to the brackets.", "He snips the wires on both ends...", "And unlocks each wire from the holding device.", "When he removes the snares, they're held together by the brackets.", "He slides a nylon strap into one of the brackets, then attaches the strap to a fixture just above the bottom head.", "The other end of the snare is attached to the strainer-- the lever that will apply tension and release it, controlling its distinctive buzz.", "For a bigger sound, there's the bass drum.", "It's made with wooden hoops.", "They attach the hoops to the drum shell with steel claws.", "As they screw the claws to the hoop, the drumhead is pulled just tightly enough to produce that low-pitched bass drum sound.", "Now it's off to be played." ]

{ "things": [ "Firefighter Helmets", "Nautical Compasses", "Packaging Tubes", "Hand Saws" ] }

[ "Today on \"how it's made\"...", "Firefighter helmets.", "Nautical compasses.", "Packaging tubes.", "And handsaws.", "In the early 1800s, luggage maker henry gratacap created one of the first firefighter hats.", "The leather helmet had a long rear brim and curved sides as a shield against falling debris and water running down the neck.", "Except for a few high-tech additions, this basic design is still used today.", "Leather is surprisingly flame-resistant.", "When reinforced, it also becomes a remarkable hard hat, protecting from heat, liquids, and sudden impact.", "On this newer model, the accessories shield the eyes and ears, too.", "A helmet starts with four die-cut leather sections.", "They sew them together to make what's called the skull of the helmet.", "This piece will become the brim of the helmet.", "To give the skull structure, a worker folds and sews each section, then flattens the crease with a special hammer.", "He uses a template to score a sewing line in the leather.", "Then he uses a powerful sewing machine to join the sections together.", "He now joins the two halves together, reinforcing them with double stitching.", "The resulting eight ridges give the skull stiffness and strength.", "He stretches the leather over a plastic mold and trims excess leather from the ridges.", "Then he clamps four vise grips to the rim.", "These attach to a hydraulic jack that stretches the skull overnight.", "After applying glue to the ridges, he runs them through compression rollers for a tight bond.", "They wet the brim piece several times to make it more pliable.", "Then they stamp it with the design used by this company since 1846.", "But first, a worker inserts a wire that will give the brim some structural support, then a temporary plastic cover and a lid to ensure an even spread of pressure across the brim.", "She stuffs the edges of the leather inside before the press applies 10 tons of force to imprint the design.", "Next, a worker sews the skull to the brim.", "He removes the excess leather at the base of the skull...", "And cuts out the center of the brim.", "Then he removes the plastic mold.", "To seal the leather, they dip the hats in a vat of hot rosin, a type of tree sap.", "After 55 minutes, they remove them and let them dry at room temperature for eight weeks.", "This slow-drying process makes the leather about as hard as wood.", "Drying it mechanically would make it brittle.", "Now for the inside.", "They insert a plastic cap to reinforce the structure.", "The fit is intentionally tight, so they use a mallet to tap it into place.", "Inside that they add another plastic cap with nylon straps to resist the impact of falling objects.", "Here a worker uses an acetylene torch to burn off any loose threads and soften the leather in order to bend the brim and straighten the ridges later on.", "Turning up the sides is basically for aesthetics, but the longer edge in the back is to direct water away from the neck.", "After adding a synthetic, fire-retardant liner, he sands the outer surface to prep it for painting.", "First, a fire-retardant chemical primer.", "Then they use a semigloss latex paint in firefighter's black or white for the chief...", "Or, if you prefer, a clear varnish to show off the natural leather.", "Add a front piece with the firefighters' signature brass eagle on top and some fluorescent stickers for extra visibility, and you've got the right headgear for a hero's job.", "For more than 1,700 years, the compass has been helping people find their way.", "It was first developed in china, but when the far east met the far west, european sailors adopted the technology, using it to chart their own courses.", "To make a nautical compass, they use this device to magnetize a special metal alloy.", "A technician slips a retainer ring onto a jig and positions the magnet on top of it.", "She places an aluminum skirt over the magnet.", "This will support the compass dial, which goes on next.", "She inserts a pivot needle in the center, which will allow the dial to rotate.", "Then she press-fits all the pieces together.", "She carefully inspects the fit, and it looks solid.", "She sprays a chemical cleaner into the pivot cavity.", "It has to be spotless because any dirt would impede its function.", "She also cleans a little jewel post that contains a tiny sapphire.", "Then she fixes the jewel post in the dial.", "The jewel post will support the dial while allowing the pivot needle to move easily as it's pulled by magnetic forces.", "She places the dial on a machine that mimics the earth's pull.", "It's a crucial step because magnetic force varies depending on where you are in the world.", "She brushes a weighted paint onto the back of the dial to counteract the pull.", "This balances the compass dial, preventing false readings due to differences in the planet's magnetic force.", "These are lubber lines-- little direction markers.", "She inserts them into holes in a jig.", "Then she lines them up with holes in an aluminum gimbal pan and press-fits the lubber lines to the pan.", "Now she inserts two pins into the gimbal ring that allow the ring to flip around the gimbal pan.", "Then she attaches the compass dial to the gimbal assembly.", "The technician spray-paints the metal compass bowl black and pops a rubber diaphragm into it.", "A bronze ring will hold it in place.", "This flexible rubber liner will contain the compass fluid and allow it to expand and contract.", "She snaps the dial and gimbal setup to the bowl.", "She just has to bend a little tab to level it out.", "She positions an acrylic dome on top.", "Using another jig, she puts a rubber o-ring over the dome to seal it, followed by a metal collar.", "With a power screwdriver, she anchors these pieces to the rest of the compass.", "Then she pumps fluid into the bowl, filling it right up to the dome.", "The fluid makes the numbers on the dial look bigger.", "Next, they magnetically charge two metal rods and install them in a compass base.", "They'll compensate for magnetic fields on the boat.", "She mounts a big metal housing unit on the base.", "Then she attaches shock absorbers to cushion the compass against engine vibrations.", "She installs the compass in the housing and taps the dome to test the shocks.", "A decorative aluminum cover fits around the dome.", "Then she installs a light to allow the navigator to see at night.", "She attaches iron spheres, another tactic to counter magnetic interference.", "Our journey through the plan is now over, and the compass is ready to be used.", "Artists first used flexible metal containers for their paints back in 1841.", "Nowadays, we use them for a range of things, like toothpaste, glue, and skin cream.", "The tube's design lets us squeeze out most of the product and yet still read that important fine print on the twisted package.", "These packaging tubes are made of aluminum because it's affordable, lightweight, and malleable.", "This company makes each tube from an aluminum slug about the size of a coin.", "A worker dumps a batch of slugs in a container, then adds a lubricating powder called zinc stearate.", "The container spins, causing the powder to coat the slugs evenly and prep the metal for stretching later on.", "The slugs then spin around in another container, which orients them horizontally so they'll fit through a channel at the bottom.", "The channel feeds the slugs into a forming press.", "In a process called impact extrusion, each slug moves onto a die, which gives it the exterior shape of a tube, including the neck.", "At the same time, a mandrel forms the interior.", "This process hardens the metal, something they'll correct later on by heating it.", "The machine applies 200 tons of pressure to as many as 150 slugs per minute.", "They can be as narrow as a half-inch and as long as 8 1/2 inches.", "This machine uses compressed air to align the tubes for the next step.", "A trimming machine cuts threads into the necks by passing each one between two synchronized rollers.", "Stationary blades trim the top of the neck, making the surface smooth and safe to handle.", "The neck on most models remains sealed until the consumer pierces it.", "Another company eventually seals the tube by rolling up the other end after they've inserted their product.", "After heating them to soften the metal, the tubes move through another machine.", "Here nozzles spray the inside with two coats of epoxy lacquer.", "This creates a protective barrier between the aluminum and the eventual contents.", "Rollers apply a coat of polyester enamel paint, which is flexible when dry and resistant to most solvents and sun damage.", "Grippers place the tubes on long pins, which move them through an oven for seven minutes so the paint can dry.", "From there, it's off to the printing machine.", "Each tube makes one complete rotation against a printing plate.", "The plate applies a colored image and information that describes the tube's contents.", "Then they go back in the oven to dry the ink.", "The printing's legible even when twisted because the polyester ink remains flexible.", "Another machine applies 2.2 pounds of torque to screw on the plastic caps.", "Most of the caps have pointy tops, used to pierce the sealed neck of the tube.", "They use flat caps to close off tubes with open necks.", "On the next machine, nozzles spray on a strip of latex sealant inside the open end of the tube.", "The latex is like a gasket.", "After the product is inserted, it seals the tube when they fold the end over.", "After a machine packs boxes with an average of 300 tubes each, a worker inspects the inside of every tube.", "A bright spotlight reveals any chip in the paint that makes the packaging deficient.", "About one in every 500 tubes is flawed.", "A sheet of sticky paper over the open ends of the tubes keeps them from twisting during shipping, and a label on the box provides tracking information and a way to show if someone has tampered with it en route.", "Empty, each tube sells for about 12 cents each, a great bargain for such a useful item.", "Even though it was invented thousands of years ago, the handsaw is still used today.", "You'll find it at every building site, always at the ready.", "Power tools are higher-tech, but the handsaw has a basic appeal.", "It doesn't need an extension cord and almost never breaks down.", "It's a time-tested building tool.", "Handsaws come in many sizes.", "To make them, a machine uncoils steel and draws it into a mechanized punch.", "The punch works at a blurring speed to cut teeth in the steel-- 140 notches per minute.", "Here it is in slow motion.", "It makes two cuts for each sawtooth.", "A reel takes up the newly serrated steel and then will feed it back to cut teeth on the other side.", "Next, a fingerlike device unrolls the steel and pushes it to automated jaws.", "The jaws bend the teeth, alternating the direction of each one.", "Here's a slow-motion look.", "This is called setting the teeth, and it will allow the handsaw to operate smoothly.", "Now a die punch cuts the steel coil into pieces called double blanks-- double because two saw blades will be made from them.", "The die also makes holes in one end of the double blank for attaching handles.", "They feed the double blanks to a sheer machine.", "A long blade descends and cuts it in half on the diagonal, making two saw blades.", "Finally, they press the saw blades up against a sand belt to smooth out the edges.", "This is called deburring.", "Here they're making a higher-end saw blade.", "They flush a piece of steel with coolant as a machine plunge-grinds it to make teeth.", "This method is more time-consuming but results in a superior tool.", "Again, they set the teeth, but this time, mechanical jaws do the job a blade at a time, rather than working on one long coil of steel.", "The sawteeth will need to be strengthened in order to perform, so rollers move the blades to an electrical coil.", "Within milliseconds, the temperature of the blade shoots up to 1,600 degrees fahrenheit.", "This tempers the steel.", "The blades drop off the conveyer into a bin.", "Here's a look at a blade before heat-treating.", "And this is after.", "The black burn line is a sign this saw can take the pressure.", "A conveyer wheel dunks them in a pool of clear protectant.", "This will keep them looking shiny.", "When they're dry, the blades undergo a trademark technique.", "They place one on a table.", "It rises and a squeegee silk-screens the company name onto it.", "At this point, the ink is still wet.", "They spend 30 seconds in an infrared oven-- enough time to bake on the brand name.", "They slide cardboard sleeves over the blades, and now it's time to attach the handle.", "A worker fits two plastic parts together and places them on a carousel.", "An ultrasonic sealer moves in.", "It emits a high-frequency sound, and the vibrations melt the two plastic pieces together, forming a handle.", "A worker fits the handle onto a blade, and a machine rivets it in place.", "Some saws have wooden handles.", "Because riveting could split the wood, they bolt it on with screws and rivnuts.", "And now you have the finished product." ]

{ "things": [ "Aluminum Screw Caps", "Chocolate", "Pills", "Pasta" ] }

[ "Today on \"how it's made\"...", "Aluminum screw caps-- we'll pop the top off this manufacturing secret.", "Chocolate-- there's nothing like the taste of sweet success.", "Pills-- watch as directed.", "And pasta-- we'll visit a factory that churns out oodles of noodles.", "Twisting off an aluminum screw cap may lack the style and sophistication of uncorking a fine bottle of wine.", "But as devices go, these caps are one of the easiest ways to put an airtight seal on a bottle or jar, and the added bonus is that they're entirely recyclable.", "There are hundreds of everyday objects that are capped.", "This plant makes 250 million metal screw caps yearly in 12 different sizes.", "The caps are made from these 11-square-foot sheets of aluminum weighing one pound.", "Some 3,500 thin aluminum sheets pass through this feeder.", "They begin by coloring the aluminum sheet with a colored varnish-- a lacquer and an ink.", "Then 12 minutes of drying is needed.", "The colored sheets set off on a conveyor for drying.", "Then designs are produced.", "The coloring is applied by this varnisher.", "The aluminum sheets pass through the varnisher one at a time.", "Here we see the sheet printed.", "Above are the colors used.", "They are highly colored inks that adhere well to metal.", "Suction cups grab the sheets and send them toward the transport system of the punch press.", "This press will give the caps the required shape.", "But the caps have to be machined in successive steps by molds, such as this one.", "The punches first cut the caps.", "Over 500 caps a minute can be produced.", "The blades of the punches are made of carbide, a very hard metal that can cut tens of millions of caps.", "At the exit point of the punch press, the caps are formed, but don't yet have the right dimension.", "This stretching press performs the last two cold-forming steps so that the tube will have the required length.", "Now for the second stretching.", "This achieves the desired diameter.", "When the cap exits the press, it will finally have the desired dimensions.", "At this point, the cap now has the required shape.", "The caps now have to be decorated to the client's requirements.", "The lateral imprint is made with this silk-screen-type decorator which colors some 100 caps in 60 seconds.", "The decorator uses an ink specially formulated to adhere to metal.", "The caps will then dry in a warm-air oven.", "The dried caps are ejected and fall into a container.", "This other flexographic type of decorator prints 155 caps a minute.", "We can clearly see the ink roller, which imprints the side of the caps as they rotate against it in a steady stream.", "All that's required now is to form the cap and make the cut.", "The profiling and jointing machine makes the cuts and reliefs on 200 caps per minute.", "Machining the cap takes but a fraction of a second.", "They sometimes have to assure the watertightness of a container such as a wine bottle.", "For this, a polypropylene liner is inserted, which hermetically seals the container.", "A check is carried out under a light to verify whether the cut has been properly made and the ridges well-formed.", "At last, the final steps-- this screw-tightening machine hermetically seals the caps onto the bottles.", "The 250 million screw caps made here each year call for the machining of 1,000 tons of aluminum.", "Working in a chocolate factory-- talk about a childhood fantasy.", "Well, \"how it's made\" is about to take a bite out of one of the all-time great dream jobs.", "Just beware of the occupational hazards-- stomachache, weight gain, and cavities.", "These delicious chocolate confections are made from melted chocolate flowing into molds.", "The master molds are first made of wood or plaster of paris.", "They are then reproduced as copies in an epoxy material.", "To allow them to become flexible and give them the desired shape, the sheets of epoxy are first heated to 350 degrees.", "The epoxy sheet is then placed onto the original molds.", "The sheet is heated, then lifted off.", "Suction from a vacuum system makes it adhere perfectly to the shapes of the molds.", "Here we see the epoxy adhering to the master molds.", "Still hot and malleable, the plastic has to be cooled.", "A jet of compressed air effectively lowers its temperature.", "The mold undergoes a visual inspection to make certain of its quality.", "And now we move on to the chocolate.", "This melting unit, whose shell is fed by boiling water, is like a double boiler and melts 1 1/2 tons of chocolate in 12 hours at about 100 degrees.", "The ready-to-be-filled plastic molds are placed onto a conveyor.", "Filling is done automatically.", "Liquid chocolate runs directly into the molds.", "This particular machine produces 400 hearts a minute.", "The hearts are filled with a concoction of chocolate, cream, and coffee that has been brewed for several minutes.", "It takes 20 minutes for the chocolate to set as the molds move along on this 9-level conveyor.", "Well-hardened, the hearts arrive at the unmolding point.", "The molds are turned over, and a rod lightly taps them on the bottom to allow the chocolates to fall out without being broken.", "The chocolates fall out onto a sheet.", "As soon as they've been emptied, the molds return to the starting point on the line to be newly filled.", "During their transport on the line, the chocolates complete their cooling and hardening.", "Now they're going to be prepared for packaging.", "Packaging depends on customers' preferences.", "The chocolates can be sold in bulk or placed in boxes.", "Here, 185 hearts are put into each box.", "Like the pure chocolate, white chocolate comes in as slabs before melting.", "Milk chocolate is often delivered in the form of one-inch pastilles.", "Some chocolates are hollow.", "They have to be molded in two halves.", "These chocolate bears need special decorations applied by hand before the pouring of liquid chocolate.", "This decoration is made of white chocolate with an added colorant.", "In just one hour, they will make 1,200 bears.", "They're made by joining two hollow chocolate halves.", "The assembly is done using a refrigerated rotating machine.", "This machine turns the molds a full 360 degrees on two axes and vibrates the chocolates to prevent the formation of air bubbles.", "The chocolates rotate for five minutes before being sent to the cooling conveyor, where they will remain for another 20-minute period.", "And now they're ready.", "At this point, the bears are unmolded, and they head off for packaging.", "Each year, this company processes 550 tons of pure chocolate.", "Many thousands of products are made here using 400 different molds in a variety of sizes.", "Now, here's a topic that's easy to swallow-- how drug companies make the pills we take.", "It's a carefully-monitored process in which quality control is paramount.", "So stand by-- we're going to give you a taste of your own medicine, or at least what goes into making it.", "Medications are essential in the treatment of illnesses.", "It begins by a grinding process where the active ingredient in a tablet or pill is ground and mixed with a binding agent.", "The quantity of the ingredient needed to be ground is transported to the dryer in this container.", "Like all the other equipment, this container is made of stainless steel so as not to contaminate the product.", "The temperature of the dryer and the airflow are programmed with this interface.", "The granulation has to be dried at around 100 or 120 degrees before being shaped into the desired tablet form.", "Molding of the pills is done by this press, which crushes the powder.", "The press exerts a pressure varying between two and five tons.", "Here's how the molding is done-- the press magazine distributes the powder in molds made of steel disks.", "Two stampers, one above and the other below, crush the powder and form the pill.", "Here the press operates at full capacity.", "It can produce 5,000 pills per minute.", "Quality testing is carried out on 5 pills every 15 minutes.", "Their hardness is verified with this apparatus in which jaws crush it with a force varying between .", "3 and 3 psi, or pounds per square inch.", "The pills must now be coated so that they won't crumble.", "A coating solution made of water and coloring pigments is used.", "This is the coating unit.", "It can hold 350 pounds of pills.", "Three plastic tubes, strategically positioned, will spray the solution onto the pills in motion.", "The quantity of dry pills to be coated is put into the unit.", "Then the door of the coating unit is carefully closed.", "A drum turns inside the unit, tumbling the pills.", "Then nozzles spray the solution in the form of a mist that quickly dries, preventing the pills from sticking to one another.", "This spraying operation lasts 40 minutes.", "Here we can compare pills.", "On the left are those made only of powder, while on the right are the spray-coated ones.", "The finished pills move down a chute to enter a counter prior to filling bottles.", "They are lined up in grooves to make filling easier.", "The quantity of pills to be placed into bottles is controlled by this automated unit connected to the counter.", "In this instance, 500 pills are poured into each bottle.", "This plant also makes capsules where the ingredient is not crushed, but encapsulated in a gelatin casing.", "The distributor places the two halves of the capsules in the proper position for filling, with the wider half situated above.", "The top and the bottom portions of the capsule are separated.", "The lower half is then filled with powder.", "When well-filled, the two halves of the capsule are joined together.", "The completed capsules are then ejected from the filling unit.", "Then, via centrifugal force, they are positioned for the packaging process.", "The weight of each capsule is verified by this counter.", "Each capsule must have the precise weight.", "The final step is packaging.", "A sheet of transparent pvc is heat-embossed, forming an impression to receive capsules.", "Then a preglued aluminum foil sheet is adhered to the back side, sealing everything in.", "This plant turns out millions of pills and capsules every year.", "Ever since marco polo brought the noodle back from china some 700 years ago, pasta has earned its place on tables around the world.", "Pasta comes in an array of shapes and sizes, like the diehard pasta lovers who just can't seem to get enough.", "Pasta is actually chinese in origin.", "When marco polo returned to venice in 1295 after spending 24 years in the far east, he brought back with him chinese pasta noodles.", "Pasta became popular so quickly that by the 15th century, it occupied a prime position in italian cooking.", "In this same era, commercial production began in naples.", "Italians today favor macaronis and raviolis with garlic and cheese.", "Pastas are generally made from semolina and water.", "These silos contain more than 33 tons of semolina, derived from durum wheat.", "The semolina heads toward the high-speed premixer, where it will be vigorously mixed with water for 5 to 10 seconds.", "This machine can treat between one and two tons of semolina per hour.", "The dough is extracted from the premixer and falls into a first-blade mixer open to the air.", "Then the dough goes into this vacuum-blade mixer.", "The mix is now ready to go through the brass molds.", "Here's a spaghetti mold and a mold for mafalda-- very narrow lasagna.", "Here are molds used to make lined shells...", "And stars for soups...", "As well as cresto di gallo.", "The dough is injected into the mold under pressure.", "This rotating blade machine cuts some 12,000 rotinis per minute.", "That's 720,000 per hour.", "With the dough being still quite fresh, the rotinis are soft.", "They will dry somewhat on this plate.", "Now we move to the lasagnas.", "The dough goes through this brass mold, and the strips of fresh dough, 42 inches long, are placed on these sticks to dry at 150 degrees.", "They dry vertically so as to retain their nice, flat shape.", "After drying for 15 hours, the strips are then cut in four-- thus making four strips measuring about 10 inches each.", "To minimize losses and make cutting the dry lasagna easier, scissors trim the dough pieces into equal lengths on the sticks.", "The long lasagna-drying process begins.", "Once dry, the lengths of lasagnas are finally cut.", "They're now ready for packaging.", "To make some of the other pastas, the mix has to be worked a bit more in order for it to have the required shape.", "The dough goes through this roller, which gives it the desired thickness.", "And now butterflies are formed.", "This mold cuts 7,500 of them a minute for a total of 450,000 an hour.", "The sheet of dough is two feet wide.", "It is produced in a steady stream and goes right to the cutting mold.", "The butterflies fall onto this conveyor to dry somewhat.", "Then they head toward the next production step.", "Certain short pastas, such as these butterflies and fusillis, have to be dried, so they're then put into this full dryer.", "Coming out of the dryer, the pastas are hard and ready for packaging.", "Here we see the ever-popular spaghettis being made.", "As with lasagnas, spaghettis are also dried vertically.", "Now this automated machine places the spaghettis onto a cutting table and breaks them to the proper length.", "The spaghettis are now ready for packaging.", "Exact quantities to be bagged are determined by computer.", "Then the spaghettis go gently down the chute.", "The amount of spaghetti going into each bag is transported and emptied out by this moving container.", "To make filling easier, the spaghettis are properly positioned by this chute.", "In just one minute, this machine can package 10 8.8-pound bags.", "Whenever needed, it can handle up to 60 bags a minute.", "Pastas are a favorite meal the world over.", "This plant makes over 100 different products and every day uses between 60 and 360 tons, or between 2 and 12 truckloads of semolina made from hard wheat." ]

{ "things": [ "Old West Holsters", "Underwater Video Housings", "Soy Beverages", "Pet Nail Trimmers" ] }

[ "In the days of the american wild west, you didn't leave home without a gun.", "Both the sheriffs and outlaws carried guns and ammunition.", "It was important to have your gun easily accessible.", "Wearing a holster around the waist putts a gun in the perfect position for a quick draw.", "These handcrafted leather belts and holsters are modeled after those made in the late 1800s.", "They're made for movies, cowboy shooting competitions, and historical reenactments.", "A craftsman starts by using a press and a series of dies to cut out out the holster and belt components.", "This is vegetable-tanned leather, the only type of leather that's flexible enough to carve or stamp.", "He lays a paper template over one end of the holster piece and marks tiny dots with an awl.", "He connects the dots with a straight line using a small knife.", "He punches a hole at each dot.", "The lines and holes form two wide loops.", "Next, he carves a groove for stitches along what will be the main seam of the holster body.", "He sprays water onto the leather to soften it.", "He makes decorative lines with a compass.", "Then, he imprints a design into the leather by striking a stamp with a mallet.", "Because the leather is moist, it compresses easily, assuming the shape of the stamp.", "These stamps are modern-day copies of the ones used in the late 19th century.", "A rosette is a common motif of that era.", "He uses one tool for the outline, one for the petals, and another for the center of the flower.", "Then, he adds details with a small chisel-edged knife and stamps on his maker's mark.", "He shaves any sharp corners and smoothly finishes the edge.", "The holster piece is now cut, embellished, and finished.", "The next step is to sew it.", "He marks the stitch holes across the bottom where he will later sew the toe plug.", "Then, he pierces the holes with an awl.", "He soaks some sheep's wool in neatsfoot oil and rubs it in.", "This nourishes and conditions the leather, preserving the impressions and enhancing the color.", "Once the oil is soaked in, he applies a smoothing solution onto the edges and rubs them with a piece of canvas.", "Now the sewing can begin.", "He folds one end of the holster piece to form a pouch.", "Then, he sews inside the groove he cut for the main seam.", "Stitches sunken in a groove are far stronger than surface stitches.", "When he completes the seam, he burns the end of the polyester thread with a lighter.", "Then, he sews on the toe plug and inserts the pouch into the double loops at the other end of the piece.", "Next, he works on the belt.", "After piercing stitch holes in the main belt strip, he sews on a thinner, flexible strip, bending it into loops to hold ammo.", "He glues on a leather lining to make the belt more durable.", "Then, he sews on the billets.", "They're the pieces that go on each end of the main belt strip.", "One billet has the buckle, and the other has the adjustment holes.", "After applying some decorative nickle studs known as spots, he threads the belt through the holster...", "And inserts the ammo.", "This double-loop holster is a copy of an 1880s holster designed to hold a single-action army pistol.", "The craftsman can make several different authentic styles from this era, customizing the holster to carry a weapon of any size or shape.", "From ocean wildlife to shipwrecks, the undersea world is breathtaking.", "Many recreational scuba divers want to capture what they see on video.", "They can do this with an ordinary video camera, encased in a specially designed watertight housing unit.", "This underwater housing has remote camera controls and a built-in monitor that shows you what the video camera sees.", "At the factory, a computer-guided mill uses a variety of bits to shape a tube of extruded aluminum.", "The machine prepares the ends to receive front and back pieces.", "It forms a groove for a rubber o-ring to keep water out and makes attachment points on each side of the housing for handles.", "Then, the mill cuts the front and back pieces out of two blocks of aluminum.", "The machining process leaves tool marks, so they polish the housing parts by putting them in a tumbler full of ceramic stones.", "After about an hour of rubbing against the stones, the aluminum is smooth and ready to be anodized.", "This process etches, dyes, and seals the metal surface, protecting it from the corrosive effects of salt water.", "Next, a computer-guided laser etches in the manufacturer's logo.", "Laser etching is far more durable than printing because it bleaches the black anodized surface white so the lettering can't rub off over time.", "Several parts of the housing are made of plastic.", "Workers pour plastic pellets into an injection-molding machine.", "The machine melts the pellets, then shoots the liquefied plastic into a mold.", "After about 15 seconds, the machine opens the mold and ejects a newly formed part.", "This part is a latch that allows you to open the housing to insert a video camera.", "The handles are made of rubber-covered aluminum.", "Each of its camera-control buttons has an o-ring around it to keep out water.", "The controls are powered by two lithium batteries that sit inside a separate sealed compartment.", "When you press a control button, the post underneath it makes contact with electronics inside.", "This produces an infrared signal that communicates with the camera through tiny glass windows.", "The back of the housing has a built-in lcd monitor, which displays what the camera sees.", "Both the monitor and camera plug into the same circuit board.", "The handles fasten to the housing with a threaded ring.", "There are also holes on top of the housing for attaching a carrying handle.", "Before attaching the front and back of the housing, they apply rubber o-rings to keep water out.", "Then, they install the flip filter.", "It attaches magnetically to a pivot on the inside of the housing and is operated by an arm on the outside.", "This filter is essential because water absorbs certain light wave lengths, eliminating the appearance of red, orange, yellow, and green, depending on how deep you go.", "To restore these colors in the video, the diver flips the filter over the camera lens.", "The factory tests every housing to make sure it's completely watertight.", "The tester inserts a video camera and submerges the housing in a water-filled tank.", "He pressurizes the tank to simulate the underwater pressure the housing will experience at a depth of about 300 feet.", "The housing passes the test only if all the seals hold up and no water leaks inside, ruining the camera.", "In addition to a flip filter, divers sometimes use lights to counter the muting effect that underwater depth has on colors.", "The housing has attachment points on the handles for mounting lights, enabling the video camera to capture the true vivid colors of the undersea world.", "Soy beverages originated in china centuries ago, long before lactose intolerance and dairy allergies.", "Recently, this dairy-free drink has become a popular alternative to milk, allowing people to order a latte, but hold the lactose.", "It's not milk, but it's a good substitute.", "A soy beverage is made from liquefied soy beans.", "It has the look and consistency of animal milk, but is an entirely different product.", "It starts with a specific kind of soybean, one that has just the right amount of protein and carbohydrates.", "They harvest these soybeans when the plants are dry.", "Less moisture means the beans will be less prone to spoiling.", "They dehull the soybeans and crack them into small bits.", "A lift carries the heavy bag of bean bits to a scale to weigh them for processing.", "The operator cuts open the bottom of the bag, releasing the cracked soybeans into a hopper.", "Here, augers move the cracked beans up to two large grinders.", "The system pipes in hot water, and the grinders whip the beans and water into a creamy soy-beverage concentrate.", "The beverage travels through steam-heated pipes.", "This kills off any bacteria that may have come from the field.", "Then, it's into a vacuum chamber for a cooldown.", "Most of the manufacturing equipment is sealed from the air to prevent contamination.", "The soy-beverage concentrate leaves the vacuum chamber and enters a centrifuge.", "It spins out much of the chunky insoluble fiber, leaving smoother, thinner liquid.", "The soybean fiber won't be wasted.", "It will be used in food products and animal feed.", "The soy liquid flows into a big blender.", "They pipe in filtered water, add refined sugar, vanilla extract, as well as various vitamins and minerals.", "He closes the lid while the blender mixes the ingredients into a frothy soy beverage.", "The soy beverage exits the blender and flows into a huge storage tank, where an agitator keeps the various ingredients well-mixed.", "The tank is refrigerated to preserve the beverage while it's held for testing.", "The operator takes a sample to test the consistency and nutritional value of the beverage.", "With his approval, the beverage is released from the tanks.", "It flows through pipes injected with very hot steam.", "This kills off any microorganisms that may remain.", "After a quick cooling, the soy beverage goes into a homogenizer.", "It pushes the beverage through small holes to break down the fat, reducing the size of the particles.", "The soy beverage accumulates in a sterile tank until it's ready to be packaged.", "The soy beverages are packaged without any exposure to contaminants in the environment.", "The packaging material is made of a polyethylene laminate.", "Machinery takes the laminate up to a steel ring that forms it into a tubular shape.", "Hot jaws seal the sides and bottom, then inject the soy beverage and seal the top.", "The cartons land on the conveyor on their side.", "They're liquid-tight so nothing spills.", "Then, a conveyor transfers them to a revolving wheel that turns them right-side-up.", "Now that they are oriented correctly, they ride a windy conveyor to a capping station.", "Plastic caps land on spouts that have been molded to the packages.", "A system of rubber belts screw the caps onto the spouts.", "This packaging can preserve a soy beverage for up to a year.", "It probably won't be on the shelf for that long because someone is always looking for a dietary alternative.", "Dogs and cats have round nails, while humans have flat ones.", "Special trimming tools have been developed to give them the perfect pedicure.", "Guillotine-style clippers have a hole for the pet's nail and a sliding blade that cuts it so the pet will be back on its feet in no time.", "Long nails can damage a dog's foot pads, so they must be trimmed from time to time.", "Pets usually don't like having their nails done, but a guillotine-style trimmer can make the experience less of an ordeal.", "Its sliding blade trims their nails quickly so it's over before they know it.", "Production of guillotine-style pet-nail trimmers starts with a feeder system.", "The feeder system uncoils a strip of steel into a punch press.", "The press cuts out two handle blanks at once.", "It also makes holes for screws and rivets, as well as a hook for a spring.", "A second press rounds the handle to make it easier to grip.", "Here is a large handle before and after the shaping.", "The handle now goes into a third press.", "This one folds the tabs down to create a pocket for the blades.", "Here is a handle before and after this forming.", "Next, a narrow strip of steel unwinds into a press.", "The press cuts and shapes it into the main sliding blade.", "The half-moon-shaped end will be the cutting edge.", "A worker slides the blades onto a rack with the half-moon edge facing downward.", "This makes it easier to load the blades into a grinding fixture.", "She places two in each slot with the half-moon facing up.", "A carriage moves the fixture back and forth under a grinding stone.", "It grinds the entire row of blades at once.", "This improves the strength and sharpness of the cutting edge.", "She inspects every blade to confirm that each one has been ground to the correct profile.", "On the left is a blade before grinding and on the right is one after.", "She dips the blades in a cleaning solution and rinses them.", "This cleaning removes lubricating-oil residue and metal filings.", "She transfers the blades to a perforated tray.", "She spreads them evenly, switches on an overhead fan, and leaves them to dry for several minutes.", "Heat treatment hardens the blades, and polishing finishes them.", "Next up is the retainer blade.", "It's the one with the hole for the nail.", "She arranges the circular blades on a magnetized tray.", "The blades cling to the tray as a carriage moves them back and forth under a grinder.", "The grinding sharpens the front of the blades and removes scale left by a heat treatment.", "This is the retainer blade before and after grinding.", "The pet-nail-trimmer parts are ready for assembly.", "The employee rivets a metal link for the sliding blade to the smaller handle.", "Once the parts have been chrome-plated, another worker hinges the large handle to the smaller one.", "He hooks one end of a spring to the metal link.", "He inserts the sliding blade into the track in the large handle, lifting the link to hook it into the blade.", "He adds the circular retainer blade.", "He places a metal plate over the track and screws it in place.", "This secures the top blade, while allowing the link to move the sliding blade.", "He hooks the other end of the spring to the larger handle and bends the circular blade slightly to give it the correct profile.", "Now a worker tests the trimmer on dried buffalo hide.", "Dried buffalo hide is tougher than pet nails.", "With his okay, this cutting tool is ready for the paws and claws for our furry friends.", "The main blade can be replaced if it becomes dull, which means this pet-nail trimmer can be used for many years to come." ]

{ "things": [ "Matches", "Carousel Horses", "Fine Porcelain", "Automobile Fuel Tanks" ] }

[ "Today on \"how it's made\"-- matches.", "Carousel horses.", "Fine porcelain.", "And automobile fuel tanks.", "Lighting a controlled fire was not always easy.", "Only 200 years ago, you'd rub a rock on steel to create sparks.", "Then a stunning discovery-- that combining certain chemicals can ignite fire.", "It wasn't long before matches were invented, putting these chemicals on handy little sticks.", "Well, nothing quite matches that.", "The first matches left behind a nauseating odor.", "But today, they're safer, and the smell dissipates in seconds.", "To make matchsticks, this company starts with recycled paperboard, which is inexpensive and thick enough to support the weight of chemicals on one end.", "A stamping press partially cuts the paper, creating stems.", "As we see in this view from inside the machine, a die first cuts the stems.", "And then a blade slices through the sheet widthwise, making strips of 120 stems each.", "At actual speed, it's all just a blur, as the press makes nearly 500 strips per minute.", "Next, the strips move through a bath of hot wax.", "It soaks into the stems about 1/3 of the way up.", "Then they dry in an oven for 15 seconds.", "When you light a match, the wax slows down the burn speed of the chemicals, sustaining the flame for four or five seconds.", "Those chemicals are gelatin and silicone-- to bind the chemicals to the stick...", "Potassium chlorate-- an animal protein glue for oxidation...", "Sulfur to fuel the flame, and two fillers.", "They mix 700 pounds of the chemicals in a large vat with hot water.", "This is enough to make the chemical batter for 25 million match heads.", "A conveyor runs the matchsticks through the batter to coat their tips.", "Three rollers in the tank raise the surface of the batter.", "The first two ensure the front and back of the heads get covered.", "The third rotates faster to remove excess batter as the heads leave the tank.", "From there, the matchsticks travel about a quarter mile while fans air-dry them.", "The factory temperature is a comfortable 72 degrees fahrenheit, just what's required for the chemicals to dry and harden.", "These minerals are silica and red phosphorus.", "Add a little glue, and you've got what's called friction-- the material in the strip you rub the match against to make the head ignite.", "To make these striker strips, as they're called, a steel wheel rolls friction onto paper that's moving through a cutting press.", "This isn't the same paper from which they make the matchsticks.", "It's a higher-quality non-recycled paper, suitable for color graphics, because many clients order custom-printed matchbook covers.", "Another press with rotary blades slices through the paper, creating segments that are 4.2 inches long.", "That's the length of an unfolded matchbook.", "Now back to the matchsticks.", "A worker arranges the strips into layers of two.", "The conveyor then feeds them into a machine that will attach them to the matchbook covers.", "The machine performs several tasks.", "It cuts the matchstick strips into rows of 10 matches each.", "And it cuts the matchbook covers to their final width of 1.5 inches.", "The machine folds the matchbook covers over two rows, or 20 matches, then inserts one strong staple through all four layers.", "Next, a conveyor moves the assembled matchbooks to another machine that counts them and creates two side-by-side rows of 25 ready for boxing.", "This company also makes its boxes out of recycled paperboard.", "Each one holds 50 matchbooks and sells for about a buck.", "That's a dollar for 1,000 matches, or just a penny for 10 matches.", "Centuries ago, soldiers tested their cavalry skills astride the rim of a large horizontal wheel.", "Eventually, europe's wealthy elite saw this as entertainment and turned the practice into a fabulous pageant.", "Nowadays, you can ride a whole menagerie of animals.", "But the star of the carousel is still the horse.", "Their life revolves around a fairground, but they're born here on paper.", "A craftsman draws a pattern of the horse's silhouette, then fills it in with the saddle, straps, and a harness.", "Some models may include a shield, a coat of arms, or even flowers.", "Another craftsman then glues together blocks of linden-- wood that's lightweight and easy to carve.", "He stacks four of them to create what's called an end block.", "It'll form part of the horse's body, what's known as the core.", "He clamps the blocks together to compress them and lets the glue set for 45 minutes.", "The finished core includes two end blocks sandwiched by top, bottom, and side panels, plus one wooden piece they'll carve into a saddle.", "The middle of the core is hollow.", "On a carousel with 50 horses, this trims the overall weight by up to three tons.", "After covering the core with carbon paper, the craftsman lays the pattern on top.", "He traces the pattern with a leadless pencil called a stylus.", "The carbon paper underneath transfers the drawing onto the wood.", "He'll follow these lines to cut out the basic shape of the horse.", "Later, they'll carve most of the finer details by hand.", "Using a band saw, he slices the core carefully along the lines.", "Next, he drills a hole for the pole that attaches the horse to the carousel.", "Here, a craftsman uses what's called a carving duplicator to create the head.", "Following a template, the machine sculpts a block of wood into the horse's head, a painstaking process that takes 90 minutes.", "The duplicator can carve up to four heads at once.", "It also adjusts to carve some finer details into the larger pieces, such as the core.", "They use something called a parting tool to shape the decorative tassels on the bridle.", "This one has a fanciful design, what an arabian horse would typically wear.", "The craftsman has a huge arsenal of tools at his disposal to create all kinds of special features, such as a flowing, windblown mane.", "The tools are sharp, and they're precise enough to sculpt even tiny, intricate parts such as eye sockets, nostrils, and teeth.", "After applying polyester adhesive putty in the eye sockets, he adds two glass eyes.", "Unlike real horses' pupils, which are oval in shape, these have round pupils for a friendlier look.", "A carousel horse is roughly half the height of a real horse, but the size of its feet is true to life, so workers nail on authentic iron horseshoes.", "These prevent the wood from chipping under the feet of riders who get rowdy in the saddle.", "Wooden pegs temporarily connect the head and tail to the body.", "Once workers verify the alignment, they'll glue the sections together.", "After sanding down the entire surface, the paint job begins.", "First, three coats of white primer.", "This highlights any imperfections the sanding missed.", "Once that's done, the artwork begins.", "This horse will wear a bright, multicolored harness.", "Its coat will be in different shades of the same color for a realistic look.", "It takes up to five coats of paint to get it just right.", "Up to seven coats of varnish will keep the horse looking beautiful for decades.", "After a lengthy production process that takes about two months, these striking creatures are ready for the fairground.", "Porcelain is often called china after the country that invented it more than 1,200 years ago.", "It looks delicate but is actually the hardest type of ceramic material.", "It's even used in electrical insulators because it withstands very high heat.", "But most people think of porcelain as decorative.", "This company makes 40 different porcelain items.", "It all starts with a sketch of the piece-- in this case, a teapot.", "After that, a master mold of the piece-- a negative made of plaster.", "Craftsmen use it to make a production mold.", "Porcelain begins as powder, a blend of three minerals-- quartz, kaolin, and feldspar.", "The workshop mixes this powder with water to make a wet paste called slip.", "A craftswoman fills the mold with slip.", "Within 10 minutes or so, the porous plaster absorbs the water, leaving a crust of hardened slip.", "After pouring the rest out, she waits another 30 minutes for the crust to continue hardening.", "Then she peels away the mold and gets a first look at her teapot.", "Here, she removes excess crust from a different mold for the spout.", "She waits about 10 minutes, until the spout is hard enough to handle but still soft enough to sculpt.", "With a utility knife, she carves open the end of the spout.", "With a little water and a sponge, she smoothes out the edges and curves the rim.", "Next, she extracts the handle from a third mold.", "Then she pierces 12 holes in the spout side of the teapot to filter out the tea leaves when you pour.", "She brushes on some slip to attach the spout and the handle.", "This model has a wedge along the collar to help align the handle correctly.", "Other designs have small notches instead.", "She brushes on more slip to ensure the parts will bond, then sponges the surrounding surface to smooth out the drips.", "After the piece dries for two more days, she carves away the lines along the handle and under the spout and sands down the rim.", "They make some pieces using a pressure-casting system-- the mold's made of resin and tiny polyester beads that create pores, which absorb the water in the slip.", "After a hydraulic press closes the mold, the machine injects slip into the cavity.", "12 minutes later, a craftsman uses a suction plate to remove what will become a serving platter.", "He places the piece on a plaster block.", "The porous plaster lets the underside dry without leaving marks.", "They fire the items in a giant kiln.", "The kiln heats up gradually, taking eight hours to reach a searing 1,800 degrees fahrenheit, then 12 more hours to cool down.", "Firing hardens the porcelain and enables it to better absorb a coat of enamel.", "After brushing off any dust, the craftsman dunks each piece in enamel-- a protective coating.", "The porcelain absorbs it right away, and this glaze turns into a shiny skin once the pieces are fired again.", "She handles each piece in a particular way to avoid leaving drip marks.", "In the second firing, they make the porcelain pure white by carefully controlling the air in the kiln.", "Reducing the oxygen level removes any undesirable colors.", "This time, the temperature is higher-- 2,500 degrees fahrenheit.", "It shrinks the pieces by about 15%.", "After a quality check, a craftsman applies the company logo with a transfer decal.", "The logo melts in when the plate goes back in the kiln for another 12 hours at 1,500 degrees fahrenheit.", "In the end, the porcelain is translucent enough for light to shine right through.", "Other pieces offer more illustrated displays for an elegant dining experience.", "Considering how much it costs to fill them, it's no wonder today's gas tanks are made to be tough.", "Factories design a gas tank to safely fit a wide range of vehicles.", "Worldwide, the industry makes 60 million tanks a year for new cars and trucks and millions more to replace old or damaged tanks in existing cars.", "Making a gas tank begins with a simple sheet of steel.", "It's nickel-plated to make the tank rust-resistant.", "A worker places the steel in a hydraulic press that applies 800 tons of pressure.", "This compresses the sheet between two dies that shape the bottom half of the tank.", "The press forces the male die up against the sheet and into the cavity of the female die.", "To make the top half of the tank or different-size tanks, they simply change dies.", "On the tank's top section, a stamping press imprints information such as the product and lot numbers, and the manufacturer's name.", "A hydraulic punch then pierces two holes-- one for a tube to fill the tank and another to vent it.", "This machine makes an opening for a component called the fuel-delivery module, or fdm.", "It will send fuel to the motor.", "A conveyor moves as many as 180 top sections per hour to the next production phase.", "There, a worker uses a steel and nylon jig to install a steel ring that will position the fdm.", "He spot-welds the ring in six spots, fusing it to the top section.", "Two notches on the ring will align the fdm properly.", "Workers tack the top and bottom sections together, aligning them properly for comprehensive welding that follows.", "Two metal wheels compress the sections together, and water cools the area as a machine called a seam-welder fuses the upper and lower halves of the tank.", "Using a gas torch, a worker fuses steel tube to the tank with lead solder.", "This is the filler tube into which you insert the gas nozzle when you fill up at the pump.", "Fuel flows in and air vents out through the tube simultaneously.", "A sensor automatically shuts off the gas pump when the air pressure inside the tube reaches a certain point.", "Most tanks fill only to about 80% capacity to leave room for vapors caused by hot weather.", "Robots weld the tanks destined for brand-new vehicles, because the work has to be precise and consistent in order to aid the assembly-line robots at the auto plant.", "The human-welded models are sold to auto-repair shops as replacements for damaged tanks.", "They don't require the same precision because a mechanic does a custom installation.", "When the robots finish welding the tanks, they transfer them to a conveyor belt that moves them to the next production phase.", "There, a worker attaches a tin-plated venting tube.", "Tin makes it rust-resistant.", "He adds a steel component called a baffle to the bottom section of the tank.", "This reduces the sloshing of fuel inside the tank.", "The result-- less noise for the driver and less metal fatigue for the tank.", "They're usually just for tanks found in larger vehicles, like suvs and small trucks.", "A worker now places the top section onto the bottom section, pulling the hose through the opening in the top.", "This hose will connect to the fdm.", "After a welding machine fuses both halves together, another machine bends the sides downward.", "This gives designers extra space to work with.", "They test every tank for leaks by dunking it underwater.", "After blocking all the holes in the tank, they pump a little extra air inside it.", "They shine bright spotlights and look for bubbles in the water.", "If air can escape, so can gasoline.", "No bubbles, and the gas tank passes inspection.", "Only then is it ready for shipping and a starring role in your car." ]

{ "things": [ "Cast Iron Stoves", "Ultralight Aircraft", "Snow Groomers", "Rubber Bands" ] }

[ "Cast-iron stoves have been adding warmth to people's lives for more than three centuries.", "Today there are new reasons to cozy up to this invention.", "It's had a major update.", "Modern stoves burn wood more cleanly and efficiently, providing heat without the dirty fallout from the chimney.", "Modern cast-iron stoves hardly resemble their smoke-belching, soot-spewing predecessors.", "The design creates a hotter fire, so it requires less fuel and releases little smoke.", "It all starts with a pile of iron scrap, things like old stoves, sinks, brake drums, and rotors.", "A magnetized crane transfers the scrap to a propane-fired preheater.", "12 minutes spent in the preheater removes moisture from the iron scrap.", "The scrap iron spills into a hopper that funnels it into an electric furnace.", "The temperature in the furnace is a blistering 2,700 degrees fahrenheit, and the iron melts into a fiery liquid.", "The furnace tilts to pour the molten iron into a ladle for transfer.", "Next, they make the molds of the stove parts, using a mix of sand, clay, water, and coal.", "They blow the ingredients between the aluminum patterns.", "A hydraulic system squeezes the patterns together.", "The sand mix compacts and takes the shape of the patterns.", "They now have sand molds.", "The molten iron arrives and flows into a channel leading to the molds.", "As the liquid metal cools, it solidifies into the shape of the mold.", "A vibrating conveyor shakes and breaks the sand molds to reveal the cast-iron stove parts.", "A worker knocks off unwanted bits, and then it's into a blast cleaner.", "Inside the blast cleaner, steel grit bombards the stove parts to remove remnants of the sand molds and expose the metal.", "Essentially it blasts the dirt off, and they come out clean.", "An employee grinds the edges of the metal stove parts.", "He blends in the line created where the two parts of the mold came together during casting.", "It takes 40 parts to make one woodburning stove, and each one is cast in a sand mold made from a pattern.", "Next, a worker drills threads for the bolts that will hold all the parts of the stove together.", "Once the surface of the parts has been prepped, they spray an enamel coating onto them and bake it on.", "A laser then cuts out a steel heat shield for the back of the wood stove.", "The intricate cuts are computer driven.", "An employee bends the heat shield to fit the stove.", "Next, a worker packs a kind of mortar into a silicone mold of the firebox.", "The table its on vibrates to settle the material and eliminate air pockets so the firebox will be able to withstand high temperatures.", "The shape of the firebox is crucial to the stove's energy efficiency, and so are the holes that have been molded into it.", "These strategically located holes will introduce fresh air to burn gases that would otherwise go up in smoke, preventing energy loss and pollution at the same time.", "The parts have all been fabricated, and they're ready to put the pieces together.", "They assemble the stove from the bottom up.", "They bolt the parts and seal the joints to make them airtight.", "The assembly takes about an hour.", "This cast-iron stove is now ready to keep these fires burning for many years to come.", "An ultralight aircraft is a lightweight, motorized flying machine that looks like a hang glider.", "Hang gliding inspired the invention of ultralights back in the late 1970s.", "The idea was to create a slow but affordable method of motorized flight subject to minimal aerospace regulations.", "They're called ultralights or microlights.", "This made-in-france 2-seater model weighs about 485 pounds.", "To be classified as an ultralight by the international air sports federation, takeoff weight can't exceed 990 pounds and minimum speed can't surpass 40 miles per hour.", "The wing surface, called the sail, is made of a sturdy polyester-based material treated with a special coating that protects it from the sun's ultraviolet rays.", "They unroll different colors of this fabric onto a cutting table marked with patterns for the four separate sail sections.", "They staple the fabrics to the table to hold them steady while tracing the patterns.", "Once they finish tracing, they cut out the pieces, then connect them with double-sided adhesive tape to position them correctly for sewing.", "They reinforce select areas with adhesive-backed polyester mesh fabric.", "Then a sewer stitches the pieces together with high-strength, u.v.-resistant thread.", "In this first stage of the sewing process, they stitch together 1/4 of the sail at a time.", "In the second stage of sewing, they sew together the top and undersurfaces of each side.", "Then, in the final stage, they stitch the right and left together.", "In another part of the factory, the body of the aircraft begins taking shape.", "It's called the trike because it sits on three wheels, like a tricycle.", "They build it in sections, welding together several stainless-steel tubes.", "After the sections receive a baked-on coat of paint, workers assemble them to each other around the fuel tank.", "The 17-gallon tank is made of lightweight polypropylene, a type of plastic that's u.v. resistant and impact resistant.", "Once the trike is fully assembled, they mount the three small wheels, similar to those on motorized scooters.", "Next, they bolt a 100-horsepower gasoline engine, similar to a full-sized motorcycle engine, to the back of the trike.", "On the front of the trike, they install pedals for propelling the craft on the ground...", "And a motorcycle-style plastic console with windshield.", "The console houses the instrumentation panel.", "They mount the radiator in the center of the trike, cover it with foam and fabric, then install a pair of upholstered seats for pilot and passenger.", "Then they protect the engine with a plastic housing.", "They mount an aluminum- and-carbon-fiber propeller on the shaft of the gearbox connected to the engine.", "Now for the wing.", "Its main structure is made up of hinged aluminum tubes which fold for transport.", "Aluminum is lightweight and rustproof, which is essential for flight.", "They slip the sail over the tubing, then unfold the wing.", "Thin aluminum tubes provide crosswise structural support.", "A system of cables keeps the wing in the open position.", "Another system of cables, called the corset, manipulates the billowing of the sail.", "This enables the pilot to alter the aerodynamics to increase or reduce speed.", "Under the wing, they install the a-frame, the ultralight's steering mechanism.", "The pilot manipulates the a-frame with a horizontal bar, changing the trike's body position under the wing.", "The last step is to bolt the front of the trike to the wing and hook up the safety backup cables.", "The pilot steers the ultralight by weight-shifting with the a-frame bar, tilting the trike toward the front to descend, to the right to veer right, and so on.", "Typical cruising speed is around 75 miles per hour.", "With an open cockpit, air temperature and oxygen levels limit how high an ultralight aircraft can fly.", "Maximum altitude is about 3,300 feet, high enough for a thrill ride yet still low enough for a spectacular view.", "After a busy day of skiing and snowboarding, ski slopes get worn down and develop ruts, bumps, ice, and bare spots.", "Ski resorts typically refresh the slopes overnight by grooming the snow with specialized track machines.", "By morning, the runs are as good as new.", "A snow groomer is like a bulldozer on tracks, except instead of pushing dirt, it pushes snow.", "It uses grooming implements mounted to the front and back.", "To build a snow groomer, workers begin by aligning front and rear frames with the vehicle's main frame with the help of positioning jigs.", "Then a welder gets to work.", "First, he tacks everything together.", "Then, with a mechanical lift, he raises and tilts the tacked frame to gain access from various angles.", "After welding on additional parts, including 10 axles, they prime and paint the frame.", "Then a mechanic installs a heavy-duty suspension system designed to automatically adapt to the type and shape of terrain, maximizing traction.", "Next, he greases the 10 axles and installs a wheel hub and bearings on each one.", "He then mounts the wheel, tightening the bolts to a specified torque to ensure optimal performance and durability.", "Meanwhile, another mechanic installs the hydraulic hoses.", "These control the grooming implements and the sprocket on which each track turns.", "Then he connects the hoses to the main hydraulic valve.", "At another workstation, a mechanic assembles the diesel engine, the transmission, and four hydraulic pumps.", "Two of these pumps drive oil to the hydraulic motors, which propel the vehicle forward and backward.", "The two others pump hydraulic fluid to operate the implements and the cooling system.", "They lower this assembled unit into the frame and make the required electrical and hydraulic connections.", "Meanwhile, another team prepares the next unit, starting with the cooling system, two powerful fans which cool the engine and hydraulic fluid.", "Next, they install the exhaust system and two batteries to power the engine.", "They mount this assembled unit above the transmission and make all the necessary connections.", "They lower the cab onto the frame, connect more electrical and hydraulic lines, and fill all systems with their respective fluids.", "The vehicle now undergoes extensive testing in a dynamometer, which operates the engine and hydraulic components at maximum capacity.", "If all systems perform according to engineering specifications, the vehicle gets the go-ahead to receive the snow-grooming implements.", "The rear implement is a tiller, which breaks up the snow into small particles and shapes narrowly spaced parallel lines on the trail surface.", "A powerful, built-in hydraulic motor spins the steel-toothed rotors at speeds of up to 1,350 revolutions per minute.", "This ensures even grooming throughout.", "The groomer's tracks are made of ultra-durable steel.", "A mechanic guides the edge of each track onto a high-strength urethane sprocket bolted to the rear of the frame while another mechanic slowly drives the vehicle forward to pull the track over the wheels.", "Then they clamp the two ends together and join them with giant hinges, closing the loop.", "It's time to mount the snow-grooming implements.", "They attach the tiller to the rear mechanism, which carries the hydraulic connections for the implement's onboard motor.", "They attach a blade to the identical front mechanism.", "The blade plows snow and sculpts features such as half-pipes, those giant, u-shaped bowls of snow in which freestyle skiers and daredevil snowboarders ride.", "For safety, the cabin has a steel skeleton with roll-over protection features.", "A specially designed joystick gives the driver precision control over the blade and tiller.", "The state-of-the-art electronics include three computers, which enable the driver to select and adjust different functions and modes, all of it displaying on a color monitor.", "The vehicle never sinks into the snow because its weight is optimally balanced on the tracks.", "This 22,000-pound snow groomer actually exerts less pressure on the snow than a single person does on foot.", "The rubber band was invented in england in the middle of the 19th century.", "The key to its success, of course, is flexibility.", "A rubber band can be stretched around items of various shapes and sizes to hold them together, so in the rubber-band industry, the possibilities for expansion are numerous.", "Rubber bands come in handy for a whole bunch of things.", "If you have a bunch of anything, a rubber band can keep it together.", "Production of rubber bands starts with natural rubber.", "These spongy slabs have been made from the sap of rubber trees.", "Natural rubber has greater elasticity than the synthetic kind, making it a better choice for rubber bands.", "A worker measures and pours rubber processing oil into a kneader machine.", "He adds powdered pigment-- in this case, yellow and white for a pale yellow shade.", "He feeds several rubber slabs to the kneader's spiral-shaped jaws.", "The spiraling blades intersect to break up the rubber and blend in the other ingredients.", "The kneading process generates heat which softens the rubber, making it easier to form into dough.", "The kneader spits out rubber-dough chunks.", "Next, a giant rolling pin transforms the dough into wide, thin pieces.", "He slices the strips and bundles them.", "In this form, it will be easier to control the weight of the rubber in relation to chemicals that are added next.", "They roll the rubber with a precise amount of sulfur and other chemicals that strengthen the rubber and make it more elastic.", "They then roll the rubber very thin.", "A worker twists and cuts it into small bundles that fit into the opening of an extruding machine.", "It forces the still-warm and malleable rubber through dies to shape it into long, hollow tubes.", "The extruder injects air and talcum powder into the tubes to keep the walls from collapsing and sticking together while warm.", "The tubes cool down in a trough of water, and they deflate as the injected air dissipates.", "Next, these aluminum poles will serve as molds for the tubes during curing, giving them the correct shape and diameter.", "The worker slides the tubes onto the molds.", "The talcum powder injected into the tubes during their extrusion will also act as a release agent, keeping them from sticking to the molds during curing.", "They load the tubes into a steam oven, and the intense heat vulcanizes the rubber to boost its tensile strength and elasticity.", "Out of the oven, workers inject air between the tubes and the molds, making it easier to peel the now-vulcanized tubes off.", "They rinse the rubber tubes to remove talcum-powder residue.", "There's so much that the water turns milky white.", "They hang the rubber tubes to drain away some of the water.", "By the time they're ready to cut, they're a bit too dry, so a worker splashes water onto them.", "With the tubes moistened, the next operation will run more smoothly.", "He feeds several tubes at once to a rotating blade which carves them.", "This creates elastic bands that are exactly the same width.", "In this case, that's 1.5 millimeters, an average thickness for a rubber band.", "With this system, they can cut 1/2 a million rubber bands in an hour.", "It doesn't take long for the inventory to pile up.", "There are millions of rubber bands here.", "A worker scoops them up and examines each one for defects.", "Once approved, all that's left is the packaging.", "The rubber bands ride a conveyor that releases them in increments into plastic bags.", "It has taken about three hours to produce this bag of rubber bands.", "On a normal day, this factory generates 40 million elastics.", "That's a lot by any stretch of the imagination." ]

{ "things": [ "Pneumatic Impact Wrenches", "Cultured Marble Sinks", "Plantain Chips", "NASCAR Stock Cars" ] }

[ "A pneumatic impact wrench is a power tool that tightens and untightens nuts, bolts, and other fasteners.", "You hook it up to the air hose coming off a compressor.", "The anvil at the tip turns at high speed to tighten until snug, then switches to a hammering action, called impacting, to tighten even more.", "You've probably seen a pneumatic impact wrench in action at your local garage.", "It's standard equipment for removing and installing wheels.", "Air pressure runs through the tool's motor, spinning a rotor within.", "That rotates the tool's anvil, which turns the wheel nut.", "At the manufacturing plant, they machine the rotor from a bar of steel mounted on a lathe.", "It takes about a minute and a half for the computer-guided precision tools to carve out the basic shape.", "The next machine carves teeth on one end of the rotor, creating what's called a hobbed edge.", "Now a computer-guided mill cuts eight slots.", "This shaping of the steel generates a lot of heat, so coolant flows throughout all these machining phases to prevent the equipment from overheating.", "Next, they temper the rotors for 10 hours in a 1,700-degree-fahrenheit furnace.", "This hardens and strengthens the steel, but to fortify it further, they pump in carbon from a propane burner.", "The carbon impregnates each rotor to a depth of .", "7 millimeters.", "Once the rotor cools, a computer-controlled grinder shapes it to the final specifications.", "Then a machine with nylon bristles smoothes the surface.", "This completes the transformation from steel bar to rotor.", "Meanwhile, the tool's magnesium housing has been getting a bright coat of paint.", "The housing has two parts-- the main section and a back cap.", "Both go into an oven where the paint bakes for a half-hour at almost 400 degrees fahrenheit.", "Now assembly begins with the trigger and the stem of the main section and then, with this tool, what's called the tipper valve.", "When you push the trigger, it tips, letting in air.", "This spring keeps the tipper valve closed when you're not pushing the trigger.", "And this bushing is where you attach the air hose coming from the compressor.", "Next, they install the reversing valve.", "It slots into the housing just above the trigger.", "When you press the trigger, the anvil rotates clockwise to tighten the fastener, but when you activate the reversing valve, it sends the air into different chambers, turning the tool counter-clockwise to remove the fastener.", "They glue a rubber pad to the top of the housing to cushion your grip on the tool.", "A laser engraves manufacturing information on the back cap.", "To assemble the motor, they start with a back cap and press in a bearing on which the rotor will spin.", "Next, a plate to enclose one end of the rotor and an alignment pin to position the plate for enclosing the other end.", "And finally, the rotor itself.", "Into each of the rotors' slots goes a vein made of resin-imbued fabric.", "These veins work like the blades on a windmill.", "The air entering the tool turns them, which spins the rotor.", "After slipping a steel cylinder over the rotor, they enclose it with a second plate, then a larger plate with a ball bearing.", "Now some oil to lubricate what they call the impact mechanism.", "This component contains the tool's anvil, as well as the parts that produce the hammering action.", "Finally, a press seals the main section of the housing to the back cap.", "Every pneumatic impact wrench this factory produces goes through extensive testing in both free speed-- that's when the tool spins like an ordinary drill-- and in impact mode.", "So, if you've got a nut or other fastener to drive, take one of these babies for a spin.", "Natural marble has a modern alternative-- a composite material known as cultured marble.", "It consists of ground marble or limestone mixed with liquid plastic.", "Less expensive than natural marble and easier to work with than stone, cultured marble is often used to create unique bathroom and kitchen fixtures.", "This vanity top and pedestal sink are both made of cultured marble, cast in fiberglass molds.", "To make a vanity top, a worker centers a sink-bowl mold on a counter mold...", "Then places a drainpipe attachment over the sink mold's exit drain.", "He marks with a grease pencil where the faucet openings will be.", "Then, he masks off areas to protect and places a bees'-wax seal all along the bowl's edge where it meets the counter.", "He sprays the molds with protective gel that will give the vanity top a shiny protective finish.", "Finally, he places cardboard tubes over the faucet-hole marks.", "The molds are now ready for casting.", "A machine equipped with a mixing pot automatically measures out the resin workers pour into these molds.", "Raw pigments like sterling silver, sandbar, wild rose, white titanium, and fawn beige gives the resin its color.", "A worker sifts them in measured amounts into the resin as it's mixing.", "Next, he adds a catalyst to the resin...", "Then some granulated limestone to thicken it.", "The catalyst sets off the chemical reaction that causes the resin mix, known as matrix, to harden.", "From this moment on, he needs to be swift.", "He has only 15 minutes to mix, color, and pour this batch of matrix into the molds before it hardens.", "He adds more white pigment to the base color, using a paddle to mix it along the surface.", "Then he takes the wild rose pigment, mixes in some resin, and again works it into the surface to streak it with color, an effect known as veining, that mimics the look of marble.", "He scoops out some of the surface mix and pours it onto the mold.", "As the matrix pulls, the rose-colored veining in the surface mix is visible.", "Now he pours out the rest of the matrix.", "He casts the sink and counter in a single piece so there won't be any grout lines around the bowl.", "A pneumatic tool vibrates the molds, bringing tiny air bubbles to the surface-- the vanity's underside.", "Air trapped in the matrix can cause it to break or mar the finish.", "A worker lays down a temporary plastic hat over the bowl.", "He weighs it down to hold it in place as he pours matrix inside the hat to cast a bowl that's as thick as the base-- about .", "8 inches.", "He lets the matrix set for 30 minutes, then removes the hat from the bowl.", "Next, he drops down the mold's backsplash and puts a hole in the drain.", "He shoots in bursts of compressed air while a co-worker carefully wedges under the backsplash to part the mold, revealing the vanity's marbled surface.", "To make sure the vanity lies level on its cabinet, a worker grinds down the underside, then the drain area.", "Next, he sands down the backsplash and the sides, working at an angle with a hand sander to dull any sharp edges.", "He removes the drain mold and buffs the surface to a mirror finish.", "Finally, he knocks out the faucet holes.", "Here's a finished vanity with a variety of integrated sink bowls on display.", "Cultured marble truly is a versatile material that offers endless possibilities.", "Many of us take time out to enjoy a tasty snack like plantain chips, but we know we should put limits when treating ourselves to a good thing.", "The trick is to learn as much as we can about the snacks we're eating so we can choose a treat that's right for us.", "Seeing how plantain chips are made can help us make an informed choice.", "This looks like a banana, but it's actually a plantain-- a staple food in many parts of the world.", "In tropical countries like costa rica, it's made into a popular snack called plantain chips.", "The cycle from fruit to snack begins here.", "A worker cleans off the root of an offspring from a mature plantain tree.", "He prepares the root for planting as if it were a seed.", "In time, this seed will grow into a mature plantain tree.", "After about nine months, the plantain is ready to harvest.", "When a worker picks the fruit, they wrap it in plastic to protect it against insects and disease.", "Each mature tree yields only one bushel of fruit its entire life.", "Once he harvests the mature tree, it's the tree's offspring that yield more fruit and continue the life cycle.", "The worker then rinses the plantain in treated water that helps wash off sap and kill any possible fungus.", "Local workers then load the cases of plantains onto their boat for a full day's trip to the processing plant.", "Their hard work is valued by the company which is proud to support the local economy.", "At the plant, a worker puts the plantain into boiling water for about a minute.", "Boiling the fruit changes its color, but more importantly, it greatly reduces the amount of sap the fruit releases, which makes handling and peeling the otherwise sticky skin possible.", "The various lengths and widths of plantain prohibit peeling it by machine.", "Workers at this costa rican plant cut more than 50,000 pounds of plantain every day, all by hand.", "Each one is then cut into slices of a specific thickness for chips.", "To do this, workers push the fruit one at a time into a cutting machine.", "The slices of plantain fall through the machine into a deep-fry oven below.", "A rotating grill and conveyor system helps ensure uniform cooking of the slices in natural palm oil as they travel on an uninterrupted 30-foot journey.", "After cooling, the worker removes any under- or overcooked chips.", "The chips then travel into a tumbler that adds salt or other seasonings or flavors, depending on the product.", "The chips then exit the tumbler and are ready for packaging.", "The packaging machine gently funnels the chips into separate chutes as it calculates the exact amount it needs to fill each bag.", "Once filled, the packaging machine then cuts and seals the individual bags, then sends them for distribution across the world.", "Plantain chips also come in strips.", "They're trans-fat free and come in a variety of formats that make a handy treat.", "Nascar is one of the most popular spectator sports in north america.", "The national association for stock car auto racing holds a series of 36 races a year, mostly at oval or d-shaped tracks on which the cars make only left turns.", "They're built from scratch following nascar's strict technical rules.", "Nascar's stock cars are based on certain american-made road cars.", "The frame is made out of steel tubing.", "The hood, roof, and deck lid-- that's like the regular car's trunk cover-- are made out of sheet steel.", "The workers who assemble the body are called body hangers.", "They position all the parts according to a nascar-authorized template.", "Here they clamp the body panels together.", "Then, with an aluminum bracket, to the template for shaping.", "To make the wheel openings on the front fender, they use shrinking jaws, a tool that curves metal by squeezing it.", "Then they switch to a tool called an english wheel.", "It rolls the curved metal into a particular shape.", "The car's front suspension is essentially the same as that of a regular car, except for the angle of the tires, which they manipulate by putting shims on this upper control arm.", "The right front tire tilts inward and the left front tire tilts outward.", "That's because these cars race on an oval track in one direction only, so they're making only left turns.", "Next, they install a brake rotor.", "Then, a steel spacing plate between the rotor and the wheel.", "This sets up the specific distance from wheel to wheel that nascar rules require.", "They load a pair of brake pads into a brake caliper and slide the caliper onto the rotor.", "The caliper contains different-sized pistons so that it applies the brake pads to the rotor evenly.", "Now they move onto the car's inner workings.", "They mount the transmission to an aluminum housing that covers the flywheel, clutch, and other components.", "Then they install the motor.", "It's an eight-cylinder, 750-plus horsepower engine.", "They attach the car's plastic windshield with bolted clips.", "If air gets into the car, these strong clips will keep the windshield from blowing out.", "The car's seat core is made of aluminum, padded for comfort.", "Every nascar driver has his car seat custom-built to his body shape.", "After bolting in the seat, they install the steering wheel.", "It has a safety release that lets the driver remove the wheel with a single pull.", "This enables him to get in and out of the car easily and to remove the wheel quickly if he's injured in a crash.", "Now, for the finishing touches.", "First, a large decal of the car's number centered on each door.", "Every nascar racecar is also plastered with decals advertising its driver's sponsors.", "Nascar's stock cars have a few key safety features.", "Fenders allow side-to-side contact between cars without their wheels hooking together.", "Roof flaps direct air downward, keeping the cars close to the ground.", "This stops a spinning car from flipping over.", "A nascar stock car weighs in at more than 3,300 pounds.", "It travels to the track in the top deck of a trailer.", "This keeps the bottom level clear as a work space for the driver's mechanical crew." ]

{ "things": [ "Paper Umbrellas", "Coal", "Aircraft Seats", "Cremation Urns" ] }

[ "Paper umbrellas originated in china and eventually spread throughout asia.", "Initially, their purpose was solely practical-- to protect against rain and to provide shade from the scorching sun.", "But before long, they took on symbolic significance and were incorporated into many ceremonies and rituals.", "They're called oil paper umbrellas because the paper is coated with oil or, like these, with oil paint, making the umbrella waterproof.", "At this workshop in northern thailand, they cut a bamboo log to the length of the umbrella's radius, then shave off the bark.", "They split the log into strips of equal thickness, then group these ribs, as they're called, into bundles of 28.", "Each bundle will become the frame of one umbrella.", "Next, they thin out the bottom half of each rib and cut a slit in the top half.", "Then, using a traditional drill, they bore tiny holes at specific points.", "Taking one bundle at a time, they string the ribs together through the uppermost hole and insert them into slots of a hand-carved wooden hub.", "Then they tighten and tie off the string to retain the ribs in position and provide a pivot on which the ribs can move up and down.", "Next, they attach the scaffold, a smaller hub with shorter ribs strung on it.", "They insert a scaffold rib into the slit of each frame rib, then attach them by threading a string through the aligned holes.", "The result?", "Raising and lowering the scaffold moves its ribs along the slit-- pushing the frame ribs up to open the umbrella, or pulling them down to close it.", "With the umbrella open now, they thread more string through holes in the frame ribs and loop it into a spider-web-type pattern.", "This produces a sturdy base to support the umbrella's paper skin.", "After mounting the frame on a wood and bamboo umbrella handle, they wrap two lines of string along the frame perimeter.", "This will support the paper skin at the edge of the umbrella.", "They make the paper from the bark of the native saa tree.", "The first step is to soften the bark by soaking it in water for about 12 hours, then boiling it for another three or four.", "Next, they mash it with wooden mallets for about an hour, turning it into pulp.", "They bleach the pulp and wash it again to remove the bleach.", "Only then is the pulp ready to become paper.", "They dump the pulp in a large basin of water and stir so that it floats in suspension while they move a plastic screen through the water, catching enough floating pulp to coat the screen in a thin layer.", "They lay the screen out in the sun for three to four hours until the layer of pulp dries into a thin, fragile sheet of paper.", "They cut the sheets to the shapes required, then saturate each piece with glue made from cassava, a tropical root vegetable.", "After applying a circular piece around the hub, they glue pie-shaped pieces onto the rest of the frame.", "Once they cover the entire frame, they repeat the process to add a second layer.", "They fold all the pie-shaped pieces over the end to thicken and, thereby, reinforce the edge of the umbrella.", "After about four hours out in the sun, the glue dries, bonding the now stiff and strengthened paper securely to the frame.", "They apply three coats of oil paint, allowing four hours of drying time between coats.", "This is a key step because aside from providing the background color, the oil paint waterproofs the paper.", "Next, they varnish the handle to make it moisture-resistant.", "And now for the grand finale-- an artist paints a design in vibrant waterproof oils.", "The themes are traditional-- flowers, animals, landscapes, people.", "No stencils to trace or patterns to follow-- the artist works entirely freehand, the result being that no two umbrellas are ever exactly alike.", "Each oil paper umbrella is a portable work of art.", "Pretty yet practical, rain or shine.", "The most-used fuel for producing electricity in the world today is coal.", "Power plants burn it in their furnaces to heat water into steam that spins giant turbines which generate electricity.", "At least 40% of the world's electricity is produced by coal-fired power plants.", "Coal developed from prehistoric vegetation that wound up buried underground due to geological changes.", "Over millions of years, these decayed plants transformed into combustible rock.", "This is why we refer to coal as a fossil fuel.", "Coal runs in seams through other rock layers.", "Miners drill holes through the seam at several locations, then mix together ammonium nitrate and diesel and pour a precise quantity of this liquid explosive into each bored hole.", "The plug the holes with dirt to contain the upcoming explosion.", "This directs the force of the blast sideways so that it'll fracture rock as much horizontally as vertically.", "They place a blasting cap in each plugged hole, then connect all the blasting cap wires to detonation lines through which they'll send an electrical charge to ignite the explosives.", "They install detonation delays to time the blast one after another because successive explosions have greater impact than simultaneous ones.", "The blast dislodge and break up the layers of rock between the surface and the coal seam deep below.", "Workers clear away the rocks and dirt with a mammoth machine called a dragline.", "Removing the blasted rock and dirt exposes the coal, which is still a solid, hard seam.", "The side of the mine pit shows how much rock is on top of this particular coal seam.", "Once miners blast and clear away that rock, they drill and load the holes to set off more explosives to fracture the coal seam itself.", "Then front-end loaders load the coal into specialized trucks called coal haulers.", "In one trip, a coal hauler can transport about 220 tons of coal out of the pit to the coal stockpile.", "From there, railcars transport the coal to the nearby power plant.", "When this company prepares to mine an area, it removes the topsoil on which vegetation grows.", "As part of a land reclamation program, the company stockpiles the topsoil until it finishes mining out the coal.", "Then it refills the pit with rock and dirt it blasted away, returns the topsoil, and plants native vegetation.", "The power plant is situated by a man-made lake, the water source for the steam with which it generates electricity.", "When the coal arrives, crushers grind it up into baseball-sized pieces.", "After a strategic blending of different grades of coal, to optimize heat output, the coal travels by a conveyor belt to indoor silos.", "Each silo feeds crushers, which pulverize the coal into powder.", "Now the coal is ready to fuel the furnace.", "Meanwhile, huge intake pumps draw lake water.", "The furnace heats the water to 1,000° fahrenheit, well beyond the boiling point, transforming it into high-pressure steam.", "The steam then enters and rotates turbines, generating electricity.", "By the time the steam exits the turbines, it's thermally depleted down to just 120° fahrenheit and depressurized to a vacuum state.", "It then passes through a condenser containing cold lake water.", "The water absorbs the remaining heat, converting the steam back to water, which is then recycled into new steam.", "The combustion process itself creates sulfur dioxide.", "The plant runs this gas waste through vessels containing a lime solution to neutralize the sulfur.", "This chemical reaction creates water vapor, which exits the plant's stack.", "Wires coming off the turbine generators carry the electricity to outdoor transformers.", "The outdoor transformers convert it to higher voltage in order to have less energy loss, as the power from coal travels through transmission lines to some 350,000 households.", "When you're traveling by air, you want to be sitting in a comfortable seat.", "Private aircraft take comfort to a level far above that of commercial airlines with seats that are as cozy and luxurious as fine furniture.", "They must also be lightweight and fire-resistant.", "On private and corporate aircraft, it's all about luxury seating.", "Armchairs often swivel and, at the push of a button, recline with an extending footrest.", "The cushions are constructed from layers of fireproof foam containing carbon fiber for optimum support and durability.", "Workers cut the cushion pieces using a band saw with a round blade that slices through foam without tearing or shredding it.", "They spray adjoining surfaces with water-based contact cement and assemble them.", "The assembly combines different thicknesses and three different densities to make the cushion soft in certain areas and rigid in others.", "The densities are color-coded.", "After letting the glue dry for 12 hours, workers begin the final shaping.", "This is the seat-cushion assembly.", "They first saw through it laterally to make the right thickness.", "Then they temporarily adhere a plastic template of the final cushion shape, trace it, then saw along the trace line.", "Next, using the technical drawing as a guide, they mark, then grind the cushion's rounded profile.", "Holding the next layer of foam over the edge, they verify the shape with another template.", "Then with yet another template, they mark lines for the cushion's creases and, with a foam saw, cut them two inches deep, just enough to insert velcro strips, the backsides of which they glue to the foam with water-based contact cement.", "Workers construct the backrest cushion just like the seat cushion-- assembling foam pieces of different thicknesses and densities, shaping the perimeter, grinding the edge profile, cutting and velcroing creases.", "Then they apply a final layer of soft foam, 1/2 inch thick, folding the edges onto the velcro inside the creases.", "They do the same with the seat cushion, armrests, and footrest.", "All the foam cushions are now ready to be covered in genuine leather.", "In accordance with safety regulations, the supplier rendered the leather fireproof by treating it with a calcium-based solution.", "Seamstresses trace patterns for the cover pieces, then cut them out.", "They line the perimeter of each piece with double-faced tape...", "Fold over the edges to create a neat hem...", "And trim the corners flat.", "Then they sew on velcro strips where required.", "Finally, they assemble the pieces into covers, sewing an identification label on each one.", "They hammer every seam flat to prevent bulges.", "Then they sew what's called a french stitch, a line of straight stitches on either side of each seam.", "Meanwhile, workers glue fireproof polyester batting to the foam.", "This layer between foam and leather will even out the surface.", "They tear the perimeter of the batting to thin it out.", "Finally, it's time to dress the cushions in their covers.", "Workers use a metal rod to help push the leather deep into the creases without bunching up.", "Velcro strips on the cover adhere to the velcro strips inside the creases.", "The covers also have velcro closures, and certain cushions have velcro strips on the bottom which attach to the seat structure.", "Once all the covers are on, workers can complete the seat assembly.", "They attach the armrest to the structure with screws, then install the footrest, which attaches with velcro.", "It contains a cavity for storing the life vest.", "The seat cushion also attaches with velcro.", "The passenger seats and pilot seat are constructed the same way, except for the pilot seat often has a sheepskin insert on the sitting surface to absorb sweat and keep the pilot cool and comfortable.", "It was the ancient romans who first began using cremation urns.", "Today the custom continues.", "The remains are stored in urns permanently or sometimes temporarily before burial.", "And with cremation, one's final resting place doesn't have to be six feet under.", "The cremation urn has an important place in some households.", "It's a constant reminder of the dearly departed, helping to keep the memories alive.", "The urn starts with a concept.", "The potter draws a large-scale design, which he'll use as a reference as he shapes a prototype urn from clay.", "He slaps a lump of clay onto the potter's wheel.", "The wheel spins, and the potter begins to transform the shapeless lump into the desired form.", "The process is called throwing, a potter's term for shaping.", "He leaves the bottom open so the walls can be more easily formed into the desired shape.", "He'll add a base to the urn later.", "As he pulls up the clay to produce the walls, he works it to a uniformed thickness.", "He gathers top to narrow the opening, a technique known as collaring.", "Then with the potter's wheel at a stop, he takes the shape from round to rectangular and tapers it at the neck.", "Then it's into a casting box, which exposes only half of the urn prototype.", "He brushes a release agent onto that half.", "Using a mixer, he whips up a mix of plaster and water.", "He blends it until it thickens to the consistency of pancake batter.", "The liquefied plaster will harden in minutes, so he quickly pours it into the box with the urn prototype and fills it right to the top.", "As the plaster hardens, the exposed urn prototype makes an impression of half the urn.", "He'll make another one exactly like it for the other half of the urn.", "He'll attach them with a key system.", "For this, he drills notches in one mold half.", "The notches match up with raised areas on the other mold half to align them.", "He ties the molds together with suspender-like straps, cinching them tightly together.", "He adds a base to the urn and straps it to the other two pieces.", "He sets the assembled mold upright, exposing the opening of the urn.", "He's now ready to make a copy of the original urn.", "In fact, he'll make 20 at once using 20 identical plaster molds.", "He pumps liquid clay into each one, filling it to the brim.", "Over three to four hours, the plaster absorbs water in the clay it comes into contact with, causing it to solidify.", "The clay in the center remains liquid.", "He pours that into a barrel to be strained and reused.", "And now the big reveal-- he opens the mold and removes the urn.", "It's exactly like the prototype sculpted by the potter.", "He lifts a lid from another plaster mold and checks the fit to the urn.", "After drying and an initial firing to harden the clay, a worker coats the urn and lid with a glaze, working from the inside out.", "The glaze is a mixture of finely milled minerals and water.", "It adds color and a glass-like nonporous surface when fired a second time.", "Cremation urns come in a range of styles and colors.", "Customers often make a selection that reflects the taste of the deceased.", "Another worker now brushes a mixture of wax and alumina onto the neck of the urn and lid.", "This will keep them from fusing together during the final firing.", "They fire the cremation urns at a very intense 2,200° fahrenheit for about 15 hours.", "This transforms the clay into a durable ceramic.", "They cool the urns slowly for 13 hours to prevent cracking.", "Four days in the making, these urns are now ready to contain a loved one's remains and, in so doing, honor a life." ]

{ "things": [ "Leather Sculptures", "Travel Hot Plates", "Ochre", "Hurdy" ] }

[ "Today on \"how it's made\"...", "The use of leather as an artist medium dates back to the middle ages, when it was crafted into fierce animal shapes that were then affixed to battle helmets.", "Fast-forward several centuries, and some artists are rediscovering leather as a sculpting material and redefining the art of sculpture.", "This is leather reimagined.", "In this studio, cowhides become art instead of a sofa or a pair of shoes.", "It's artistry over utility.", "The artist starts by developing a pattern.", "He draws imagery within a paper fish shape.", "It represents the life cycle of a rainbow trout.", "He places the pattern on a cowhide, and using a scriber, he lightly etches the fish shape into the leather.", "Using a razor blade, he follows the etched lines to cut out the fish shape.", "He dampens the entire piece with a wet cloth.", "This softens the leather to prepare it for the drawings on the pattern, which will be transferred to it.", "He places the pattern on the dampened leather double.", "Using a round-tip tool, he traces the drawings.", "The tool makes light impressions on the supple leather.", "Following those lines with a swivel knife, he carves the imagery into the leather.", "When the leather starts to dry, he redampens it.", "Then, with a wedge tool and mallet, he depresses the leather around the main artwork.", "This raises the images above the background.", "He hammers a disc-tip tool into the leather to make a fish-eye indentation.", "Then, using an actual stone, he lightly pounds the rocks in the image.", "This transfers the stone's texture to the leather.", "He also uses the rock to create shading on the trout and the foliage.", "For the fish-scale detail, he pounds a tool with a crescent-shaped tip into the leather.", "He works in a linear fashion, row on row, to punch tight scales across much of the art.", "This creates a textural symmetry throughout the piece.", "Turning to a second matching fish shape, he shaves leather from the back of the fins to give them a lighter, more realistic look.", "He applies glue to the edges.", "This plain fish shape will serve as the back of the sculpture.", "He applies more fins to the glued areas in the underbelly of the fish art.", "He then brings the two sides of the fish together and glues them, leaving the bottom fins and the mouth open.", "Using an industrial sewing machine for leather, he stitches the fish together with heavy nylon thread.", "This fish art is now ready to go from flat to 3d.", "He stuffs polyester fill into it.", "The leather has been moistened again so that, when it dries, it will shrink tight to the filling.", "As he stuffs the leather, he uses a wooden rod to distribute the filling.", "He then glues a carved leather fish mask onto the face.", "This adds drama to the piece.", "He trims the mask.", "Then he applies a rainbow of color to the trout, beginning with a silvery shade of white.", "He paints an olive-green shade on the top of the fish sculpture and a pinkish-red hue in the middle.", "This reflects the colors of the rainbow trout.", "He dabs black paint on the fish sculpture to replicate the spots normally found on trout.", "He then marks the fish sculpture extensively with silvery white speckles.", "He defines some of the etched lines with the same paint to make the imagery bolder.", "The artist signs the leather fish.", "Making the entire leather sculpture takes over a month.", "Now it's ready for public viewing.", "With a travel hot plate, who needs room service?", "Just unpack this single-burner appliance and plug it into an electrical outlet in the hotel room.", "It can be used to warm up soup, fry eggs or make espresso.", "It's economical and convenient, no tips necessary.", "A travel hot plate offers another way to eat on the road.", "Travelers can whip up something to eat pretty much anywhere there is an electrical outlet.", "Production starts with steel wire for the heating element.", "The wire unwinds and travels over rollers.", "The rollers keep the wire at an even tension as machinery pulls it forward.", "The machinery winds the wire around a mandrel to produce a tight coil.", "A blade then chops the coil to the correct length.", "Each coil will serve as a heating element.", "A worker slides the coils' ends onto hooks attached to a fixture.", "The fixture revolves and meets up with an automated welder, which fuses the hook to the heating coil.", "It welds one hook to each end of the coil.", "To demonstrate the coil's heating capacity, a technician connects it to an electrical source, and it very quickly becomes so hot it glows.", "A worker is now ready to install the coil in the cast-iron burner.", "Robots pick up the burners using magnetic power and transfer them to a conveyor system.", "The conveyor pushes the burners forward.", "In the meantime, a worker threads the coil between posts in an applicator head.", "This puts the coil in the correct configuration.", "An automated system then moves the applicator head forward on the production line.", "A vibrating device applies 16 1/2 tons of pressure to pack an insulating compound into the cast-iron burners.", "This compound is made of talcum, magnesite, water, and other ingredients.", "The applicator head embeds the heating coil within the insulation, allowing the hooks to protrude.", "This isolates the coil from the cast-iron burner to prevent short circuits.", "A worker coats each burner with a rustproofing varnish.", "The burners bake at a temperature of 212 degrees fahrenheit for 12 hours.", "This dries the varnish and hardens the insulation in the burners.", "Out of the oven, a worker welds wires to the protruding hooks, which will connect to a thermostat later.", "She attaches ceramic sleeves to the wires for electrical insulation.", "She then spot-welds metal connectors to the ends of the wires.", "She installs an intermediate backplate through which the insulated connectors protrude, and screws the backplate in place.", "Another worker installs the cover plate with numerous holes to vent heat from the burner.", "She screws a threaded bolt into the hot plate and attaches a ground wire to the center screw.", "She slides the thermostat onto the threaded bolt and secures the ground wire.", "She adjusts the position of the thermostat and connects the wires.", "She now attaches a plastic base and screws a temperature knob into it.", "She joins the wires to a power cord and stabilizes the connection with a plastic clamp and cover.", "She installs a metal plate over the exposed wires to encase them within the base structure.", "She slides rubber feet onto the nubs in the plastic base and applies a label with all the technical details.", "Using a probe, she confirms that the hot plate is functional, that there is no current leakage and the wiring is properly isolated from the cast-iron burner.", "A technician brings water to a boil on a randomly selected hot plate and measures the temperature to confirm it heats water consistently.", "He also aims an infrared camera at the hot burner.", "The image proves that heat is evenly disseminated across the surface.", "Once it passes all these tests, this travel hot plate is ready to hit the road.", "It should provide the means to cook food wherever in the world it happens to land.", "Ocher is the original earth tone because it's actually colored earth, yellow, orange, red or brown, depending on its specific mineral composition.", "Humans have used ocher as a pigment since prehistoric times and still use it today to tint paint, plaster, and other materials.", "From prehistoric cave paintings to renaissance frescoes, the natural hues of ocher endure to this day.", "The natural color of ocher depends on the amount and type of iron oxide it contains.", "Yellow ocher can also be baked to a shade of red.", "There was a time when men mined ocher ore underground with picks and shovels.", "Today the old mines are a tourist attraction in roussillon and gargas in the provence region of france, home of the world's largest ocher deposits and where the industrial process for making ocher pigment was invented in the late 1700s.", "Today at the last active mine in gargas, france, workers quarry-mine ocher using heavy machinery rather than manual tools.", "The ocher ore contains about 10% pure ocher.", "The rest is stones and sand, which is why the ore requires processing.", "The first step is to wash it.", "This turns it into liquid unrefined ocher.", "Next the liquid flows through sieves.", "Then the liquid ocher flows into troughs leading to a collection basin.", "Pumps transfer the liquid ocher at high pressure to the separator, which spins it at high speed.", "The centrifugal force separates the sand.", "The pure liquid ocher is pumped to drying tanks.", "Over several months, the ocher gradually settles to the bottom.", "Workers drain the water, then collect the coarse ocher powder that remains.", "Traditional processing machinery is on display at the old ocher factory in roussillon, france.", "The crusher would reduce blocks of ore into fist-sized pieces for the mill to grind.", "The ground ore would then drop through three consecutive sieves, which allowed only fine ocher powder to pass through, and collect in a barrel below.", "At this modern factory, this mill grinds the coarse ocher powder until the particles are no more than 30 microns in size, the consistency of flour.", "To make red ocher, workers put yellow ocher in a gas-fired oven and bake it for 15 minutes at 1,380 degrees fahrenheit.", "The heat dehydrates the iron oxides, which turns the color to red.", "When an order comes into the factory, a worker releases the required amount of ocher from the storage silos to the packaging machine.", "This factory has packaging machines for several retail sizes.", "Ocher isn't merely a red or a yellow pigment.", "One can produce a wide range of colors by playing with the percentages of those two base colors as well as by adding other types of natural pigments.", "For centuries, artists have mixed ocher into oil and other media to make paint.", "This artist is making what's known as tempera.", "She cracks an egg, separates the white and sets aside the yolk to use.", "She drops a few spoonfuls of ocher on her palette.", "Then adds some stirred egg yolk to bind it.", "She mixes the ingredients thoroughly with her palette knife and crushes lumps with a mortar until the tempera is just the right smooth consistency to begin applying to her canvas.", "Another medium one can pigment with ocher is cheese.", "This is known as casein painting, casein being the milk protein that's a major component of cheese.", "It must be fresh fat-free white cheese.", "And an artist mixes it with lime to make it water-soluble.", "Casein paint resembles oil paint once dry.", "However, it's inflexible and too brittle to use on canvas, so it's suitable only for rigid surfaces such as artist board, furniture, woodwork, and walls.", "Ocher can also pigment plaster, concrete, ceramic, and other construction materials for an authentic earth-tone palette that only nature can create.", "A hurdy-gurdy is a stringed musical instrument with a unique sound.", "To play it, musicians do two thubgs simultaneously-- turn a crank and play a keyboard.", "The crank turns a wheel that rubs against the strings like a violin bow.", "The keys press on the strings, changing their pitch.", "This french hurdy-gurdy maker specializes in restoring antiques like this instrument crafted in 1918 and this very damaged gem from 1882.", "The artisan carves new support struts using the original ones as templates.", "The struts are curved outward, making the soundboard convex.", "He uses spruce because it's a lightweight wood which vibrates well to conduct sound.", "Constructing a different instrument now, he runs a strip of maple through a sander to reduce the thickness to less than a tenth of an inch.", "This will become the two ribs which form the sides of this instrument.", "He cuts the strip in half and marks the direction of the wood grain, so he can butt the ribs in mirror image.", "He dampens each rib with water and runs it against a hot iron.", "This steams a curve into the wood.", "He repeats this process again and again until the curve fits a wooden form that's the exact shape of the instrument.", "He clamps both ribs to the form and lets them set for a full week.", "French hurdy-gurdies are traditionally guitar-shaped or lute-shaped.", "To construct a new lute-shaped body, the artisan removes the ribs from the antique instrument he's restoring, traces each one onto a strip of maple, then cuts out the shape with a band saw.", "He constructs a lute-shaped wooden form, then uses the hot iron to curve the new ribs to the shape of the form.", "This instrument has nine ribs.", "He alternates between maple and pearwood.", "He tapes the ribs together and lets them set for a week.", "This hurdy-gurdy was made in 1741.", "The original crank-driven wheel rubbed against the strings to produce sound like a violin bow.", "The wheel is all warped now, so he crafts a new one, on a lathe, out of pearwood.", "The keyboard's black keys are made of ebony wood.", "He cuts the basic shape with a small circular saw.", "Then he refines the dimensions with a small router.", "These new keys are part of the restoration of this 1893 instrument.", "He lightly files the original key-box slots so that the new keys will insert smoothly.", "The bottom row has 13 black keys, the top row, 10 black keys with white tops made of bone.", "Just below the key box, the top third of the wheel sticks out through a slot in the soundboard.", "And just below that is this component, the main bridge.", "The artisan traces a template on a block of maple, drills an access hole for his fine marquetry saw, then cuts it out.", "The main bridge props up the instrument's two main melody strings.", "He checks the height and shaves off excess wood with a small plane.", "He'll stain the bridge to match the rest of the instrument and glue it onto the soundboard.", "This hurdy-gurdy has new keys and a new wheel-and-crank mechanism.", "He installs new strings, starting with the two melody strings.", "Attached to a tailpiece at the bottom, they pass over the bridge, the wheel and through the key box, wrapping around new steel tuning pegs at the top.", "This restoration also requires new tangents, two wedges of maple set into each key.", "Playing a key presses the tangents against the strings.", "The artisan installs four more strings which hit the sides of the wheel, pass over smaller bridges and attach to the bottom of the instrument.", "They make a buzzing background sound, so they're called drone strings." ]

{ "things": [ "Lighters", "Fossils", "Hockey Pucks", "High" ] }

[ "Today on \"how it's made\"...", "Lighters...", "Fossils...", "Hockey pucks...", "And high-pressure cylinders.", "It's a case for combustion.", "Spin the wheel, and you have an instant flame.", "Flip the lid, and the flame is extinguished.", "A version of the lighter first appeared in the 19th century.", "At the time, it was more of a conversation piece than anything, a curiosity that received plenty of interest.", "Lighters aren't a novelty anymore, but they're still used every day.", "To make lighter cases, a machine uncoils brass from a spool, pulling it to a press.", "The press stamps the brass repeatedly to shape both the top and bottom parts of the case.", "A worker collects them and places them on a revolving table.", "Another worker slides on a hinge to link the top and bottom pieces.", "An electrode welds the hinge to the case.", "Then a mechanical arm knocks them down a chute to a worker who inspects the welding job.", "As the cases move on a conveyor system, they get a quick buff to prepare them for plating.", "The lighter cases are now plunged into a series of washing solutions and rinses, followed by a nickel solution...", "Then a chrome one.", "It's the finishing touch for the lighter cases.", "It's time to move on to the inner workings.", "A die shapes a piece of steel to make the inside cases.", "Mechanized arms then place a tube and plate in the case.", "The tube will hold the flint stone, and the plate will form the top of the inner case.", "Epoxy seals them in place, and the cases move through a curing oven to harden the epoxy.", "A worker arranges a pile of flint wheels so that the teeth are in the proper direction.", "Grippers load the flint wheels into an assembly jig.", "These cams will eventually act as a catch for the lighter lid.", "A gripper places the cam in the jig beside the flint wheel.", "The assembly jig now receives little brass eyelets between the flint wheel and the cam.", "The machine slides the inner case over the flint wheel, cam, and eyelet.", "And an automated device rivets it all together.", "A machine lowers a wick to the eyelet and threads it through.", "Blades move in from the side and snip the wick.", "This machine stuffs pieces of cotton into the inner case.", "The cotton will soak up and retain fuel when the consumer adds it later.", "Steel plungers tamp down the wick and cotton.", "Here a die punch cuts a piece of felt to size.", "Automated arms pick up the felt and shove it into the top of the inner case.", "Here grippers place a flint spring in the case just over the flint stone.", "Pneumatic screwdrivers drive the screw home.", "A rubber wheel spins the flint, and sparks fly as a light sensor checks their intensity.", "After the flint check, technicians install the inner unit in the case.", "They check the fit.", "They test the function.", "And they're off to be shipped.", "It takes many hours of work to make a fossil replica.", "Real dinosaur bones, millions of years old, are used to make life-size renditions.", "You'll find these fossil facsimiles on display in museums.", "They're very exact, almost indistinguishable from the real thing.", "The dinosaur looms large once again, brought back to life thanks to an evolution in casting techniques.", "Building these replicas is a job that can involve both high-tech know-how and hands-on skill.", "They start with the real thing, an ancient fossil.", "This is a dinosaur's upper jawbone.", "They laser-scan it, producing a three-dimensional image.", "The scanner feeds the image to a computer.", "Then it's time to go to print.", "But this isn't an ink-and-paper job.", "This tray is filled with plaster powder.", "The printer outlines the jawbone shape with a liquid hardener.", "The result is this plaster cast of the jawbone.", "There is a more traditional way to make a fossil replica.", "They arrange plywood around a fossil of this dinosaur foot.", "Then they lay sheets of clay on the wood and press it to the dinosaur bone.", "With a clay pick, they make a 90-degree angle at the bone to give it a clean line.", "Using more clay, they build a spout and a riser at one end of the bone.", "They etch an i.d. number into the clay.", "Then they paint liquid rubber onto the fossil and the abutting clay.", "They place fiber-glass sheets on the rubber, wetting it down with a polyester mix first.", "They work the fiber glass into the shape of the fossil, then paint a red gel coat onto it.", "It's a color code to identify the species-- a duckbilled dinosaur called a lambeosaurus.", "Now they have one side of a mold.", "When both sides of the mold are fabricated, they pair them up, and this fossil mold is complete.", "The rubber layer inside picks up the fossil's detail, while the outer fiber-glass one will hold the rubber rigid as they pour a polyester- and-water mix into the spout.", "It takes 45 minutes to harden.", "And now it's time for the big reveal.", "It's an exact replica.", "Next they form part of the skull.", "They make this part with hollow fiber glass instead of solid polyester.", "This will ease the load on the steel framework later.", "All the larger bones are cast with hollow fiber glass because of weight issues.", "This is a mastodon head.", "They mold up to 300 pieces to produce these skeletal replicas.", "On one side of the skeleton, they literally flesh out some details.", "They sculpt scales onto a clay-like fill to demonstrate how a dinosaur would look with some skin.", "The other side remains bare bones to give the viewer an inside look.", "A little glue completes the spine work.", "Then they mount the skull.", "When the front leg goes on, this 2-sided fossil is ready to go.", "It's a real museum piece.", "Early hockey pucks were made of wood.", "But for informal games, even objects like stones would suffice.", "Eventually rubber became the puck material of choice.", "The modern puck is three inches wide by one inch thick.", "Pucks are usually frozen before games to reduce their bounce on the ice.", "11 different ingredients go into making these rubber hockey pucks.", "The recipe begins with natural rubber.", "Two types of oil make the rubber durable.", "Certain minerals act as curing agents and antiaging agents.", "And a form of coal dust, called carbon black, serves as a filler.", "Workers feed the ingredients into a preliminary mixer-- first the slabs of natural rubber, then antioxidants to lengthen the rubber's life-span, then one type of oil to help blend in the dry chemicals, then another type to refine the rubber's rigidity level, then additives such as calcium carbonate and sulfur to help cure the rubber during the molding process, and finally, the carbon black filler.", "After 10 to 15 minutes of this preliminary blending, the mixture goes down a chute and onto a conveyor belt, which transports it to a machine called the mill mixer.", "It will perform the final mix.", "At this point, workers add more natural rubber.", "Then they add another, harder rubber that will make the hockey pucks more resilient.", "The recipe is formulated to produce a very hard rubber, one that can stand up to the rigors of repeated blows from a hockey stick.", "It's critical that the ingredients blend evenly.", "That's why workers continually cut the rubber while it's mixing.", "In the company lab, technicians evaluate a sample from each batch.", "This device is called a rheometer.", "It analyzes what's called the curing curve-- how the rubber hardens and to what degree.", "A computer compares the curing curve to the quality model.", "If they match, the batch gets the go-ahead.", "The rubber hasn't yet gone through the curing process, so it's still malleable.", "An extrusion machine squeezes it through a round die.", "This produces logs about 40 inches long and 3 inches wide-- the exact diameter of the hockey puck.", "The next machine slices each log like a loaf of bread into 39 pieces.", "Each piece is 1.1 inches thick.", "These pieces are called preforms because at this stage they're not quite fully formed pucks.", "Workers put them into compression molds that look like giant muffin pans.", "Each mold cavity is the exact size of the finished hockey puck.", "A cover goes on.", "Then the molds go into a curing press, which compresses the preforms and heats them to 300 degrees fahrenheit.", "It takes 18 minutes for the rubber to cure.", "The preforms come out as hockey pucks-- rock-hard and 1/8 of an inch thinner than before.", "They cool for 24 hours.", "During the compression phase, excess rubber oozed out and stuck to the pucks, so workers run each and every puck manually through a trimming machine.", "There is excess rubber stuck to the molds, as well.", "The factory scrapes it off, grinds it up, and uses it as filler in subsequent batches.", "The mold embedded a dimple pattern on the puck's edge.", "This texture creates friction between the puck and hockey stick.", "The more friction, the better stickhandling and the greater control the players have.", "High-pressure cylinders are metal containers designed for storing gases and for dispensing them at high pressure.", "Think fire extinguishers and oxygen tanks.", "The contents are often flammable, so the challenge is how to make these often lifesaving cylinders safe yet still easy enough to use.", "These cylinders are made out of chromoly, a steel alloy containing chromium and molybdenum.", "They start with disks that have already been heat-treated at 1,300 degrees fahrenheit for 36 hours.", "Now they go into the first of five hot chemical baths that will help the metal flex.", "After a quick drying period, each disk moves over a die.", "This process is known as deep drawing because a series of machines will gradually draw out the disk to the shape of a cylinder.", "A mandrel press begins stretching the metal, applying up to 800 tons of force-- the weight of two fully loaded jumbo jets.", "Shaping the cylinder from just one piece of metal means it will be seamless, and that's a key safety feature.", "After the disk comes through, steel jaws clamp down on the mandrel, and the cylinder slips off.", "Now another press stretches it even more.", "This machine applies 250 tons of force to continue forming the walls of the cylinder.", "That liquid is a coolant to prevent overheating.", "The cylinder goes through as many as three presses, each one stretching it another 60%.", "This press forms the closed bottom end into a concave shape.", "That reinforces the base, helping the cylinder withstand up to a thousand times more pressure than a can of cooking spray.", "A band saw now slices up to 4 inches off the other end, which will become the top of the cylinder.", "Next, a torch heats that end to 1,800 degrees fahrenheit for 90 seconds.", "In a process called hot spinning, a worker then places the cylinder in a device that spins it at 1,000 rpm.", "As a torch maintains the temperature, the machine shapes the edge of the searing-hot metal into a curve.", "In this way, the machine gradually closes off the top end and shapes two rounded areas called the shoulder and neck.", "Making these areas curved is the best way to contain pressurized gases.", "Curves spread out the stress on the metal.", "A sharp corner would focus the stress in one spot.", "The only exit for gases will be through a valve at the top.", "Workers then place 18 cylinders in a furnace heated to more than 1,600 degrees fahrenheit.", "After 90 minutes, a machine then dunks them in a chemical bath to cool for six minutes.", "The cylinders are then reheated to 1,200 degrees fahrenheit for 90 minutes, then left to cool for two hours.", "These transitions between hot and cold-- a process called tempering-- strengthen the metal and make it somewhat flexible.", "A cutting tool carves open the neck and cuts threads inside it.", "This provides the best seal when the valve screws into the neck.", "Workers clean the cylinder's surface using a process called shotblasting.", "A machine shoots these tiny steel pellets at the cylinders at very high speed.", "They test the cylinder by filling it with water.", "Then they seal it off and immerse it in water.", "The machine then adds more water to the cylinder and gauges how well it withstands the extra pressure.", "They rinse the inside with hot water, then dry and clean it by blowing in some purified air.", "Next, a hydraulic press indents the shoulder of the cylinder with legally required markings, such as the manufacturing date and the serial number.", "A machine then stretches a steel collar over the neck.", "Another device, called a valver, tightly screws on the valve, creating a leakproof seal.", "After a trip to the paint shop, these high-pressure cylinders are ready to be filled and keep it all under control." ]

{ "things": [ "Cotton", "Rodeo Roping Chutes", "Asian Noodles", "Rotary Engines" ] }

[ "The exact origins of the cotton plant are unknown, although archeologists have unearthed pieces of cotton cloth over 7,000 years old.", "Through the centuries, cotton fiber was traditionally processed by hand until the first 18th century, when the first automated processing machine was invented.", "Before cotton arrives at the textile mill to be spun into thread and woven into fabric, it makes the journey from field to bale.", "Cotton takes about five months to grow from a planted seed to a ripe plant.", "This harvesting machine, called a cotton picker, plucks fluffy seed cotton out of the plant's bowl, leaving a trail of burrs and sticks behind.", "The machine empties the plucked cotton into a tractor-drawn buggy.", "This machine builds the seed cotton into a humongous rectangular block called a module.", "A truck transports the module to the processing plant, known as a cotton gin.", "Once the cotton arrives to the processing plant, sticks and burrs are removed, as well as any lingering debris and seeds.", "A truck dumps the module into a feeder, which moves the packed seed cotton into a dispenser.", "The ground seed cotton falls onto a conveyor belt, which leads to the hot box.", "The hot box mixes the seed cotton with hot air, which allows the moisture to evaporate, making the seed cotton easier to clean.", "A machine called the wad buster breaks up the clumps of seed cotton by tossing it against a screen.", "Loose debris falls through the screen openings, down a narrow shoot.", "Then the seed cotton moves through a machine called the steady flow, which divides it equally between two processing lines.", "On each line, the seed cotton enters a burr machine, which grabs the seed cotton with a circular saw and swings it against metal bars.", "The centrifugal force shakes off the heavier debris.", "The seed cotton exits the machine through one pipe, and the debris through another.", "A large auger transfers the debris to a waste chute and out of the plant.", "The seed cotton is ready for the final stage of processing.", "A network of pipes feeds a row of machines called gin stands.", "The gin stand separates the seed from the fluffy stuff, called the lint.", "Inside each stand are 116 circular saws, which are arranged horizontally, each separated by a steel rib.", "The saw teeth grab the seed cotton and pull the lint through the narrow gap between saw and rib.", "The seed is too large to pass through, so it spins in front of the rib, then drops into a conveyor.", "The lint goes into a flue which leads to the packing area.", "Cotton seed is sold as livestock feed, particularly for dairy cows.", "It contains 23% protein, 20% fat, and 25% fiber.", "Cotton seed is also milled into cotton seed oil, a cooking oil that's a common ingredient in salad dressings and mayonnaise.", "The cotton lint is now ready to be formed into bales.", "Pipes feed the loose lint to the press area.", "When it arrives, a pusher moves the lint into a machine called the tramper, which shoves it down into a bale-shaped box.", "Once the box reaches 500 pounds of cotton lint, a press compacts the lint...", "And tie-wraps the bale.", "Next, a conveyor moves the bale to a bagging machine and past grippers, which pull a sample from each side.", "While the bale slides into a protective plastic bag, the grippers deposit the sample into a bin.", "Technicians label the bale with an i.d. number, then open the bin to retrieve the corresponding sample.", "Then the sample is bagged and labeled with the bale i.d. number.", "The factory submits the sample to the united states department of agriculture, where it's analyzed for fiber length, cleanliness, color, and other criteria.", "Once the analysis is complete, the bale is given a grade and processed accordingly.", "A roping chute is a temporary stall with a spring-loaded gate.", "During roping competitions, livestock are placed in this holding device until the gate opens, releasing the steer.", "The steer is given a head start while a professional rider follows on horseback while another steer enters the chute, ready for the next chase.", "In a roping competition at the rodeo, the chute is the starting point and holding gate for the steer.", "An operator opens the gate to release the animal into the arena, signaling the games to begin.", "To make a roping chute, technicians start with a coil of steel.", "The coil unwinds, moving between rollers.", "The rollers form the coil into tubing that will be used for the chute's framework.", "A constant flow of coolant prevents overheating and flushes away dirt and contaminants.", "Next, the tubing travels through a welding operation.", "Rollers close the gap, and a welder fuses the seam.", "Then the tubing travels through a channel with flowing coolant.", "Once out of the channel, a blade cuts it to size.", "An operator loads the tubing into a rotary bending machine.", "He activates the machine, which rotates to form rounded corners.", "The operator makes two bends in the tubing, which creates the frame for a gate.", "He will need to make two of these to complete the gate.", "An automated shear cuts steel sheets, creating panels for the walls.", "At the next station, a computerized laser cuts out parts on another steel sheet to make a control box.", "The laser cuts holes for components and perforates the steel.", "The perforations map out the locations for folds and make it easier to fold the steel.", "Next, a technician works on parts called linkages, welding rivets to each end.", "These linkages will connect the tailgate to the frame, allowing the gate to slide open.", "The technician locks the tailgate frame in a fixture.", "The fixture holds the frame steady as he welds one end of the linkages.", "The other end is riveted.", "The rivet has a head to allow a pivoting action as the gate slides open.", "He welds steel panels to the tailgate.", "They'll serve as shields, keeping the animal's legs protected from becoming trapped in the chute.", "He also welds a shield to the threshold.", "At the next station, another technician begins construction on the head gate.", "He welds steel pipes to the upper part to create grating for ventilation.", "He creates steel panel enclosures instead of more open grating to protect the animal's legs.", "On the top of the two doors, he welds more paneling, which will keep the animal's head inside the gate when it's closed.", "The roping chute's head gate is now complete.", "It operates like a saloon door, swinging open to release the animal into the arena.", "Next, the parts are placed in a welding jig.", "One of the welders installs a release mechanism for the head gate while the other welds the tailgate to the sidebars.", "At the front, the assembler adds a braking device that will keep the gate open when needed.", "They align side panels to the frame...", "And open the gates to gain access to the chute as they weld the panels to the frame.", "This completes the structural components of the rodeo roping chute.", "Springs are installed to support the opening and closing of the head gate.", "The tension is adjusted accordingly.", "Then the roping chute is immersed in vat of blue paint.", "A crane lifts the chute out of the vat, and it's set aside to dry.", "The operating levers are painted separately.", "Once try, operators bold them to the release mechanism and brakes.", "During a roping competition, the operator will turn the head gate levers to release the animal at specifically timed intervals.", "Then, it's up to competing professionals to grab the bull by the horns as fast as they can.", "The word noodle is derived from the german word nudel, but the food itself was invented in china as early as 4,000 years ago.", "Even though cooking with noodles originated in china, cultures from around the globe have used noodles in an array of unique and tasty dishes.", "Noodles seem simple.", "They're just unleavened dough formed into different shapes and sizes and then cooked, but manufacturing them isn't as simple as you'd think.", "Noodle recipes always start with flour.", "At this facility, a food-processing technician pours wheat flour and water into a large mixer.", "The technician makes sure the ratio equals 80.4% flour to 17% water.", "The remaining 2.6% is salt.", "The dough is flattened and rolled in a molding machine.", "Once the molding machine has finished flattening and winding the dough into big rolls, they're set aside to mature.", "Then each roll goes through this machine, called a calendar mill.", "A calendar mill is a series of pressure rollers designed to reduce a material to a uniform thickness.", "The dough is flattened and rolled six more times in the molding machine until it reaches its desired thickness.", "The calendar mill quickly and accurately slices the dough into slender noodles before cutting them to 47 inches.", "It's important for dough to mature.", "This helps give it strength and elasticity.", "The noodles fold over hangers and head to the next station.", "A food-processing technician transfers seven hangers of noodles to one hanger, which is the appropriate density needed for the final maturation phase of noodle production.", "The technician wheels the hangers into a device called a steam boiler.", "The noodles will spend 3 1/2 hours steaming at temperatures up to 212 degree fahrenheit.", "Once thoroughly steamed, the noodles are moved to a station to cool and dry for 24 hours before they're ready for packaging.", "The workers who package these noodles are specially trained using a scale, which helps them determine how many noodles should be bundled together.", "Once their training is complete, the technician can bundle the right quantity of noodles by eye.", "This facility relies on a traditional, manual process to manufacture their noodle.", "According to the facility, this allows workers an opportunity to closely inspect the quality of the noodles.", "This facility also manufactures a dry noodle.", "The process is nearly the same, except that rather than go through a maturation phase in a steam oven, these noodles dry, step by step, in a thermostatic room.", "The production line manufactures the noodles at 45 inches before transferring them to small bins where large, stainless steel blades chop them down to 7 inches.", "For these noodles, the manufacturers have added turmeric, a spice which provides both color and flavor and is also believed to have health benefits.", "While this facility packages certain noodle varieties by hand, it also has a fully automated packaging line for other types of noodles.", "Manufacturers produce different varieties of noodles based on customer demands.", "They sell them packaged and in bundles.", "This line is packaging them in 3-ounce bundles.", "After thousands of years, people all over the world still can't get enough of eating a variety of dishes made up of noodles.", "Throughout the 20th century, multiple versions of the rotary engine were manufactured.", "Even though they were small, light, and fast, those produced had high fuel consumption and released large amounts of emissions.", "Today, the rotary engine has been redesigned, revving up for a comeback.", "The rotary engine that powers this go-kart is one-fifth the size and weight of the piston engine it has replaced.", "With less to weigh it down in the engine department, this go-kart can gain some major speed.", "This rotary engine aims to boost fuel efficiency and cut emissions.", "Produced on a limited scale, this prototype is small enough to fit in a backpack.", "The housing is made from a solid block of aluminum.", "Computer models are used to generate the machining instructions.", "Traditional rotary engines have an oblong shaped housing and a triangular rotor that spins within the interior.", "This new design performs differently.", "Computerized tools profile the triangular housing, creating combustion chambers on the inside and cooling fins on the outside.", "They transform a solid hardened steel cylinder into a hollow crank shaft.", "The cylinder turns in a lathe as a series of cutters sculpt it together, creating a hollow crankshaft that will funnel air and fuel into the engine.", "Computerized tools mill a piece of steel to a precise geometry.", "This peanut-shaped rotor is the heart of the rotary engine.", "The rotor is immersed in de-ionized water as an electrified brass wire generates a spark that cuts into the steel.", "This step forms a ridged hole in the center that will connect to a gear.", "A technician inserts the pinion gear in a vessel which will engage with the ridged profile in the center of the rotor.", "Then the technician fills the vessel with liquid nitrogen, which freezes to negative 374 degrees fahrenheit.", "The liquid nitrogen causes the gear to shrink.", "He transfers the frozen pinion gear to the rotor.", "Using a press, he drives the pinion gear into the rotor to a specific depth.", "As the pinion gear thaws to room temperature, it expands to its original size, allowing it to fit snugly in the rotor gear.", "Another computerized machine carves into a piece of cast iron steel, held in the fixture by bolts.", "This piece will be the seal for the engine.", "The seal is sliver thin and tightly engineered.", "It's a critical part that will keep the rotary engine's working chambers air-tight.", "The seals will slide between the rotor and one of the engine's chrome-plated side plates.", "An automated grinding wheel gives the side plate a level and mirrored finish.", "Heating the side plate causes the center board to temporarily widen.", "A technician inserts a bearing into the bore and, as it cools, it shrinks to the bearing.", "The assembler inserts the crank shaft in the side cover.", "He turns the assembly over and slides a ring gear into the cover.", "He sets the fixture in an upright position and turns the crankshaft to confirm that it revolves smoothly.", "He slides the rotor, equipped with one of the seals, onto the crankshaft.", "Next, the technician assembles the housing to the motor...", "And tests the rotation of the rotor.", "As the rotor turns, it forms chambers where the combustion cycle will take place.", "He slips a bearing and a counterweight onto the shaft, followed by a bell mouth.", "The exhaust cover has three ports to release gasses.", "The port in the center is the opening for the bell mouth.", "The technician attaches an engine intake adaptor to the bell mouth.", "After the components have been secured with bolts, a dynamometer machine runs the engine and measures its performance.", "Capable of running on a variety of fuels, this new rotary engine is ready to start powering things." ]

{ "things": [ "Skateboard Wheels", "Baklava & Galactoboureko", "CO2 Scrubbers", "Honeycomb Candles" ] }

[ "Today on \"how it's made\"...", "The invention of polyurethane skateboard wheels in the early 1970s suddenly made jumps and tight cornering possible because these wheels had a better grip on riding surfaces than the old metal or ceramic wheels.", "They were more durable, and the shock absorption was greatly improved.", "Skateboard wheels come in different sizes, hardness, colors and graphic designs.", "For the rider, there are may practical and aesthetic considerations.", "Making skateboard wheels starts with a computer design.", "A designer uses the software to guide cutting tools.", "The tools carve into a solid aluminum puck and transform it into one half of a wheel mold.", "Next, the other half of the mold takes shape as the computerized tooling sculpts another puck to a profile that fits to the first one perfectly.", "Not all of the skateboard wheel molds are two-part versions.", "Others are one-piece structures, each with a pin in the center to form a bearing cavity.", "A nozzle dispenses freshly mixed polyurethane liquid into the wheel molds.", "The liquid starts to solidify immediately.", "To complete the process, a worker loads the polyurethane-filled molds into an oven and bakes them at almost 240 degrees fahrenheit for 40 minutes.", "During baking, any bubbles in the polyurethane rise to the top and are diffused, leaving solid forms with no weak spots.", "Workers remove the pins from the molds.", "Then it's on to the next station.", "Here, a worker blasts compressed air between the wheels and the molds to pry the wheels free and pop them out.", "Another worker probes the wheel using a durometer gauge to ensure the urethane has cured to the right degree of hardness.", "If the sample wheel is sufficiently hard, the batch is ready for the next step.", "The worker clamps the skateboard wheel in a lathe.", "The lathe spins the wheel while an automatic cutter contours the edges to a softer, more rounded profile.", "To give the skateboard wheels some visual impact, an artists selects and arranges graphic designs on a computer.", "He prints a film negative of the images he's chosen.", "A worker will use this negative to produce a printing plate from a piece of metal that's been coated with a light-sensitive substance known as emulsion.", "He places the film negative on the plate inside a uv light chamber.", "He closes the lid and activates the uv light.", "This triggers a photochemical reaction that transfers the image from the negative to the plate.", "The worker then applies a solution that removes unexposed emulsion and, in the process, etches the image into the printing plate.", "He rinses off the chemicals.", "Next, he dries the plate to reveal the etched artwork.", "Another worker positions a magnetized ink cup overview the image and installs it in a pad printing machine.", "An operator loads skateboard wheels onto posts that index them forward for printing.", "The ink cup deposits ink on the printing plate.", "A silicone pad picks up the inked image and stamps it onto the skateboard wheel.", "The operator removes the printed wheel and sets it on a tray.", "A technician now clamps one of the wheels in a testing device, which will gauge the rebound.", "He drops a metal ball onto the wheel and measures how high it bounces or rebounds.", "A high rebound is desirable.", "These skateboard wheels are now cleared for shipping.", "A worker wraps the wheels in plastic and heat shrinks it.", "It takes about 3 days to make these skateboard wheels.", "But how long they'll last depends a lot on the rider and how he or she rolls.", "Galaktoboureko and baklava are traditional greek desserts.", "Although several european and middle eastern countries have versions of baklava, most consist of filo pastry filled with nuts drenched in honey or syrup.", "Galaktoboureko is filo filled with custard and coated with sweet syrup.", "This variety of baklava called burma is made not with filo dough, like classic baklava, but with kataifi, shredded wheat dough.", "Burma, like classic filo baklava, contains whole pistachios, never pistachio powder.", "This burma chef pours granulated sugar over the pistachio kernels.", "Next, he sprinkles rose water, although this ingredient is optional, then syrup made with sugar, water, cinnamon and nutmeg as well as lemon to prevent the sugar from later crystallizing.", "He mixes by hand to thoroughly coat the kernels.", "The kataifi is made of all-purpose flour, milk and water.", "The chef lays out a section of dough, then takes a handful of pistachio filling and places it on the dough, forming a line running down the middle.", "For a burma loaf this size, the filling is about an inch wide and high.", "He folds the end closed and rolls the dough at an angle down the length of the burma, tightly encasing the filling as he goes.", "At the end, he folds the opposite end closed.", "It takes a burma chef months to perfect this technique.", "He places it on a tray to air-dry for 24 hours to ensure the dough maintains its rolled shape.", "Unlike classic baklava, which is baked, burma is fried.", "And the risk of burning the pistachios makes this the most technically challenging type of baklava to make.", "The chef fries the loaves for 3 minutes in oil heated to around 350 degrees fahrenheit, turning them once per minute.", "He lets the oil drain off for half an hour.", "Then, he pours warm caramelized sugar over the loaves and lets them soak for 20 minutes.", "The sugar-to-water ratio and the boiling time of the caramelized sugar have to be just right.", "Otherwise, it will become either too hard or to gooey when it cools.", "After letting the excess drain off, the loaves rest for about 3 hours.", "Then the chef rolls the loaf to flatten out the bumps and slices it into equal pieces.", "But if there's a protracted battle waging between your sweet tooth and your willpower, you've got plenty of time to work your way through a box of burma because it stays fresh for 2 weeks.", "To make galaktoboureko, the chef begins with two ingredients, milk and semolina.", "After bringing the milk to a boil, he gradually adds the semolina while whisking and lowering the temperature.", "Once the mix thickens, he sets it aside to cool.", "In a separate bowl, the chef whisks eggs, adds vanilla, then lemon or orange rind.", "Other options are orange blossom or rose water extract.", "He transfers the ingredients to an electric mixer, adds butter and sugar.", "Then he adds the semolina and milk mixture.", "This mixture must be cool so that the eggs don't cook.", "Once everything is thoroughly blended, the galaktoboureko custard is ready.", "The chef now turns his attention to the filo dough.", "He stacks 24 parchment-thin sheets of filo and slices them into squares.", "He places one scoopful of custard in the center of each square.", "The traditional greek way is to roll the squares or bake a large galaktoboureko in a pan and then cut it into squares.", "However, this chef folds over each square to make lebanese-style triangles.", "He douses the top with clarified butter, butter that's been boiled to separate out the solids and leave just the oil.", "Then he bakes the pastries for 45 minutes at 325 degrees fahrenheit.", "The golden-baked top shines thanks to the clarified butter.", "The chef cooks the same syrup he made for the baklava, sugar, water, cinnamon, nutmeg and lemon and generously drizzles the mixture all over the galaktobourekos.", "He sprinkles on cinnamon for traditional flavor and some crushed pistachios for decoration.", "The annual apple harvest is just 2 months long.", "To keep apples fresh in storage for several months, growers lower the storeroom oxygen level to put the apples into hibernation.", "Then they use machines called co2 scrubbers to absorb and remove the carbon dioxide gas the apples give off.", "This co2 scrubber pulls air from the airtight apple storage room through carbon pellets, which absorb the co2 gas molecules.", "The machine then blows the co2-free air back into the room.", "Workers build the machine's frame out of tubular steel.", "The frame supports all the components, including two sealed vessels filled with carbon pellets.", "The first vessel starts absorbing co2, a process called scrubbing, until its pellets are saturated.", "Then the second vessel takes over the scrubbing.", "The first vessel automatically kicks into a regeneration cycle, which blows fresh air through the pellets to remove the co2 molecules and exhaust them out the building.", "When the second vessel's pellets max out, vessel one resumes scrubbing while vessel two regenerates.", "To construct each vessel, workers weld a steel sheet into a circular shape, then weld on a base and a top ring.", "The ring has holes along its perimeter for bolting on a lid.", "They use a ring template to make corresponding holes in the lid, making the exact center of each hole with a punch tool.", "Then a worker mounts the lid on a fixture and following those marks, uses an automated steel punch to perforate the steel.", "The vessels go to the paint booth for a coat of powder paint, then into an oven to bake the paint.", "When they come out, the vessels are ready to be filled with carbon pellets and sealed.", "Once filled to the top, workers lay in a steel baffle.", "Its holes evenly distribute air passing through the vessel.", "A worker then places a foam rubber gasket around the perimeter and bolts on the lid tightly.", "This seals the vessel and prevents the air being blown through it from leaking out.", "The sealed lid also prevents oxygen from getting into the machine and from there into the apple storage room.", "Next, workers install the pvc piping that feeds air through the vessels along with two blowers.", "One blower pulls air from the apple storage room into the machine for scrubbing.", "The other sends it back to the room after scrubbing.", "The air flow through the pipes is controlled by valves, which are wired to the machine's electrical panel.", "That electrical panel, consisting of relays, pumps, gas analyzers and a touch screen, is built in-house in accordance with the required electrical standards of the customer's country.", "The panel is wired to a computer which controls the entire operation.", "Then a worker installs an electrical box into the machine's frame.", "And he installs the electrical panel inside the box.", "Next, the worker connects the wires to the valves, installs the touch screen and hooks it up to the computer.", "The touch screen lets the machine's operator program oxygen and co2 target levels specific to the type of apple stored in the room.", "This is critical, as different varieties of apples give off more co2 than others.", "How does it all work?", "The grower stacks bins of apples in an airtight storeroom.", "A nitrogen generator feeds in nitrogen to reduce the room's oxygen level to 1.8%.", "When that happens, the nitrogen feed automatically stops, and the continuous co2 scrubbing automatically begins.", "Many growers have in-house labs which conduct quality control tests on samples taken from each lot of scrubbed apples coming out of storage.", "No apples would pass these tests after the 2-month harvest season if not for the co2 scrubbers.", "Co2 scrubbers lengthen an apple's freshness by about 8 months, making it possible to bite into crispy apples year-round.", "Honeycomb candles are glowing reminders of the cleverness of the honeybee.", "These candles are embossed with a hexagonal pattern that mimics the cell structures bees build to store their honey.", "And interestingly, these candles are actually made from the wax foundation sheets used for beekeepers' hive frames.", "Honeycomb candles create a certain ambiance.", "They shine brightly.", "And the hexagonal pattern that's borrowed from the bees adds visual interest.", "The candle makers start with beeswax that has had the impurities filtered out and has been bleached.", "A worker first pours the beeswax into a big gas-heated kettle until it melts.", "It only takes around 1/10 of an ounce of powdered dye to tint the big vat of wax.", "He measures the amount carefully.", "The worker adds the dye and, as it dissolves in the liquid beeswax, he stirs it to distribute it evenly.", "He then opens a valve, and the wax flows into a trough beneath a large drum.", "This drum is cooled by a system of chillers.", "As it rotates, it picks up the wax.", "And the wax solidifies on contact with the drum's cool surface.", "The system then pulls the wax sheets through a narrow aperture to squeeze it thinner.", "At this point, the consistency of the wax is similar to that of taffy.", "But unlike taffy, it's not very sticky, so the layers don't adhere when rolled onto a shaft.", "The next member of the team now prepares a bath of warm water and soap.", "He then loosens up the coil of beeswax by hand.", "The roll slackens.", "The wax layers separate, leaving spaces between them.", "He immerses the wax in warm water.", "And it flows between the layers.", "The warm water softens the edges as a thinning machine reduces the thickness of the wax by half.", "Using blocks of ice, the operator then cools the softened wax to firm it up again.", "He constantly adds liquid soap for lubrication.", "This keeps the beeswax moving through the thinning machine and prevents snags.", "Using a measuring instrument called a caliper, he gauges the thickness of the wax to confirm that it's 0.16 of a centimeter.", "Next, the operator removes the roll of beeswax from the thinning machine spindle and transfers it to the spindle for the next machine.", "This machine pulls the wax through a bath of icy water to firm it up even more.", "This will top the wax from sticking to embossing rollers that now impress the hexagonal pattern onto it.", "Each of the embossing rollers is studded with 3,500 hexagonal-shaped rivets.", "They stamp the pattern onto both sides of the wax.", "A blade slices the embossed beeswax into sheets that are 16 inches in length.", "The sheets pass under another roller.", "And this one propels them off the track.", "The sheets are briefly airborne and then, they land in a neat stack.", "To make them into candles, another member of the team cuts the sheets to the desired length and width.", "The dimensions will vary depending on the size of the candles to be made.", "Leftover remnants will be melted down to make new candles.", "These beeswax sheets are now ready to be rolled by hand.", "The candle maker places a cotton wick on one edge of the sheet.", "She then wraps the wax around the wick, applying gentle pressure as she works.", "She presses the layers firmly together because the tighter the roll, the longer the candle will burn.", "At room temperature, the wax is warm, so the layers of the candle adhere.", "Finally, she packages them in plastic cellophane and applies all the necessary labels.", "These honeycomb beeswax candles are now ready to light up a space and help set the mood.", "They should burn for 8 or 9 hours or until it's time to call it a night." ]

{ "things": [ "Stainless Steel", "Football Helmets", "Resin Figurines", "Laboratory Glassware" ] }

[ "Today on \"how it's made,\" stainless steel...", "Football helmets...", "Resin figurines...", "And laboratory glassware.", "Stainless steel was invented in the early part of the 20th century.", "The key ingredient is chrome, which forms a protective oxide film on the surface.", "Originally called nonrusting steel, it amazed consumers because it didn't need to be polished and today, the concept hasn't lost its luster.", "Stainless steel is made to look shiny and new even though it starts from scrap.", "Old stainless steel is recycled to make new, giving trashed sinks, pots, and other refuse a new lease on life.", "Tons of scrap steel are fed into a roaring furnace along with chrome and nickel alloys for added strength and rust-proofing.", "Enormous electrodes heat the mix to the melting point, creating a dramatic fireworks display in the process.", "After several hours, the molten mix goes into a refining furnace.", "Pipes blast in argon gas and oxygen, converting some impurities to gas and causing others to float to the surface for easy removal.", "A technician regularly checks the temperature and takes samples to make sure the chemistry is right.", "A bit more scrap is added to bulk up the mixture as it melts.", "The scrap also causes a chemical reaction that helps to fuel the refiner.", "The bubbling steel soup now flows out of the refining furnace.", "Rollers guide it as it's cast into a long mold.", "The result is a 75-yard-long ribbon of steel.", "Torches cut it into shorter chunks called slabs.", "A worker writes identification information on each one using chalk designed for hot surfaces.", "Then, the slabs are hoisted over to another station to await further processing.", "After this break in production, the slabs are reheated to soften them up for more processing.", "By now, a rusty scale has accumulated on the steel surface.", "Workers pressure wash it away without cooling the hot metal.", "The slab shoots back and forth through a machine with rollers.", "A constant spray cools the rollers as they stretch the steel longer and thinner.", "It's now over 650 yards long, the length of a couple of city blocks.", "A spray of water cools the stretched steel a little, but not too much because it needs to be soft and flexible enough for coiling.", "This spool coils the strip tightly like a roll of toilet paper.", "Then, the roll is transferred to another station.", "Here, the steel goes into a hot acid wash that removes the scale that's built up since the last cleaning.", "Burners in this machine also heat the steel, then slowly cool it.", "This relieves stress in the metal, softening it for further processing.", "The steel is now unwound into a machine that rolls it to the customer's specified thickness.", "Rolling the metal when it's cold also hardens it and closes its surface pores, making it shine.", "After one last cleaning, the stainless steel strips are gleaming and the chrome in the steel combines with oxygen in the atmosphere to form that rust-preventing oxide film.", "Finally, rotating knives trim the edges and slit the steel to various widths, again, to meet customer's specifications.", "This job is now done, and it's a brilliant finish indeed.", "Up next, meet the starting lineup at a football helmet factory.", "Football helmets cushion the cranium, helping players score touchdowns without sustaining head injuries.", "Helmets have been part of the sport for over a century.", "First made of leather, then padded plastic, they keep the end zone from becoming a danger zone.", "In a game of tackles and tumbles, a helmet is essential equipment.", "To make one, plastic pellets are suctioned into a machine that melts and molds them into a dome shape.", "This fist-like device shapes the inside of the shell, which hardens in just a matter of seconds.", "A robot then collects it and transfers it to a conveyor.", "It's quite a lineup.", "The shells move into position for a trimming, and the extra plastic from the molding is clipped off.", "Next, a robot drills up to nine holes in the shell.", "The holes will be used to attach a liner, face guard, and various pieces of hardware.", "This robot works far more quickly than a human can, performing all the drilling in just 30 seconds.", "This is the ultimate in computerized precision.", "A worker collects the drilled shell and moves a new one into position for the robot.", "The outside of the helmet shell is roughed up with an orbital sander.", "This preps it for priming and painting.", "This factory uses a high-grade brand of automotive paint, and it takes three coats to make sure this paint job is rugged enough to survive a go on the gridiron.", "The helmets cure in the open air for up to 18 hours.", "During this time, a chemical reaction hardens the paint to a glossy finish.", "Not every helmet is painted.", "Some teams prefer tinted plastic.", "It all depends on the look the team is going for.", "Labels are attached, including safety information, trademark logos and the date of production.", "This padding is made of vinyl and foam.", "Workers snap it in place in the crown of the helmet.", "The padding for the side and back is made of the same material.", "The back is reinforced with a plastic bumper.", "A helmet from each production run undergoes an impact test.", "It's fitted on a head-shaped form equipped with sensors which are carefully calibrated.", "The technician presses a button and the helmeted head falls.", "This mimics the effect of a player's head hitting the ground during a tackle.", "The computer then measures the force of the impact on the head.", "Once the production run gets the okay, the face guard is attached.", "It's made of plastic-coated steel and has been custom produced at a different factory.", "There are dozens of face guard styles for the player to choose from.", "This helmet is now looking pretty fierce.", "But it's not ready for action yet.", "It needs a chin strap and cup.", "This machine uses heat to transfer a foil logo onto the polyester chin straps.", "It also cuts them to the correct length.", "Once a chin cup has been sewn to the strap, the assembly is loosely fastened to the helmet.", "Later, it will be precisely fitted to the player's head.", "This helmet is now almost ready for kickoff.", "There's a final inspection and then they wrap it up, complete with the manual and fitting instructions.", "It's taken less than a day to manufacture a football helmet that can withstand thousands of blows.", "Because in the game of football, protection against head injury is a victory in itself.", "When we return, bringing resin figurines to life.", "Figurines are made of many materials, from porcelain to plaster to resin-- not the kind that comes from trees, but a synthetic resin, a kind of plastic.", "It's affordable, lightweight, and easy to use, making it the material of choice for many artists and craftsmen.", "Each figurine in this collection is cast from a mold of the original sculpture, then hand painted.", "This character is a 19th-century federal marshal.", "Working from period photographs of her subject, the artist makes a sketch she'll use as a model.", "She needs plastic-based clay so it's easier to sculpt.", "She works on the facial features, constantly referring to the photographs.", "She usually starts with the figure's head and then adds it to the body.", "She works from more photographs to create his rifle.", "It's a delicate piece, so she sculpts it separately before setting it onto the figure.", "Bearing the artist's signature, it's now ready for casting.", "First, the sculpture bakes for 30 minutes at 275 degrees to harden.", "Then, workers cover it with a thin layer of releasing agent so it won't stick to the production mold they're about to make.", "They place a wall around the piece, tightly seal the base to prevent leaks, then pour in the silicone rubber mix.", "In two days, the rubber hardens enough to hold the shape of the sculpture, but is still flexible enough that workers can remove the original artwork without damage.", "After removing the retaining wall, suction is used to gently pull the piece from the mold which retains the sculpture's shape down to every last detail.", "Now, figurine production can begin.", "Workers fill the mold with a mixture of resin and flour made from ground pecan shells.", "This colors the resin and makes it stronger.", "The mixture sets in less than an hour and out comes the first of many figurines, an exact replica of the original artwork.", "The base is sanded to level it.", "Then, it's stamped with the figurine's name, i.d. number, and copyright information.", "Resin is an ideal material for casting because it captures all the details of the original artwork.", "It creates lightweight, durable reproductions that can be finished in a variety of ways.", "Here the first artist coats the figurine's broad areas with acrylic paint.", "Working color by color, she uses various brushes depending on the area she's painting.", "She finishes up with the smaller details.", "Then, she passes the figurine on to the next artist.", "This second artist fills in the facial features and other fine details.", "She starts with the whites of the eyes, then views the figurines from all angles to make sure she hasn't overlooked any tiny details.", "Her fine brushwork on the facial features is what truly bring this figurine to life.", "Bass reeves, u.s. marshal, is just one figurine in this series that proudly honors the contribution of african-americans in shaping the history of the united states.", "Once marshal reeves passes inspection, workers wrap him up in protective bubble plastic.", "Each piece in the series comes with a certificate of authenticity bearing the artist's signature as well as the name and life story of the person the figurine portrays.", "Collecting this set of resin figurines isn't just for the knickknack lover.", "This is indeed affordable art for the history buff, small-scale figures that pay a large-scale tribute to african-americans pioneers.", "Coming up, behind the scenes of a real test-tube birth.", "Their size, shape and function run the gamut, ranging from beakers and test tubes to petri dishes and vials.", "Mixing, measuring, storing, or sampling is all in a day's work for a piece of laboratory glassware, built to withstand even the most potent of chemical concoctions.", "Many scientific breakthroughs are born inside laboratory glassware, the containers scientists use to hold samples for chemical experiments.", "The glassware starts off as thin glass tubing stacked by size, weight, length, and diameter.", "Workers select the correct size for the culture tubes they're about to make and place them in a magazine.", "As it spins, it drops a tube into each slot on a cutting bed.", "Then comes the flame.", "When the heated tubing contacts the wet steel blade, the thermal shock results in a clean separation of the glass.", "The tubes get a second thermal shock treatment which cuts them to length.", "Then it's on to the glazing bed.", "A glazing burner shoots out 1,200-degree flames.", "The heat melts each tube at one end, forming a lip called the glass bead.", "Just two seconds of heat splits the tubes in half and forces the glass bottom of each tube to close in on itself.", "The finishing fire smooths out the closure.", "Then, a small amount of air is shot into the open end of the tube to form its round bottom.", "Now, the tubes head into an annealing oven side by side.", "They bake for about 15 minutes at 1,200 degrees.", "This strengthens the glass so it will better resist cracking.", "The heat also sterilizes the tubes.", "Once the tubes cool, workers collect and pack them.", "Here they're making pipettes, long tubes that labs use to transfer fluids.", "A flame heats the glass to form an indentation which determines the flow rate through the pipette.", "A wider flame then heats the glass, making it soft and malleable.", "Large rollers tug at the sides, drawing the soft glass to form the pipette's tip.", "Now, for the other end of the pipette.", "Thermal shock is used to cut it to length and again, a glazing burner forms a glass bead along the rim.", "A cutting wheel slices through the tip end, creating two tubes of identical length.", "This production line makes vials.", "These gizmos, called top turrets, feed large glass tubes into a machine.", "First, a punch-out burner heats the end of the tube to create an opening.", "Then, a steel pin widens the hole on the upper part of the vial.", "A forming dye squeezes the heated glass to sculpt the shoulder while a steel plug rises from the bottom to open the vial even wider.", "Then, a second forming dye shapes the neck.", "Next, a parting burner splits the vial into two.", "A bottom turret plucks the newly created half and draws out the soft glass to lengthen it.", "Fingers inside the turret prevent the glass from breaking.", "All that's left now is shaping the bottom of the vial.", "A burner forms a concave base in less than a second.", "The vials now slide down to what's called an after-former machine.", "Here, suction cups lift and place each vial into metal grooves on a printer bed.", "It's a basic silk-screening process with a squeegee pushing paint through the screen's holes onto the vial.", "Grippers place the vials on a rack headed for the oven where they'll bake for about 20 minutes.", "Finally, a robotic arm whisks the finished vials to packaging.", "From there, it's off to a blood bank, a hospital, or chemistry class." ]

{ "things": [ "Handcrafted Skis", "Septic Tanks", "Hydroformed Chassis Parts", "Aquarium Windows" ] }

[ "You can buy mass-produced skis from a large company, or you could choose to purchase a handcrafted set from a small independent.", "It's a matter of preference-- much like drinking beer produced by a major brewery versus a microbrewery.", "In fact, many ski-buying guides call small, independent brands microbrews.", "Handmade skis typically feature exclusive designs with high-end craftsmanship.", "They're produced in limited quantities by small, independent companies.", "This maker builds the core of the ski from two types of wood-- colorado aspen and colorado pine.", "They're harvested from trees killed by pine beetles.", "Workers glue together 8 to 10 pieces, depending on the width of the ski.", "The pieces form a laminated block that's structurally stronger than a solid piece of wood.", "They clamp the block in a press for two hours while the glue dries.", "After they remove the block from the press, they use a band saw to cut off strips.", "Each strip will be the core of a ski.", "One block typically makes six ski cores.", "Next, they shape the ski cores with a router, using a template underneath the ski contour.", "They apply a blowtorch to strips of ultra-high molecular-weight plastic to make it bondable.", "Then they coat the plastic with epoxy and adhere a strip of it to each side of the ski core.", "This forms a sturdy sidewall to protect the core from side impact.", "After the epoxy sets, they saw 6 inches off the front and back of the ski.", "With a hand planer, they taper the thickness of the ends.", "Then they heat the sidewalls again to prep them for bonding.", "But first, workers glue a plastic core called a tipspacer to the front of the wood core.", "This holds the parts together during construction.", "Then they use a hand-crank die machine to die-cut the brand name and logo into a strip of ultra-high molecular-weight plastic.", "They die-cut the same letters in white, then place them in the black cutout strip.", "This is the ski's base.", "Now they can begin constructing the skis.", "They take a left and right base and spread epoxy over the entire surface.", "They lay down a layer of epoxy-saturated fiberglass and position the ski core on top.", "Then they spread epoxy on the core and tipspacers, as well as lay extra fiberglass where the bindings will be installed.", "They position steel plates for mounting the bindings, then cover the entire ski with another layer of fiberglass.", "Finally, they add a nylon top sheet printed with a graphic design.", "They cover the assembly with a series of metal sheets and silicone heating blankets, then place everything in a custom-design ski press.", "When workers activate the press, rubber air bladders inflate, pressing the wood into a ski shape.", "35 minutes later, the skis come out of the press.", "A worker separates them with a band saw.", "Using a jigsaw, they trim the tip and tail.", "The saw leaves a rough edge, so workers sand the entire perimeter.", "Then they taper and bevel the sidewall.", "This gives the skis a better edge grip on snow.", "The final step is to peel off the film that has been protecting the nylon top throughout construction.", "These handmade skis come in several different styles, shapes, and sizes.", "All they need now are bindings.", "Then it's all downhill from here.", "Septic tanks are the perfect sewage-treatment solution for houses that aren't connected to a sewage network.", "The tank collects and treats domestic wastewater using a bacterial process to decompose waste.", "It filters the dirty water before recycling it back into the ground.", "Septic tanks are usually made of concrete and have access covers on top.", "The waste-treatment process takes place in separate chambers inside the tank.", "Steel bars called rebars reinforce the concrete structure of the tank.", "A welder assembles the rods to form a cage.", "Then he spot-welds the rebar with a mig welding torch.", "The welded cage will maintain the structural integrity of the concrete septic tank.", "The welder measures the cage's diagonals to make sure it's straight.", "Next, the worker places rebar spacers to keep the cage centered in the mold and leveled on the floor.", "A crane lowers the cage into a custom formwork made of high-strength steel plates.", "Workers close the walls around the form and secure them in place with heavy-duty locks.", "The crane lowers machined steel cores to form the interior walls of the tank chambers.", "A rigid plastic tube is inserted inside a rubber sleeve to create a flow hole between chambers.", "Using an acetylene torch, a worker cuts holes in the rebar for access openings.", "The mold allows concrete to flow over the rebar and embed the access-opening covers in the septic-tank lid.", "Workers pour over 1,300 gallons of wet concrete into the mold.", "They use a stick vibrator to eliminate air pockets and level the walls with a putty knife.", "Next, they mix more concrete and pour it over the top-slab rebar.", "Concrete blocks are used to keep the plastic covers from floating in the wet concrete.", "While one worker pours the concrete in the mold, the other consolidates the mixture with a vibrating stick.", "Then a worker levels the top of the slab with a trowel.", "Once the concrete tank is cured, workers strip the forms.", "They remove the concrete tank using an overhead crane and a compressed-air system, which forces the mold away from the concrete tank.", "The crane takes the stripped core away for cleanup.", "A worker brushes the top of the walls and sweeps the floor inside the tank.", "Then he applies a butyl-rubber tape around the top of the exterior wall.", "This forms a watertight seal between the tank and the lid.", "An overhead crane lifts the lid out of the formwork and brings it to the tank mold.", "The crane slowly lowers the lid onto the tank.", "Workers keep it aligned to make sure it seals properly.", "Then they label the tank to indicate its capacity.", "Next, the mold is opened, revealing a finished septic tank.", "The rubber sleeve molded into the wall ensures a watertight connection between the pipe carrying waste from the home and the tank.", "This tank is now ready for delivery.", "They set the tank in the ground at the client's home using a radio-remote-controlled knuckle-boom crane.", "A septic tank like this will provide a three-bedroom house with a fully independent sewage system.", "Building a vehicle begins with the chassis.", "Chassis used to be made out of welded-steel parts that were very heavy and lowered fuel efficiency.", "But thanks to a manufacturing process called hydroforming, steel chassis parts are now much lighter and stronger.", "Years ago, this suspension-system component would have been made by stamping a number of parts out of heavy steel, then welding them together.", "But today, the same component is made out of a single steel tube at a hydroforming plant.", "A solid tube is stronger than welded parts, allowing the component to be made out of lighter steel.", "The first step is to insert the steel tube in a computer-guided machine called a rotary draw bender.", "The machine inserts a mandrel to prevent the tube walls from collapsing.", "Then it bends the tube into a starting shape for the part.", "This operation may look effortless, but the machine's hydraulics must generate nearly 9 tons of pressure to bend the steel.", "After several bends, the part has its starting shape.", "The hydroforming process begins when a robot places the tube in a press for preliminary shaping.", "This is called preforming.", "The press forces the tube against a die to prepare it for the hydroforming mold.", "Here's the tube before preforming...", "And after.", "Next, a robot places the steel tube in a part mold that's already mounted on the hydroforming press.", "The machine fills the tube with water and seals the ends to trap the liquid inside.", "Then the machine closes the mold and raises the water pressure to 20,000 p.s.i.-- more than 600 times the air pressure in a car tire.", "The high pressure softens the steel tube, allowing it to conform to the shape of the mold cavity.", "When the press opens, a robot removes the now-fully-formed part from the mold.", "The hydroforming press even punched holes in it for screws and bolts.", "Next, a robot transfers the part to a circular saw, which cuts the component in half.", "This creates mirror-image right and left suspension parts.", "The saw left sharp edges on the ends of the part, so a worker smoothes them out with a handheld grinder.", "Then they inspect the parts by putting them in a specially designed dimension-verification fixture.", "They use tools called precise-diameter spheres to make sure the clearances between each part meet specifications.", "If the parts pass inspection, they're shipped to the assembly plant.", "There, workers position these parts and adjacent suspension parts in an assembly jig.", "An automated machine welds them together.", "Then a worker positions the next part and welds it to the rear-suspension unit.", "He repeats this process until the entire assembly is complete.", "To make the suspension unit corrosion-resistant, they apply a chemical coating which is bonded to the steel with an electrical charge.", "Once the coating dries, automated machines insert bushings for parts that will be installed on the suspension later.", "Bushings are rubber or polyurethane pieces that go in between two metal components to absorb shock and reduce noise.", "Workers put the finished rear suspension into a shipping cradle for delivery to the auto plant.", "At the plant, assembly-line workers install springs and shock absorbers.", "They also mount struts, wheels, and brakes.", "Then they install the entire unit on the vehicle.", "Hydroforming allows auto manufacturers the ability to produce chassis parts in shapes impossible to achieve by the older method of stamping steel and reduces the weight of the car.", "Acrylic aquarium windows are designed to be transparent.", "But they also need to be virtually indestructible and able to hold back several hundred gallons of water.", "Some of the largest ones are built to withstand repeated hits from sharks or other big fish that are swimming around inside the tank.", "Acrylic aquarium windows can be molded into different shapes and sizes.", "They can also be made to various thicknesses.", "Round, flat, or just slightly curved, these windows are worth looking into, because they offer close-up views of aquatic ecosystems.", "Each acrylic window starts with an engineer's design.", "He takes into account the anticipated water volume and the type of marine life to be housed in the tank.", "Next, a technician measures specific amounts of chemicals to be added to the acrylic.", "Two are strengthening agents and another is a u.v.-light stabilizer to counteract the damaging effects of the sun's rays.", "After the chemicals have been mixed with the binding agent, they add them to a small amount of acrylic.", "This premix will be added to a much larger amount of acrylic later.", "They blend in some dye to offset the yellowish tone that's common in acrylic.", "The result is a homogenous mixture with a syrupy consistency.", "Using a crane, they bring two halves of a steel mold together and place them on supports.", "Once the walls of the mold are in place, they lock them together with bolts.", "The final acrylic mixture is ready.", "It now flows into the mold cavity.", "A thermostat for heat coils located in the walls is activated.", "They roll the mold into an autoclave.", "The acrylic slowly bakes under pressure to ensure a consistent cure.", "It takes five days for the acrylic to turn into a solid slab.", "An employee monitors the temperature readings daily.", "Once the acrylic cures, they slice a piece off and bend it with a hydraulic tool until it breaks.", "If the piece can withstand 14,000 pounds per square inch without breaking, it passes the test.", "At another station, they test the elasticity of the acrylic.", "They do a few more compression tests to prove that the acrylic holds strong under heavy pressure.", "After testing, they're ready to cut the acrylic slab.", "Acrylic shrinks unevenly during the curing process, so they need to cut it to the desired size and shape afterwards.", "As you can see, aquarium windows are a lot thicker than normal windows.", "To make a contoured aquarium window, they lower a flat acrylic slab onto a curved molding bed.", "Then they heat it in an oven for up to a month.", "This causes the acrylic to soften and conform to the rounded shape of the molding bed.", "Once again, they've made the slab oversized to account for the distortion and shrinkage that can occur during the curing process.", "A worker cuts the curved slab to the engineer's specifications.", "He cuts off big chunks.", "They're so heavy that it takes three people to carry them away.", "They test the optical clarity of each window.", "To do this, a worker on one side of the window moves a grid pattern around while a worker on the other side scrutinizes the grid lines for distortion.", "Satisfied that the aquarium window offers a clear view, they clean and polish it thoroughly.", "They'll do a final clean after the window is installed on-site.", "The time it takes to manufacture an aquarium window depends on the complexity of its design and the window's thickness.", "Some can be produced in as little as four weeks.", "No matter how long it takes, there's no doubt that the views will be well worth the wait." ]

{ "things": [ "Replica Foods", "Traffic Cone Dispensers", "Rocking Horses", "London Taxis" ] }

[ "This meal may look delicious, but it actually tastes like plastic.", "This is fake food.", "It's not for tasting-- it's for tempting.", "Restaurants and food stores use these imitations to entice customers.", "Fake food is also used as props in movies and tv because the camera loves it.", "This fake food will keep that fresh-cooked look forever.", "That means there will be no waste from the restaurant display case.", "These authentic-looking fakes start out with the real thing.", "In this case, it's a sea bass.", "The worker blots up excess oil from the skin.", "He then uses an adhesive to glue the fish to the base of a wooden box.", "Next, he immerses the fish in liquid silicone.", "24 hours later, after the silicone is set, he breaks open the box and removes the fish.", "This detailed silicone negative can now be used to mold exact replicas of the original fish.", "They preheat the mold until it's warm to the touch.", "This kick-starts the curing of this liquid plastic, which they pour into the mold.", "Once the mold is filled, they zap it in a microwave oven for 45 seconds.", "It solidifies the plastic significantly, but it still needs a bit more curing, so the worker transfers it to a conveyor.", "It carries the mold under a lamp, whose intense energy completes the curing of the plastic.", "The worker now extracts the mold and plastic replica.", "Spillover from the molding has created a few ragged edges, so he trims them with a pair of scissors...", "Then grinds the edges to smooth away the rest.", "He also uses the grinder to do some contouring.", "Now for the real artistry.", "The worker sprays silvery paint onto the plastic bass.", "It gives the fish scales a lifelike, luminous texture.", "A bit of dark-gray paint brings out the silvery undercoat.", "Brown paint on the tail and fins make them look more realistic.", "Using an artist's brush, he paints the eyes.", "He brushes on fine lines that look like natural creases and adds some other typical sea-bass markings.", "A coat of lacquer keeps the paint from chipping and makes the sea bass look moist.", "Now the sea bass will always look like the catch of the day.", "And unlike a real fish, it won't start to decompose.", "At this faux-food factory, there are 3,500 molds.", "Each one can be used hundreds of times and will produce an exact copy of the original every time.", "For things like meat and potatoes, they add color to the liquid plastic before they do the molding.", "This reduces the amount of painting they'll need to do later.", "It takes some trial and error to get the pigments just right, but when they do, this fake meal looks good enough to eat.", "They drizzle the beef and side dishes with gravy-colored glue that makes the fake food adhere to the plate.", "Now that they've pulled this meal together, it should never come apart.", "It takes a couple of days to produce all these dishes, but it should be worth it because, compared to real food, it will last forever.", "Traffic cones create a necessary diversion.", "They keep drivers away from dangerous situations.", "But sending workers out onto the highway to set up those cones can be a perilous job.", "Now there's an automated machine that both dispenses and collects cones to keep everyone out of harm's way.", "The automated traffic cone dispenser goes where some might fear to tread-- the middle of the highway.", "Its robotic arm swings back and forth for a speedy deployment of traffic cones.", "To make one, workers slide three big metal disks onto a shaft and space them evenly apart.", "They pull a string from disk to disk to confirm all three are aligned.", "Once they're in place, a worker welds the disks to the shaft.", "They reinforce this installation job with several braces, welding five to each disk at the point where it meets the shaft.", "They spin the shaft and inspect the work.", "Next, they install the tracks that will shuttle the traffic cones to the robotic arm.", "They weld 13 of them to the disks.", "The framework for the automatic traffic cone dispenser is now complete, so it's over to the paint booth.", "They prime and paint it bright yellow, so it will be clearly visible on the highway.", "Here, a technician then assembles the main control panel.", "It's the brains behind the cone-dispensing robot.", "The technician connects cables that deliver power to the motors.", "He installs a series of switches and relays that will activate the motors that rotate the drum, swing the robotic arm, and deliver the traffic cones.", "Finally, he tests the circuit breakers to confirm that all systems are go.", "Down the production line, this worker attaches the gripper to the arm.", "A pivot bolt allows the gripper to open and close, and this chain will keep it pointed downward, so it's always in position to deploy a traffic cone.", "He tightens the turnbuckles and then checks the chain's tension.", "He swings the arm to confirm that it and the gripper move freely.", "Now he installs the transmission for the motor that will move this robotic arm.", "Finally, he snaps a retainer ring onto the transmission shaft.", "Two workers then carry a heavy extender mechanism over to the gripper arm and bolt the mechanism to it.", "This extender will both support the arm and allow it to move easily from one side of the dispenser to the other.", "A sensor device, called an encoder, will keep track of the gripper arm's position when it's moving.", "The technician then installs the motor that will power the gripper arm to oscillate and deploy the traffic cones.", "Once the gripper arm has been attached to the cone dispenser, they mount the whole unit on a trailer, with the main control box on the front.", "They adjust the settings for traffic-cone deployment and put the machine through all its paces.", "This test run ensures that all the parts are functioning properly.", "A technician tweaks the machine's computer program to fine-tune the drop-off coordinates.", "After all, releasing the cones too soon could cause them to topple.", "Every automatic cone dispenser undergoes a road test on the open highway to confirm that it will perform in real conditions.", "The driver activates it from the safety of the truck cab, while the robotic system is at center line, doing all the lifting and taking all the risks.", "If they find a problem now, they'll send it back to the factory for modifications, but this machine handles the drop-offs and pickups with precision, and that means it's ready for traffic duty.", "The ancestors of toy rocking horses may be the wooden horses on wheels of the middle ages, on which knights would practice their jousting skills.", "Child-sized wooden horses on bow-shaped rockers emerged in england and germany in the 1700s, when queen victoria famously had dapple-gray rocking horses made for her children.", "This rocking-horse company in the u.k. handcrafts antique reproductions and originals.", "Some have traditional bow rockers, but most glide back and forth on a safety stand.", "The horses are made of durable hardwoods, such as oak, maple, and tulipwood.", "After cutting off knots and other defects, workers run each piece through a ripsaw, slicing off the rough and discolored wood directly under the bar.", "Then they cut the pieces into 12-inch-wide blocks, and with a planer, slice off a thin layer of wood.", "This makes the surfaces nice and smooth.", "These are the blocks with which they'll construct the horse's main body.", "To make the legs, an artisan lays a template on an as-yet-unplaned piece of wood and traces it.", "Then he cuts along the trace line with a band saw and runs the leg through the planer.", "Each leg has a protruding piece on top called a tenon that fits into a slot called a mortise beneath the main body.", "To build the body, they roll glue onto the body blocks and assemble one to the other, building a large rectangular box with a hole at the center.", "This hole reduces the horse's weight and relieves structural stress.", "In some models, the hole also serves as a secret locking compartment.", "After clamping the assembly and letting it set for 24 hours, they coat each leg tenon with glue and insert it into a mortise.", "After rough-carving the body, a highly skilled craftsman outlines the head features in pencil-- cheekbones, nostrils, eyes, teeth.", "Then he begins the meticulous task of carving the horse to completion, hitting a mallet against a u-shaped gouge.", "This painstaking carving process takes 2 to 3 days.", "Now, after inserting a glass eye, he rough-files the whole horse using a rasp to remove all the gouge marks.", "This takes another few hours.", "Then he smoothes the entire surface with an electric sander four times over, using progressively finer sandpapers.", "He does the final sanding touch-ups by hand.", "The wood is now ready to be either stained or painted to the customer's specifications.", "If it's the latter, the artist first applies a coat of water-based primer, then, for this client's custom order, a coat of light-blue paint that turns gray when varnished.", "Once the background color dries, he hand-stipples a pattern.", "After the surface is varnished and waxed, he dresses the horse in a suede saddle blanket.", "He uses brass tacks to affix it along the leather trim.", "Next, he nails the leather saddle in place.", "He squeezes globs of glue into a slot running down the horse's neck and inserts the mane, a weft of genuine horsehair.", "Then he nails it in place.", "Now he applies glue to the tail hole and fits a tail, also made of real horsehair.", "Now they begin constructing the safety stand, on which the rocking horse will glide.", "To make the posts, they turn cylindrical blocks of wood on a lathe.", "Then they assemble the posts to the other parts of the stand and stain the wood.", "They apply two coats of varnish and let the stand dry overnight.", "They install the stand's stained and varnished gliders and mount the horse.", "They drill a hole through each hoof and glider, then join them with a nut and bolt.", "The gliders connect to the front and back of the frame with plated steel swing irons.", "The angle at which the irons are set ensures a continuous smooth glide.", "So even though these rocking horses are built to withstand the weight of two adults, riding them is child's play.", "With curved lines and classic styling, the black cabs of london are internationally recognized as british icons.", "Many say the london taxi system is the best in the world, and for many london visitors, a taxi ride is more than just transportation-- it's a tourist attraction unto itself.", "The modern black cab was born in 1948.", "Today, there are about 20,000 black cabs on the streets of london.", "Because the taxi can easily be driven 30,000 miles each year, the cars need to be robust.", "To start, operators position steel panels into a press that uses hydraulics and air pressure to fold them.", "The press can apply up to 800 tons of force to fold and form each chassis component.", "Once they get their 3-dimensional shape, the supple panels become stiff side rails.", "Welders then assemble two side rail with a cruciform to create the chassis assembly.", "They clamp the side rails firmly in place before welding them.", "The taxi uses a 4-cylinder, direct-injection, turbodiesel engine that is hoisted in with the gearbox.", "Then they connect the radiator hoses and pipes to the engine.", "The axles, wheels, suspension, and exhaust system are now in place.", "To build the components of the taxi's body, welders assemble sheet metal using a spot welder.", "The device has two copper electrodes that clamp the sheets together and concentrate electric current into a small spot.", "Forcing a large current through the spot melts the metal and forms the weld.", "Now it's time to assemble the taxi's sides and floor.", "Since the floor is completely flat and the roof is high, passengers with reduced mobility can easily enter and exit the taxi.", "The body has been covered with an anticorrosion coat and a gray primer.", "Before the car gets its final color, a worker inspects it for any surface damage.", "Infrared lamps warm the body shell to 122 degrees fahrenheit to make paint application easier.", "Not all london taxis are black.", "They spray this one with yellow paint.", "Later, they apply a shiny clear coat.", "Each painted car moves to the polishing room.", "The bright lights allow the technicians to check for any dirt, runs, dry spray, or other paint defects as they carefully polish the car.", "A worker bolts the hire sign to the roof.", "A rubber seal prevents water leaks.", "They carry the front windshield with rubber suction pads and carefully put it in place.", "They seal the rubber sides to ensure they are watertight.", "The body is covered with plastic casing to protect it from damage as it's hoisted down onto the chassis.", "Although these taxis are large and roomy, their mandatory 28-foot curb-to-curb turning circle allows them to easily perform u-turns.", "A driver tests the car at different speeds, changing gears, and testing the a.b.s. brakes.", "Each taxi also undergoes a water test.", "They check for leaks through the glass and around the doors.", "With an access ramp and fold-down seats, it's easy for wheelchairs to board the taxi.", "The taxi offers enough space for five seated passengers.", "It takes about two weeks to build a taxi.", "Then it's off to navigate the streets of london." ]

{ "things": [ "Champagne", "ATMs", "Marine Turbochargers" ] }

[ "The word champagne is often used to describe sparkling white wines.", "But true champagne can only come from the champagne region of france.", "It must meet a long list of special requirements before receiving the coveted label.", "The champagne industry is heavily regulated.", "The grapes must be locally grown in the champagne region of france.", "They can only use three types of grapes, black pinot noir, pinot meunier, or white chardonnay, to produce champagne.", "Additional rules regulate how the grapes can be pruned, picked, pressed, fermented and aged.", "Workers harvest the grapes in mid-september.", "They use aerated crates to transfer the crops to a grape press.", "They crush the grapes and immediately filter the juice.", "The grape skins and pulp can alter the juice's flavor, so they have to be removed quickly.", "Vintage champagne is fermented in old oak barrels.", "They use a sulfur disk to disinfect the barrels between uses.", "First, a worker lights the disk and inserts it through a hole on the side.", "The flame goes out once it's sealed inside the barrel.", "The sulfur smoke fills the barrel and kills off any bacteria.", "Non-vintage champagnes are produced in these stainless steel tanks.", "They start the fermentation process by adding yeast to the grape juice.", "In about 10 days, the yeast turns the sugar into alcohol and carbon dioxide gas.", "The alcohol level of the wine is now about 10 1/2 percent.", "There are no bubbles yet because the co2 escaped through the top of the tank.", "Each fermentation barrel and tank is labeled based on where the juice inside originated.", "The grape juices from each village have distinctive tastes, caused by differences in soil composition and sun exposure.", "Blending begins after the first fermentation.", "The winery's experts experiment with different combinations until they find the taste and aroma they're looking for.", "They bottle the mixture with yeast and sugar, and place it in a cold, damp cellar for 5 weeks.", "This second fermentation raises the alcohol content to 12 1/2 percent.", "After fermentation, they lie the bottles down horizontally and let the champagne age for up to 10 years.", "After the aging, the bottles go into a machine that freezes the neck.", "The yeast residue freezes in a small ice cube under the cork.", "The carbon dioxide is invented during the second fermentation.", "When workers open each bottle, the gas pressure ejects the ice cube.", "This procedure is called disgorging.", "A worker turns the bottle to minimize the amount of champagne that escapes.", "Then he smells it to make sure the champagne hasn't spoiled.", "The winery makes a special liqueur out of wine and cane sugar, which they add to the champagne.", "The amount of liqueur added brings the champagne to one of three sweetness levels, known as brut, sec, or demi-sec.", "The filling machine secures the new cork with a wire cap.", "The next machine rotate the bottles to mix in the liqueur.", "Then the bottles go into the cellar for at least 3 months.", "After they come out of the cellar, the bottles go through an automated washing machine.", "A worker inspects every bottle for floating cork particles or flaws in the glass.", "The labeling machine's first station places gold foil over the neck.", "The foil label bears the winery's name.", "The second station fires a shot of compressed air to mold the foil to the shape of the cork.", "The third station glues on the neck label.", "It's made of varnished paper.", "Then, the last station applies an adhesive label to the front of the bottle.", "A scanner makes sure the foil and labels are in the correct place.", "This bottle of champagne is finally ready to drink.", "When you pop the cork, the gas trapped inside gently escapes.", "Shaking the bottle just before opening will cause an even more dramatic champagne explosion.", "Either way, it's the perfect drink to celebrate any occasion.", "Cheers.", "Before the automated teller machine, withdrawals and deposits were made in person.", "Then, in the 1960s, simple cash machines started to appear all over europe.", "Later, more sophisticated versions were developed.", "Today's atms make it easy and convenient to bank outside of normal business hours.", "Atms are made of two sections.", "The bottom is a steel safe that houses the cash dispenser.", "The head module contains all the user features on top.", "Most of the atm's non-electronic parts are cut from steel sheets.", "Workers load the steel sheets into a computer-guided laser cutting machine.", "The laser uses focused light to generate intense heat.", "The heat melts the steel to make the cuts.", "The simpler parts are stamped with a die and a press.", "Next, a robot loads the piece into a fully-automated computer-guided bending press.", "The press bends the part into the required shape.", "A computer guided spot welder fuses the simple parts together at set intervals.", "For more complex parts, a computer guided 3-d laser welds the entire joint.", "An automated transport system dips the steel parts in a metal primer to prevent corrosion.", "After dipping, they dry the parts in an oven.", "The housing parts are sprayed with liquid or powder paint.", "Then they go into an oven to bake on the color.", "This is the internal structure for the atm's head module.", "Workers assemble all the module's internal components, including the power unit and the atm's computer.", "Then, they lower the head module onto the atm's steel safe.", "The safe's walls can be up to 2 inches thick.", "There's a separate assembly line for the operation panel.", "This panel goes on the front of the head module.", "It contains everything used in an atm transaction, from the card reader, to the key pad, and even the speaker system.", "The key pad encrypts the user's personal identification number inside the atm.", "The machine has up to three security cameras.", "They record the key pad, the cash tray and the atm user.", "Workers connect the monitor to the internal computer.", "They also install the card reader and the receipt slot.", "At the bank's request, they can install a separate module for deposits.", "However, this atm uses the cash out slot to accept deposits.", "Workers also install the shutter, a computer-controlled flap on the cash out slot.", "It opens when the machine accepts a deposit or dispenses money.", "Next, workers mount the operation panel to the head module.", "On a separate assembly line, they prepare the electronic mechanical unit.", "It dispenses the money and accepts cash and checks for deposits.", "Workers load cassettes into the unit for each cash denomination.", "The bank will separate and stock the cash for their atm.", "Before they install the unit in the atm, they hook it up to a test computer.", "They test a few different transactions with fake bills to make sure it dispenses the correct amount.", "If the unit passes testing, workers install it in the atm safe.", "They run a couple of the finished machines through several quality control tests.", "First, a shake test ensures the atm can withstand a bumpy ride during transport.", "Next, they conduct a shower test to ensure that rain won't damage an outdoor atm.", "There's also a climate test.", "They place the atm in a chamber that simulates temperature ranging from negative 40 degrees to over 120 degrees fahrenheit.", "Atms designed for extreme temperatures usually have built-in heating or cooling systems.", "Every atm comes with basic operating software installed.", "The banks then install their custom software or have the manufacturer do it for them.", "It takes a powerful engine to move a cruise liner or a cargo vessel.", "Turbochargers help make it possible.", "They double the diesel engine's output to 100,000 horsepower or more.", "Turbochargers also use exhaust gases to run the compressor.", "In a ship's engine, the turbocharger is a welcome breath of fresh air.", "It's capable of significantly boosting the engine's performance.", "It does this by compressing almost 200 feet of air per second, then thrusting that air into the engine's combustion chamber.", "First, they make the turbine wheel.", "It's used to extract the exhaust gases.", "A long cutting tool known as a broach carves a tree-shaped pattern around the edge of a steel disk.", "The pine tree shapes are designed to interlock with the matching blades.", "Next, a computer-guided saw slices a brass alloy cylinder into small bearings.", "These bearings will support the turbine shaft.", "They make several bearings in a range of sizes and materials for different turbochargers.", "Computerized tools mill the surface of the axial bearing.", "They also drill holes to connect the turbine rotor and the casing.", "This is the completed bearing.", "A worker inserts one of the turbochargers nickel alloy blades in a mold.", "He leaves the foot of the blade sticking out.", "He slides the mold directly under a spout, which dispenses a hot liquefied tin alloy.", "He fills the mold to the top.", "The tin alloy solidifies, encasing the blade just below the foot.", "This structure will fit into a clamping device in the grinding operation.", "An employee inserts the tin-encased blades into tensioning devices in the grinding machine.", "Inside the tensioning device, a clamping mechanism grips the blades.", "As coolant flows, a computerized grinder carves grooves in the feet.", "They're specially designed to engage with the tree pattern on the turbine disk.", "They pull the tin alloy blocks out of the machine.", "They break the tin alloy, and remove the blade inside.", "Now, it's ready to be connected to the turbine wheel.", "A worker slides the blade foot into place on the turbine disk.", "Then he bends a clip back halfway, with pliers.", "He tightens the alignment with a clamp.", "He hammers the clamp down further, until it lays flat against the blade foot and turbine wheel.", "This secures the blade to the wheel.", "He continues until the blades are in place.", "It takes 41 blades to complete the job.", "Next, computerized tools mill the aluminum compressor wheel and prepare it for cutting.", "The tools carve blades and grooves in the compressor.", "The design makes the compressor more aerodynamic.", "An aerodynamic compressor is important because it allows more air to reach the ship's engine.", "Here's the compressor wheel before and after the milling operation.", "Next, they run through compressor through a safety test.", "They lower it into a chamber and spin it a lot faster than it would normally operate.", "They confirm that the compressor can withstand a speed of 27,000 revolutions per minute without breaking.", "Next, the compressor wheel receives an ultrasonic cleaning.", "High frequency sound waves ripple through the water to scrub off any grease and contaminants.", "A worker uses a blower to start drying the compressor wheel.", "Then, he lowers it into a dryer to get rid of any residual moisture.", "When we return, this marine turbocharger will become seaworthy.", "Stay tuned.", "Turbochargers deliver fresh air to big ship engines.", "This enhances their combustion and adds to their mechanical might.", "Turbochargers help make these diesel engines among the most powerful in the world, allowing them to move gigantic vessels swiftly through the water.", "A technician shines an ultraviolet light onto the surface of the compressor wheel.", "This illuminates any fine cracks that could compromise its quality.", "If no cracks are found, they start assembling the rotor.", "The employee slides bearings onto the main shaft and turbine.", "He uses a crane to align the center hole of the compressor wheel with the shaft.", "He guides it into place and fits it to the bearing.", "Then he screws a cone-shaped cap onto the end.", "The turbine wheel is connected to one end of the shaft, and the compressor is connected to the other.", "The core parts of this turbocharger are now assembled.", "A technician locks the rotor in a balancing machine.", "When he activates the machine, the rotor starts spinning.", "Sensors detect the speed and the angular position of the rotor.", "They also check for any possible imbalances.", "The team uses this information to shave down the rotor and bring it into balance.", "Then, the final assembly of the turbocharger begins.", "The team screws the iron casing to the gas outlet.", "They attach three bearings to it.", "This insert is called the labyrinth cover.", "It will act as a seal for the turbine disk and shaft.", "The long bolts fit into holes in the bearing casing.", "He moves to the other side, and secures the protruding bolts and nuts.", "He removes the compressor wheel temporarily to slide the shaft through the center bearing.", "The turbine wheel fits perfectly over the labyrinth cover.", "On the other side, he bolts the labyrinth disk to the casing.", "The labyrinth disk protects against hot turbine exhaust gas and prevents oil leakage.", "Then, he re-installs the compressor wheel.", "Meanwhile, an employee wraps rock wool insulation around the gas inlet casing.", "It's made of cast iron and built to withstand gases as hot as 900 degrees fahrenheit.", "They cover the part with a heat-resistant fabric jacket.", "Then it's ready to be mounted to the gas outlet casing.", "Workers use a crane to move it into position.", "They align the holes in the part with the threads in the casing.", "Then they bolt it into place.", "They install a cast iron casing around the compressor wheel and secure it with numerous nuts and bolts.", "They hoist an insert part into place between the compressor wheel and the casing.", "Air will flow between the insert and the compressor before traveling to the engine for combustion.", "The turbocharger is now ready to be installed in a ship engine.", "This is done in the factory's assembly hall.", "Once in place, they fire up the engine and test its performance.", "They evaluate how much power the turbocharger adds to the engine.", "They also assess the turbocharger's impact on fuel efficiency.", "This turbocharger meets expectations.", "Some cars and trucks use small turbochargers in their engines, but these behemoths should deliver twice the air pressure of those models, so the ship's captain will have all the power he needs to navigate the high seas." ]

{ "things": [ "Swiss Army Knives", "Player Piano Rolls", "Oil Tankers", "Racing Wheels" ] }

[ "The swiss army knife is an entire tool kit in a pocket-sized package.", "This little multitool actually dates back to 1891 with the original swiss soldier's knife.", "It wasn't long before it morphed into other versions for sale to the general public, and a century later, it continues to come in handy.", "Lost in the wilderness, or are you a serious multitasker?", "Either way, a swiss army knife has tools to help you cope.", "Production starts with this big coil of stainless steel.", "Equipment pulls the steel between a press and a die.", "The press forces the steel against the die to punch out blade shapes.", "It also forms the finger groove for pulling the blade out of the handle.", "They mass-produce parts like can openers and pliers using the same technique.", "They load the blades into a vibrating mix of ceramic stones and water.", "The friction polishes the steel.", "A little powder keeps the parts from sticking together.", "After several hours, they activate a powerful magnet to extract the parts from the vibrating mass.", "The process has smoothed the blades significantly.", "But the metal is weak and dull.", "So a worker arranges the blades on a mesh conveyor which goes into an oven that exposes them to intense heat.", "A quick cooldown follows, which toughens the steel considerably.", "The hardened blades now ride a carousel into a grinding station, which slims and trims them.", "That green liquid keeps them cool during this process.", "Afterwards, a computerized tool measures the blades.", "If the dimensions are even slightly off, they won't fit into the knife handle.", "A quick stamp gives the part its trademark name.", "To build the swiss army knife, they slide everything onto brass rivets, beginning with an aluminum spacer.", "A flat metal spring goes on next, followed by a can opener, a screwdriver, and an awl, a punch to make holes in leather.", "They stack another spacer and spring on top.", "They tamp it down and then slide a multipurpose hook and a pair of scissors onto the rivets.", "Another divider, another spring.", "And then they add a wood saw to this multitool sandwich, because you never know when you might need one.", "They press-fit the main blade, a corkscrew, and a smaller blade onto the assembly.", "One final spacer, and then they secure the rivets with attachments called bushings.", "Incredibly, they've packed nine tools into a bundle that's just under an inch thick.", "They chop off the tops of the rivets to make them flush with the bushings, and then this spinning tool flattens them.", "The result is a multipronged tool that's virtually impossible to pull apart.", "The blade on the swiss army knife is thin compared to other pocket knives to allow it to fit into the casing.", "They grind the cutting edge to angle it at just under 15 degrees.", "This makes it razor-sharp, ensuring there won't be many dull moments in this blade's lifetime.", "They measure the angled edge with a laser to verify that it's on the mark.", "And now it's time for the handle.", "It comes in two parts.", "They sandwich the tool bundle between them and press everything together.", "This embeds the bushings in the handle's holes for a tight installation.", "Amazingly, there's still space in this swiss army knife for a set of tweezers and a toothpick.", "Finally, they inspect every tool to confirm that it's in perfect condition and that it springs out of the handle as it's designed to.", "Making a swiss army knife is a job performed with almost military precision.", "There's no room for error when it comes to packing all these tools into a pocket-sized unit.", "And once they do, this multitool is ready to spring into action.", "The first self-playing piano system was invented around 1895.", "It sat in front of a regular piano, and the machine's wooden fingers would play the keys.", "Guiding those fingers was a roll of perforated paper.", "By the early 20th century, piano companies incorporated the roll mechanism right into the piano itself.", "The player-piano rage petered out around 1930, but there are still plenty of old player pianos around, so there remains a market for the music rolls they play.", "The original roll-making method used a recording piano.", "as the musician played, each key would trigger a pneumatic valve which pressed the corresponding rod against piano roll paper over carbon paper.", "Then they just perforate the carbon marks.", "The modern method uses an electronic keyboard and a computer.", "As the musician plays, the computer converts the notes to data.", "The musician edits the data, then loads it into a computer that's hooked up to the roll perforator, a machine that produces 18 rolls simultaneously.", "Like the old recording machine, the roll perforator has a pneumatic valve for each note of the piano keyboard.", "As the computer activates each note, the corresponding valve triggers a steel punch to descend and pierce a hole in the passing paper.", "The longer the hole, the longer the note.", "Most music consists of multi-note chords, so the machine vibrates like crazy, punching many notes simultaneously.", "When the machine finishes perforating, the operator cuts off the paper and sticks on a temporary label bearing the song title.", "The paper then moves on to another area, where they permanently stamp on the title and other information.", "Here, they slice the front end of the paper into a point.", "Meanwhile, this machine rivets brass eyelets onto an adhesive-backed polyethylene strip.", "Then around each eyelet, a die stamps out a tab.", "They stick one eyelet tab to the pointed tip of each roll.", "This tab end, as it's called, hooks into the mechanism of the player piano.", "A touch of cornstarch over any exposed adhesive prevents the papers from sticking to one another.", "When the music has lyrics, they print the words right on the rolls so you can sing along as the piano plays.", "The first step is to make a lyric stencil, which requires cranking out each word, letter by letter.", "The placement of words on the stencil is tricky because they have to synchronize with the notes.", "The stencil goes into a printer which applies the lyrics with an ink roller.", "The last step is to roll up the rolls.", "They wind each one around a cardboard spool that has a plastic flange on each end.", "When you load a roll into the piano, you mount its flanges on holders, then hook the tab end to a spool that pulls the roll through the player mechanism.", "A rubber band to keep the roll from unraveling-- then it's into a custom box.", "A machine shapes and hot-glues sheets of ornately printed cardboard into the box tops.", "The finishing touch is a sticker with the title of the music.", "When a roll moves through a player piano, air flows through the perforations, triggering the corresponding pneumatic valves.", "Each valve pushes down the corresponding note.", "This factory produces more than 4,500 different song titles on player-piano rolls, from classic favorites to top-10 hits.", "The first oil tanker was launched by the british in the latter part of the 19th century, and it fueled a revolution in transportation.", "These enormous ships now dominate the world's oceans.", "They move millions of tons of oil daily.", "And without them, most of the world's economies would be powerless.", "The life-size version of this tanker ship will be bigger than two football fields.", "It's so big that they build it in sections called grand blocks, which they assemble by crane in a dry dock.", "The process takes plenty of planning and engineering.", "They map out the job on a computer and assign a number to each of the 110,000 parts.", "In a big job like this, computer-coordinated labeling is the only way to go.", "They weld steel sheets to build the ship's hull.", "Sand, placed on the seam, melts during the welding to shield the seam from any contaminants in the air.", "Workers ready the structural steel beams.", "A robot places them at just the right spot on the welded section of the hull.", "Then an operator verifies that the placement is correct.", "More robots weld the beams to the hull section.", "Next, they submerge a steel plate in water.", "The water suppresses the noise and smoke from a plasma cutter as it carves holes in the steel.", "This steel plate will be part of the ballast tank.", "Some of the holes will allow water to flow through while others lighten up the steel structure.", "The superheated plasma also cuts slits to interlock with the structural beams on the hull part.", "They then weld the assembly and install a top plate for a double-layered hull.", "Double hulls provide extra protection against oil spillage.", "After a paint job, powerful machinery transfers the double-hull grand block to its final position on the side of the tanker.", "When fully assembled, the hull will have 12 cargo tanks with a total capacity of 14 million gallons.", "The engine section is situated at the stern of the tanker.", "It will take three diesel generators to power the ship's lighting, ventilation, and computer systems.", "They carefully lower each one onto the deck of the ship.", "A 10,000-horsepower diesel engine will be the tanker's driving force.", "Installing it is a very precise business.", "It has to be in just the right position to turn the massive propeller.", "Four months later, the hull is complete and the massive propeller is in position.", "It's all hands on deck to build the deckhouse, where a crew will live for months at a time.", "There will be an incredible 10 miles of piping on this ship.", "Here, workers weld and bolt them to the deck grand blocks.", "It's an elaborate maze with an impressive master plan.", "They connect these pipes to the series of tanks in the hull so they can be used to load and unload cargo.", "Meanwhile, inside the hull, those cargo tanks are coming together.", "On the very bottom, the crew builds a network of heating coils.", "They'll be used to heat crude oil to a more fluid form so it can be pumped out of the tanks.", "Other workers grind welded seams on the ship's outer skin.", "This evens the surface for painting.", "The paint is an epoxy blend that resists corrosion in salt water.", "They apply it in three or four layers and measure its thickness with a special ultrasonic gauge.", "In total, they spray more than 38,000 gallons of paint on this tanker.", "In this time-lapse video, our tanker comes together like toy building blocks in a matter of seconds.", "But as you've just learned, this is a complex job.", "It actually takes 16 months.", "A couple more months of testing, and this tanker should be good for the long haul.", "At first glance, a racing wheel doesn't look much different than a standard wheel.", "But look a little closer.", "There are subtle differences in the angles and contours that set it apart.", "They give it the strength to handle the extreme forces of racing and to corner well at high speed, which should have them cheering in the stands.", "The driver will get the trophy and the credit, but a good set of wheels is behind every win.", "They start with high-strength, low-alloy steel, which is a very stable material.", "The first of a series of die presses gives the center disc a concave profile and forms lug holes.", "The next press punches a hole for the hub and others called windows.", "Windows help cool the brakes while maintaining strength where needed.", "They stamp rings around the windows.", "This is called coining.", "The rings give the windows a nicer look, and the action compresses the steel to further strengthen the part.", "The next press is critical.", "It forces the disc into a bowl shape and gives it precise dimensions to accommodate brakes.", "The specific angles also reinforce the part.", "It has taken a lot of punching and pressing, but the center disc of this racing wheel has really taken shape.", "A smaller press now punches out the lug holes that were outlined earlier.", "These holes will allow the wheel to be mounted to a vehicle.", "Then the center disc goes for a spin as a series of tools trim it.", "The part is now complete.", "To make the rim, a machine unwinds coiled steel, and rollers iron out the curl.", "A mechanical arm maintains slack as the flattened steel goes under the knife.", "The blade, called a shearer, cuts the steel to length and stamps product information onto it in one swoop.", "An operator now winds the steel between three rollers to twist it into a band.", "He then places the band into the jaws of a welder, which fuses the two ends together.", "He then slides the band into a machine that scrapes off excess material from the well.", "It's still warm, so it can be easily removed.", "Now the band comes under some serious pressure as a machine forces it around dies at both ends to create flares.", "This rack transfers the rim to a series of rollers which shape its inner ledge.", "This part of the rim is called the bead seed, and it will be attached to the bead wall of the tire.", "They trim the rim to make the edges neater.", "This finishes off the part.", "They nestled the center disc loosely in the rim.", "As the rim spins, they heat the outside with a torch.", "This causes the steel to expand, and the center disc drops further into the rim.", "As the rim cools, it contracts, shrinking to the center part.", "The two parts are now interconnected, and a welding job makes the bond permanent.", "A worker drills threaded holes onto the wheel to attach valve stems.", "As it exits, the drill turns in reverse so it doesn't wreck the threads.", "After a fresh coat of paint, they apply a thread-locking adhesive to the valve stems and screw them into the holes.", "The valves will be used to add air to the tires.", "The wheel rotates as a small roller paints a stripe onto the rim for accent.", "Then a press stamps a number onto it to identify this wheel in the event of a problem.", "And now this wheel is on a fast track to the finish line." ]

{ "things": [ "Wax Figures", "Awnings", "Sandwich Crackers", "Pewter Tankards" ] }

[ "We can't all rub shoulders with political greats and movie stars.", "But for the price of admission to a wax attraction, anyone can mingle with their wax replicas.", "These look-alikes aren't much for conversation, but the likeness can be startling, thanks to a process honed over centuries.", "Famous faces come to life in beeswax, so it's almost like seeing them in the flesh.", "But how do they do it?", "It often starts with a face-to-face meeting with the subject, during which they take more than 200 measurements of the face alone and still more of the body.", "Drawing on those measurements and using photos and additional research, an artist sculpts a clay body onto a metal skeleton.", "This clay sculpture will be used to make a mold.", "The head, of course, receives special attention.", "They sculpt it in stages, and this takes about six weeks.", "To check the symmetry of the sculptured face, the artist stretches a wire from the temple to the chin.", "She measures it from all angles and compares the numbers to measurements of the actual subject.", "Every single aspect of the clay face must mirror that of the subject's precisely so if it's even slightly off, she makes adjustments.", "Here, she redefines the teeth a bit more.", "And then she tweaks the hairline.", "They're now ready for the next step-- the making of the head mold.", "The worker paints plaster onto the sculpture in 14 different sections.", "This multi-part mold can be easily removed from the clay head once the plaster dries.", "After the clay head has been discarded, they give the reassembled mold a quick rinse.", "The wax artist turns the plaster head mold upside down and slots it into the wax bench, so named because it secures the mold during the wax casting.", "They melt blocks of japanese beeswax and funnel the liquid wax into the neck of the plaster cast.", "They let it set for an hour, just long enough for the wax to solidify and form a thick crust around the inside of the cast.", "The artist removes crust at the neck and pours out the rest of the wax, leaving a hollow wax face inside.", "They set it aside for another hour to further solidify.", "The wax artist removes the plaster mold and comes face to face with the wax creation.", "She examines it thoroughly, confirming that the detail from the mold has been effectively transferred to the wax and that the wax face is a dead ringer for the human subject.", "The team then casts the wax figure's hands, and an artist matches the subject's skin tone against a chart.", "She mixes paint and dabs the brush in it.", "She then strikes her brush with another one so the paint splatters across the hand.", "She blots up the paint to blend it in.", "This technique gives the wax a speckled look that mimics human pores.", "She paints on knuckles, veins, and distinctive markings to mimic those on the subject's hands.", "She gives the nails a manicure to make the hands look identical to the subject's.", "In the hands of a skilled artist, these wax hands have come to life.", "As a medical glass eye spins, the artist blots on a very wide pupil first and then paints the periphery to mimic the person's iris.", "Iris color and pattern are unique to the individual, and the artist replicates those qualities as closely as possible.", "She glues red silk threads onto the whites of the eyes to simulate broken blood vessels.", "It's another touch of realism.", "They slot the eyes into sockets in the wax head.", "Then the wax figure is ready for its hair-- actual human hair matched to the subject's.", "They pierce the wax with a hot needle to insert each hair individually.", "The wax melts and closes around the hair.", "This process can take four weeks.", "They also plug in brows and lashes and then brush on paint like makeup.", "With his face on, the wax figure now looks true to life.", "Once completed, wax figures get movie-star treatment.", "Their hair is washed and styled regularly, and their clothing is routinely dry-cleaned.", "After all, even wax versions of famous people have to keep up appearances.", "The unfurling of awnings usually marks the roll-out of patio season.", "It's a long tradition, one that actually dates back centuries.", "Early romans were among the first to seek refuge from the hot sun under fabric awnings.", "And today, design innovations mean there's always something new under the sun.", "With modern mechanisms, unfolding an awning has never been easier.", "This manual crank system is designed for a smooth roll-out.", "And for extra convenience, there are motorized awnings operated by remote control.", "Production begins with the fabric, which comes in a range of weather-resistant synthetics.", "The seamstress cuts out patterns from thick acrylic material and sews the pieces together.", "Here she works on the awning's front valance.", "A roller keeps the fabric correctly aligned and stops it from bunching up as she sews.", "She stitches a long pocket along the border.", "A plastic rod will later be channeled through it to connect the valance to the awning framework.", "She traces a scalloped edge onto the bottom of the valance and then carefully cuts along the penciled line.", "With a steady hand, she follows the outline precisely to give the valance those distinctive curves and notches.", "Workers then position the awning panel in front of an aluminum tube.", "They thread the pocketed end of the awning into a channel in the tube and then slide a plastic rod into the pocket.", "This secures the end of the fabric to the tube.", "It takes two people to avoid any buckling of the fabric.", "They insert a plastic cap into one end of the tube but leave the other end open for the installation of the motor.", "They now wind the awning panel around the tube, synchronizing their efforts so the tension in the roll is equal at both ends.", "Next, rollers carry a squared aluminum tube to a circular saw.", "Once in position, arms descend to steady the tube, and the saw slices it to the correct length.", "The cut tube will be the carrier bar, an important part of the awning framework.", "A worker now builds that framework, starting with the carrier bar.", "He slides a bracket partway down the tube and uses it to attach the retractable arms, securing the assembly with a heavy-duty steel pin.", "Two workers slide connector pieces into the grooves in the drop bar for the valance.", "Then they raise the bar and attach the retractable arms.", "They install a side bearing in the end of the connector bar.", "It's one of two that will support the awning's main tube.", "Next up is that fabric-wrapped tube.", "They attach it to the framework and tuck the other end of the awning fabric into a round slot in the drop bar.", "They slide another long plastic rod through a pocket in the fabric to secure it.", "They're now ready for the motor.", "It's a tubular model.", "He attaches a metal bracket for assembling the motor to the main framework.", "He then equips the tubular motor with two plastic rings, one at each end.", "Powered by the motor, these rings will revolve to open and close the awning.", "A test confirms that it's fully operational.", "He slides the tubular motor into the open end of the awning tube.", "He attaches the second side bearing to the metal bracket...", "And caps the open end of the drop bar.", "A few taps with a hammer drives it down the shaft.", "He now tests the awning to confirm that everything unfolds as it should.", "He tightens some screws.", "And when it's perfectly operational, he'll install the valance.", "It takes about an hour to manufacture a motorized awning, and it should supply about a decade of shade.", "Sandwich crackers are one of life's little conveniences-- crispy wafers with peanut butter or cheese spread between them, all wrapped up in a neat package.", "In north america, factories have been mass-producing these snacks since the early part of the 20th century to satisfy the need to nibble.", "Sandwich crackers come in handy for a quick refuel.", "Just unwrap and snack while continuing on your routine.", "They start with the smaller ingredients for the dough, which include baking soda, a powdered cheese additive, and a kind of phosphate, which, like the baking soda, is a leavening agent.", "Next are enzyme tablets and the yeast, two ingredients that will later cause the dough to ferment to give the crackers textural strength.", "They add water and thicken the liquefied blend with a little flour.", "This makes it easier to pump into the next mixer.", "This one is a big trough full of flour.", "They add ice to chill it and then pipe in the small-ingredient blend.", "Cooling the mix with ice preserves the yeast and enzymes to hold off on fermentation.", "If fermentation happens too soon, the dough could turn to mush.", "They lower a lid equipped with three spiraling blades and set the blades in motion, pumping in more water to augment the moisture from the melting ice and small-ingredient blend.", "It's now ready for fermentation, so it's into a warm room to activate the yeast and the enzymes.", "The dough swells, and a worker breaks the crust to release gas.", "An automated system tips the trough of dough into a chute that takes it one floor down to the rolling station.", "The chemical changes caused by fermentation have made this dough less sticky, so it can now be rolled into sheets without adhering to the equipment.", "The dough now travels between rollers that flatten it and squeeze it to a specific thickness.", "The sheets of dough exit and accumulate.", "When several layers have piled up, the dough is on the move again.", "Several layers at a time now, it moves between a series of rollers, which compress the dough to its final thickness.", "A quick dust with flour, and the dough now goes under a rolling cutter that scores it to cracker-size proportions.", "The cutter is also spiked with pins that puncture the dough.", "The holes give the crackers a dimpled look, and they have a practical purpose, allowing steam to escape during cooking for a crispier snack.", "A sprinkle of salt, and the cracker dough now heads into the oven.", "This oven is more than 65 yards long, with several heating zones.", "The hottest is around 700 degrees fahrenheit.", "A roller breaks them cleanly along the score lines.", "A quick spray with vegetable oil adds flavor.", "The crackers then transfer from one conveyer to another and land in neat stacks.", "They head into an inspection station, where workers pick out any damaged crackers and adjust the alignment of the shingled rows so it's a smooth transition as the crackers move into lanes.", "Down the line, workers pull off samples to weigh them.", "Then equipment flips the crackers upright, positioning them to enter the filling line.", "The peanut-butter filling is ready and kept warm so it's smooth and creamy enough to pump.", "The top crackers now head downward in a precise configuration, while below, the bottom crackers whiz by the peanut-butter depositor.", "It pumps a dollop of peanut butter onto each bottom cracker.", "The peanut-butter-covered bottom crackers now move forward to meet up with the top crackers.", "And again, with perfect timing, the top crackers land on the bottom ones in exact alignment.", "Equipment separates them into sets of three as they head into packaging.", "Plastic wrap envelops them, and a heat sealer cuts and closes the packets.", "Suctioning arms collect the packets and transfer them to cardboard boxes.", "From mixing to packaging, it has taken about 24 hours to produce a packet of sandwich crackers.", "Once it reaches a hungry snacker, it will be gone in no time at all.", "A traditional drinking vessel typically used for beer, a tankard often has a hinged lid you raise and lower with a thumb lever.", "Dating back to 15th-century england, they were initially made of wood, then silver or pewter.", "The tradition of hand-crafting pewter tankards continues today.", "This manufacturer makes pewter tankards in many styles, one of which has the legend of the king's shilling engraved on it and a reproduction of a shilling coin from 1816 encased in the glass bottom.", "Every step is done by hand, beginning with a sheet of pewter that's just 1/14 of an inch thick.", "Using a punch press, they cut it into the shape required to form the tankard's body.", "Next, they place the pewter on a copper plate that has on it, in raised lettering, the story of the king's shilling.", "They feed this in between two rollers that press the lettering into the pewter.", "A soft metal, pewter is composed mostly of tin, along with smaller quantities of two other metals-- antimony and copper.", "Next, a metalsmith takes over.", "He manually bends the pewter into the cylindrical shape of the tankard's body.", "He brushes on flux, a chemical which helps molten metal flow more easily.", "Then, with a soldering tool, he fuses the edges of the body with pure tin solder.", "Traditionally, both the pewter and solder contained lead, but today, both are lead-free.", "Next, the metalsmith slides the cylinder onto a steel form and hammers the solder seam flat, rendering it virtually invisible.", "Now a specialized tradesman known as a pewter spinner slips the body onto a lathe.", "As the lathe rotates, he uses a series of tools to smooth the surface, trim excess off the top and bottom, and turn the top edge over to form a lip.", "Next, a buffer uses pumice and a cloth buffing wheel to remove imperfections and make the surface silky-smooth.", "Meanwhile, in the casting department, they heat solid pewter to 465 degrees fahrenheit then carefully pour the now molten metal into a rubber mold.", "Inside are several cavities for shillings and large rings.", "After about 30 seconds, the pewter solidifies, and the parts can come out.", "To make the tankard's handle, the casters pour molten pewter into a steel mold, then tilt the mold in all directions to spread the rapidly setting metal all along the wall of the cavity.", "This makes the handle hollow and therefore lightweight.", "They grind the ends on an abrasive belt so the handle will fit flush against the tankard body.", "Another worker, meanwhile, assembles the tankard's glass base.", "A glass disk, a shilling, a ring, then a second glass disk.", "The ring acts as a spacer, creating enough of a gap between the glass disks to allow the coin to slide around.", "He applies waterproof glue around the perimeter to adhere everything together.", "Next, he places this shilling sandwich in a pewter base and adheres a second ring to hide the glue.", "Back to the metalsmith now.", "He dabs the tankard's body onto a pad impregnated with flux.", "He then solders together the body and base.", "Once the parts are attached, a final buffing with a soft felt wheel.", "Next, the metalsmith dips the handle ends in flux and solders them to the body.", "To avoid scorching the tankard's surface, this time he uses a bismuth-and-tin solder, which requires a lower temperature to melt.", "The tankard is now fully constructed.", "They clean it in a dishwasher, then shine it up.", "First, the polisher does the inside, using a rough-grid abrasive compound, producing a matte finish.", "Then he polishes the outside, using a finer-grid compound.", "This produces a contrasting mirror finish.", "In 18th- and 19th-century england, a volunteer for army or naval service accepted a shilling as a bonus upon signing up.", "However, volunteers were in short supply, so recruiters are said to have visited pubs and slipped shillings into the pewter tankards of inebriated men, who, upon their last sip, discovered they'd been duped into serving.", "It may well be a myth, but it still makes a darn good story to share over a pint." ]

{ "things": [ "Hammers", "Swiss Cheese", "Roller Skates", "Coloured Pencils" ] }

[ "The need to hammer things goes back to prehistoric times when early man used stones as tools.", "The modern hammer evolved from those first crude implements.", "But with its forged-steel design and user-friendly handle, the hammer of today is strikingly different.", "No one-hit wonder, the modern hammer is made to endure.", "It maintains its structural integrity despite repeated pounding and pulling.", "It starts with a thick steel bar.", "An automated system loads it into an induction furnace set at more than 1,800 degrees fahrenheit.", "The fierce heat makes the steel malleable.", "This forge-hammer pounds the hot steel into a series of hammer-shaped compressions.", "Then it's into a punch cutter which trims the ragged edges of the forged steel.", "The cutoffs go into a bin for recycling.", "A worker sandwiches the newly trimmed shape in a press that fine-tunes the shape.", "The hammer is cooled down on this revolving rack.", "Then they load the hammers into a tumbler, along with tiny bits of steel-- so tiny, they're hard to see.", "But their impact will be very noticeable.", "As they toss about, the bits rub off scale and debris on the hammers, for an impressive cleanup.", "They then clamp the hammer in a device that spins it against abrasive belts to contour the striking head.", "These belts also bevel the hammer's head.", "It's a safety feature.", "The sloped edge is less likely to chip nails on impact.", "Now this jagged cutting wheel carves ridges into the hammer's head.", "The device repositions the hammer so the wheel can cut it in a different direction to create a grid.", "This surface is less likely to slip off nails on impact.", "Next comes the tempering process.", "The hammers plunge into a very hot bath.", "Then they dip them in quenching oil, which cools the metal so quickly, it hardens.", "Now it's time for another polish.", "This one makes the steal gleam.", "It's the finishing touch.", "Next, they assemble leather rings in a tray-- 25 to each one.", "They place plastic rings at each end to break up the look and buttress it with a pronged metal disk.", "They slide the tray into a compartment and insert the end of the hammer in the rings.", "A hydraulic tool rams it through them, encasing the handle in a neat wrap that's comfortable to grasp.", "They secure the end of the hammer in a clamp, and then a spinning tool flattens the prongs that protrude from the metal plate, riveting it to the leather wrap.", "Then, using a series of sanding belts, they smooth the rough leather for a seamless finish.", "This is a tank of heavy lacquer in which they immerse the hammers repeatedly.", "When it dries, the lacquer will give the leather wrap a tough, sleek finish, and the leather will look like one textured piece instead of many.", "For a different kind of handle, they pour liquid vinyl on the hammer shaft that's encased in a mold.", "The vinyl adheres to the hammer as it hardens.", "The mold leaves a dimpling impression that will make the hammer easier to grip.", "They grind off the hardened vinyl spillover and contour the handle.", "These handles are preferred by some tradesmen because the vinyl is an antishock material.", "They stamp the model number onto it.", "Paint guns mist the steel with lacquer for a little rustproofing.", "The hammers then travel through an oven, which cures the lacquer.", "After they stamp the company logo onto the vinyl, each hammer is visually inspected.", "Only then does it get a seal of approval.", "It takes about a day to make a hammer, and with the different handle wraps and sizes, they've really nailed it.", "The swiss call this cheese \"fromage d'alpage,\" which means \"cheese from the high-mountain pastures\".", "Master cheesemakers retreat to their chalets high in the swiss alps to make this special cheese.", "These individuals follow a tradition of cheesemaking that goes back to the middle ages.", "Fromage d'alpage is produced by cheesemakers who bring their cows high into the alps for five months-- to this region of gstaad, switzerland.", "In the morning, they milk their cows for about seven minutes using an automatic milking machine.", "Each cow produces around 2 1/2 gallons of milk, which contains water, protein, and fat.", "12 hours later, he removes the fat, which rises to the surface.", "He adds a starter culture, which helps preserve the milk.", "A wood fire then heats the milk for 20 minutes at a constant 86 degrees fahrenheit.", "He then adds an enzyme called rennet and more starter culture to the milk.", "After about 40 minutes, these active ingredients coagulate the milk into cheese curd.", "He cuts the solidifying curd into smaller pieces.", "To maintain an even heat, he keeps blending the curd and the liquid together.", "He continues mixing and cutting the curd until the active ingredients separate the curd from the liquid, called whey.", "To make cheese, he will use only the grains of curd.", "An electric mixer then completes the separation.", "He washes his arms and hands thoroughly, because any impurities in the cheese would ruin it.", "After heating the mixture for 20 minutes again, the curd is now the perfect texture for making cheese.", "Using cheesecloth, they remove the grains of curd.", "What started out as 80 gallons of milk will end up producing only 66 pounds of cheese.", "The cheesemaker stuffs the sack of curd into a mold and works out some of the whey.", "He then puts three molds filled with curd into a wooden press.", "And using a wooden block that distributes the pressure evenly, he squeezes out more of the whey.", "To get all the excess liquid out of the curd, he turns each 22-pound piece of cheese over so he can press it again.", "Too much liquid in the cheese would affect its shape and quality, so he does this a few times, then leaves them in the press overnight.", "The next morning, he trims off the excess cheese created around the edge by the pressing mold.", "Like every step in this cheesemaking process, this work is also done by hand.", "He soaks the cheese in salt water for 24 hours to conserve, harden, and intensify its taste.", "The cheese then goes through a salting and maturing process that lasts six months.", "During this time, they flip each piece of cheese often so it ages evenly.", "After a final surface cleaning, they put the 22-pound pieces on their sides to air-dry.", "They'll remain edible for at least 10 years.", "But, of course, you don't have to live in the alps to enjoy the taste of swiss cheese.", "When roller skates were invented by the dutch in the 18th century, they put a whole new spin on skating.", "Before that, people could only skate on iced surfaces, so the sport had definite seasonal limitations.", "The wheels of those first roller skates were wooden spools.", "But today's manufacturers have come up with some better tricks to make them.", "Roller skates have improved by leaps and bounds.", "The wheels are made of strong, lightweight polyurethane, so there's nothing to hold you back.", "They start with the shoes.", "A die press punches out leather patterns, called quarters-- four per shoe.", "They place one quarter under a foil strip, and a hot die stamps it with the manufacturer's trademark.", "Then, using a template, they mark the locations where components are to be sewn...", "Such as these racing stripes.", "They stitch them onto the leather quarters in two rows.", "The four leather quarters have been partially pieced together.", "Here, the operator finishes the job, sewing the shoe's outer layer to the liner.", "She then stitches the rest of the liner to the shoe, while a little blade on the machine trims the excess leather.", "Now the roller-skate shoe really takes shape, as she folds the leather in two and sews the toe.", "This machine punches holes and inserts eyelets for the shoelaces.", "This machine, called a laster, glues the shoe to an insole.", "They insert a shoe and insole together into the laster.", "Its nozzles coat the toe of the insole with cement while pinchers pull the leather around it.", "Then automated arms press the leather onto the insole, bonding them together.", "Another machine then nails the rest of the shoe around the insole, and a worker pounds them in further.", "A final laster folds the edge of the shoe around the heel and then drives nails into it.", "The hot lights of this machine activate cement that's been applied to an outsole and the shoe body.", "This allows the two to adhere.", "As the cement dries, this hydraulic machine presses the outsole to the shoe to aid the adhesion.", "They stitch the outsole to the shoe for reinforcement.", "After all, roller-skate shoes have to hold up to the rigors of the sport.", "They insert nails into holes of this heel-attaching machine...", "Then position a fiberboard and leather heel on it, followed by the roller-skate shoe.", "Mechanical drivers thrust the nails up into the shoe, firmly attaching the heel.", "An operator then forces the rubber sole against a circular cutter to remove the excess material.", "Next, they screw a polyurethane toe stop into a skate frame.", "They drill through holes in the frame to make corresponding holes in the shoe.", "They push bolts into the holes.", "Then, using a pneumatic socket wrench, they bolt the skate frame to the shoe.", "The bolts are too long, so they cut them down to size with a special breakoff tool.", "They slide polyurethane cushions onto kingpins, then install bearings in the hub of each wheel.", "A carousel conveyor delivers the wheel and bearings to a tool that presses them together.", "With the wheels now linked by axles, these skates are almost ready to roll.", "They mount each wheel assembly on a kingpin, then install a second cushion ring.", "These cushions can be adjusted by the skater to change the feel of the skate.", "A tweak to the axle confirms the wheels spin freely.", "It takes about four days for the experts to make a pair of roller skates.", "That's somewhat less time than it takes for the average person to master using them.", "Colored pencils come in basic color packages for schoolchildren, upgraded sets for architects and other professionals, and elaborate collections of shades for the serious artist.", "It isn't so much the color variety that determines the quality, but the pigment concentration in the lead.", "The core of a colored pencil doesn't actually contain any lead.", "It's composed of pigments, minerals, and binding agents.", "This company invented a unique type of colored pencil.", "The lead composition is such that it allows you to brush on a bit of water after you draw to create the effect of watercolor paints.", "Colored pencils start with a combination of pigments.", "Every shade has a specific pigment recipe.", "They produce a large quantity of one shade at a time.", "Following that color's recipe, they meticulously weigh the different portions of ingredients.", "Then they boil a specific quantity of water and additives and add binding agents-- a secret blend of gums, resins, or waxes.", "The ingredients expand in hot water, forming a paste.", "Workers then mix the pigments into this paste.", "The next machine processes the paste into fine chunks, intensifying the color.", "The chunks move by conveyor belt with a cylinder that compresses them, then feeds them into an extrusion machine.", "The extruder squeezes the paste in a continuous stream that's the diameter of the pencil lead.", "In a top-secret process, the next machine chops this long lead into pencil-length leads.", "But the leads can't write just yet.", "They're bathed in a vat filled with a mixture of chemical waxes.", "These waxes coat and impregnate the leads-- in this case, red ones.", "Wax is a color-delivery vehicle.", "As you write, it rubs off and adheres to the paper, taking pigment with it.", "With the leads now finished, the factory subjects random samples to quality control testing, including a break test and a durability test in which each lead must yield 100 yards of writing.", "This company makes its pencil bodies from cedar wood.", "This machine carves grooves for the leads, then coats the surface with a thin layer of glue.", "The planks pass under a wheel that places the leads...", "Then through another machine that slips a second grooved plank on top.", "The next machine carves the hexagonal shape, then slices the pencils apart.", "One at a time, the pencils shoot through a vat of colored varnish.", "Their exterior is now the same color as the lead inside.", "Once the varnish dries, a heat stamp burns the company name and color number into the wood, filling the lettering with colored film.", "Then the pencils roll across an abrasive wheel, sharpening as they go.", "The unsharpened end gets a cap of varnish, either in white or the same shade as the pencil lead.", "The factory's equipment feeds the appropriate colors to the packaging area.", "As the pencils slide into their grooved tray, workers visually inspect each and every one.", "From pigments and planks to an artistic medium, the story behind the making of colored pencils is hardly black and white." ]

{ "things": [ "Robotic Arms", "Tattoos", "Sanitary Napkins", "Concrete Pipes" ] }

[ "Today on \"how it's made,\" robotic arms...", "Tattoos...", "Sanitary napkins...", "And concrete pipes.", "The term \"robot\" comes from the czech word \"robota,\" which means \"forced labor\".", "Most robots are designed for repetitive work that's difficult, dangerous, or would just bore human beings to death.", "Robotic arms have varying degrees of freedom, meaning they can pivot in different ways.", "A robotic arm resembles a human arm.", "It has a shoulder, an elbow, a wrist, and a hand.", "The shoulder is actually a stationary base to which the rest is attached.", "An engineer first designs all the parts on a computer.", "Then those plans go into action.", "To form the base's outer casing, they bend steel sheeting into shape using a computer-guided press.", "Next they paint the casing in powder paint, using an electrostatic process that guarantees a thorough, even coat.", "They run a negative electrical charge to the casing and a positive charge to the paint particles.", "This makes the casing draw the paint to it like a magnet.", "Once the paint on the base casing dries, they use silk-screen printing to apply what's called the \"user diagram\".", "It illustrates which parts move where and how.", "Now they build the robotic arm's hand, called the end effector.", "Robots can be outfitted with all sorts of end effectors.", "Here they're making a gripper, whose two claws come together to grasp and carry objects.", "To make each claw, an automated metal drill cuts a groove lengthwise and widthwise in a piece of aluminum.", "They assemble the electrical circuit board that will later go inside the base.", "The robotic arm's six separate motors will plug into it.", "Next they assemble the mechanical parts of the base.", "First the motor that makes the arm rotate, then the gear that goes on the vertical shaft holding the robotic arm upright.", "When the motor makes the gear and the shaft turn, the robotic arm turns with it.", "At the arm's shoulder level, they install a system of four pulleys.", "Each consists of two plastic wheels on a separate axle with a rubber belt running between them like a clothesline.", "The belt has little teeth that grip grooves on the wheels.", "It rotates the wheels, making the robotic arm move.", "Each joint in the robotic arm is capable of and programmed for a specific range of movement.", "Like the human arm, the combination of these movements manipulates the end effector.", "They plug an electrical wire that links the gripper to the shoulder into a circuit board located in the shoulder.", "Then they screw the entire arm to the base.", "They link up the wires from the circuit board in the base to the motors in the shoulder.", "To do this, they have to bunch the wires, 48 of them in total, and thread them through the shaft that attaches the base to the arm.", "Once everything's connected, they fine-tune and test the gear and pulley systems to see if they run smoothly.", "Now they can install the gripper and the shaft and gear system that operates it.", "Turning the gear one way opens the grip.", "Turning it the other way closes it.", "Now they mount the assembled gripper to the forearm, plugging its motor into a circuit board that they've already installed there.", "They plug the wires from all six motors into the main circuit board which they then install at the back of the base.", "The robot controller-- the brain that runs the arm-- is a separate unit.", "It controls everything connected to the circuit.", "To move the robot, the computer inside the controller switches on all the necessary motors.", "It can control eight motors-- six in the robot and two optional accessories.", "You can program it to perform a variety of tasks.", "From start to finish, it's taken just under 30 hours to assemble this robotic arm.", "It can lift up to 10 pounds-- about the weight of a full-grown cat-- and it can move at a speed of a little over one mile per hour.", "Most robots are reprogrammable-- meaning that to change their behavior, you simply write a new program.", "From an employer's perspective, robots may be the ideal workers.", "Granted, they have no ideas of their own, but their productivity is constant, they never call in sick, and they never take lunch or coffee breaks.", "Tattooing dates at least as far back as the bronze age.", "A 5,000-year-old body found in a european glacier had several tattoos on his skin.", "Archaeologists have even uncovered what they believe are stone age tattooing instruments-- sharp bone needles and clay disks containing mineral pigments.", "Walk into a tattoo parlor and the vast selection of elaborate designs will astound you.", "Once you make your choice, the tattoo artist traces the image.", "Next, he places the traced image on carbon paper and re-traces the lines.", "This creates a carbon outline of the tattoo on the reverse side.", "The artist will use his blueprint, as it's called, as his guide.", "He cleans the customer's skin, then firmly presses on the blueprint.", "The carbon image transfers easily because the skin is damp.", "Now it's time to construct the needles.", "Most tattoos require two needles-- one to make the outline of the image, the other to shade and color it in.", "Each needle is made up of as many as 20 smaller needles.", "The artist aligns these small needles in a jig, then solders them together onto one end of a steel rod.", "There's an eye on the other end.", "The number of small needles in a needle depends on the tattoo design-- how thick the lines are, how big its colored areas are.", "The finished needles go into an autoclave to be sterilized.", "That takes 20 minutes at precisely 338 degrees fahrenheit.", "The tattoo artist uses that time to assemble the tattoo gun.", "After cleaning the frame with rubbing alcohol, he installs the motor, called the coil.", "When an electric current runs through the coil, it oscillates the needle at up to 50 times per second.", "Once the two needles are sterilized, he takes the one for outlining, called the liner, and slides it into the tattoo gun.", "He hooks the eye on the other end onto the spring.", "As the spring moves back and forth, it moves the needle up and down.", "The tattoo artist stops and starts it with a foot pedal, like a sewing machine.", "Time to tattoo.", "He turns on the power supply to 10 volts and dabs the needle in the ink cap.", "The gun sucks up the ink.", "Some petroleum jelly on the skin helps the needle glide more easily.", "He begins by tracing the lines of the blueprint.", "The needle punctures the skin at a rate of up to 3,000 times per minute, injecting micro-particles of ink, which intermingle with the cells of the dermis, the skin's second layer.", "The artist continually wipes away the excess ink to keep his work area clean.", "After finishing the outline, he reapplies petroleum jelly.", "This seals the pores of the skin and prevents bleeding.", "Then he changes to the other needle and begins shading and coloring the image with a back-and-forth movement.", "He applies one color at a time, overlapping them to ensure thorough and even coverage.", "The needle can penetrate from .", "04 to .", "15 of an inch, and a good tattoo artist knows just how deep to go to create the different parts of the image.", "For example, he has to inject the outline the deepest, but going too deep can tear the skin and cause excessive pain and bleeding.", "But not going deep enough misses the dermis and leaves marks after healing.", "The cells of the dermis are remarkably stable, so tattoos last a lifetime.", "This tattoo has taken approximately 45 minutes to do from start to finish.", "The area will dry and scab over.", "Then the scab will fall off, and this body art will be ready for exhibition.", "Believe it or not, world war i led to the invention of disposable sanitary napkins.", "American nurses serving in france discovered that the bandages they used for the troops could double as very absorbent menstrual pads.", "This led the bandage company to introduce disposable sanitary napkins in 1921.", "Today's disposable sanitary pads are made of layers of cellulose, combined with super-absorbent polymer powder.", "Polymer is a fluid-absorbing chemical derived from either petroleum or wheat.", "Cellulose is the fiber that makes up the cell wall of trees and plants.", "It also retains fluid.", "Pulp and paper companies grind and moisten it to form a product called pulp.", "Producing sanitary napkins begins with 20-inch-wide rolls of cellulose pulp.", "The rolls feed one long machine that does everything.", "First, knives spinning at 3,000 thousand rpm shred the pulp into a fine fluff.", "Then the machine sprinkles that fluff with polymer powder.", "The polymered fluff then travels through what's called the doser, a device that measures out the required amount of fluff per pad layer.", "The machine then suctions each dose into a closed chamber where an air current blows it into a pad-shaped mold.", "Then another air current blows it out of the mold onto a wheel that transfers it to a conveyer belt.", "The machine simultaneously makes a second pad layer.", "This one is smaller, rectangular, and at least double the density of the first layer, meaning it has more cellulose compressed into a smaller size.", "The compression roller also embosses a pattern that will disperse the menstrual flow, helping absorption.", "This demonstration shows the critical absorption role the polymer powder plays.", "It can retain up to 40 times its volume.", "As the polymer soaks up the liquid, it transforms from powder to gel.", "Different types of polymers have different reaction speeds.", "This type absorbs at average speed.", "This will be a two-layer pad.", "The number of layers and their weight depends on the degree of menstrual flow a pad is designed to absorb.", "Now the machine's conveyor belts merge, bringing the two layers together.", "Now the machine sandwiches the layers between plastic sheets.", "The top one is perforated to allow fluid to pass to the absorbent layers underneath.", "The bottom one acts as a leak-proof barrier.", "A roller stamps the contour of the pad, sealing the absorbent layers inside.", "Now the machine applies glue to a paper strip and to a pair of small paper rectangles.", "It slaps the strip on the back of the pad and the rectangles on the side flaps, called the wings.", "To secure the pad to underwear, you remove the paper to expose the adhesive.", "The pads are still connected to each other.", "A cutting die excises each one.", "Abrasive foam on either side of the die grips then pulls away the material surrounding the pads.", "A vacuum then sucks this excess away.", "Now the pads move onto the packaging line.", "The equipment first folds over the adhesive wings, then folds each pad in three.", "The folded pads now go into plastic wrap.", "A hot, iron-like device, called an embossing press, seals the plastic around each pad.", "Then a knife cuts in between the pads, separating them into individual pouches.", "Next, two belts sandwich the pouches and carry them down to the stacker, where an automated counter lines them up for packaging.", "As a vacuum opens the bag, a mechanical arm inserts the pads.", "The equipment then seals the bag shut.", "Everything you've seen happens at an impressive pace.", "From start to finish, it takes just 40 seconds to make and package a sanitary napkin.", "Most underground sewer and drainage pipes are made of reinforced dry-mix concrete.", "\"reinforced\" refers to the fact the concrete has steel bars inside it for added structural strength.", "\"dry-mix\" refers to the type of concrete.", "You can mold it then immediately extract it, and it holds its shape.", "Concrete pipes can be as small as 10 inches or as large as 11 1/2 feet.", "It has a hundred-year life span.", "Dry-mix concrete is made of stone, coarse sand, portland cement-- which is a finely-ground blend of clay and limestone-- water, and a chemical that acts as a water reducer.", "Trucks unload the sand and stone into outdoor storage bins.", "The materials automatically drop onto a conveyor belt which transports them to storage silos above the factory floor.", "The cement arrives by cement tanker, which blows it into a silo.", "All the silos feed the mixer.", "As the ingredients blend, the cement and water combine to form a paste that coats the sand and stone.", "The water reducer enables them to use minimal water.", "The less water, the stronger and more durable the concrete.", "Meanwhile, workers use a special machine to build what's called the cage-- a circular steel frame that will form the pipe's internal structure, its backbone.", "They insert 8-foot-long steel rods in a circular configuration, pushing each rod partway through the machine to the other side.", "There, an automated spot-welder fuses a steel cable to one rod.", "Then the machine begins turning, winding the cable tightly around the rods.", "Here a worker is turning the machine manually just to show us the process in slow-motion.", "This is what it looks like at the normal automated speed.", "As the rods pass through the machine, the welder fuses the cable to them in one continuous spiral.", "As the spiraled cable reaches the end of the rods, the machine's claws spread outward, forming a wider section on the end.", "This is called the bell section.", "Workers position it on a base ring designed to hold the cage in place.", "Then they close a hinged steel mold over it.", "Now they're ready to pour the concrete.", "A forklift transports the mold to a machine called the packer head.", "They position the mold directly under it.", "A long, drill-like screw descends into the mold.", "As concrete pours in, the screw turns at high speed, moving up and down.", "Its blades propel the concrete outward against the mold walls, forming the pipe.", "This process is called centrifugal projection forming.", "The process for making large-diameter pipes is slightly different.", "A welder fuses spacers to the cage, both inside and out.", "These will center the cage inside the mold.", "Workers position the cage onto a base ring, then lower the outer part of the mold-- called the outside form-- over it.", "After securing it to the ring, they lower the unit over the smaller, inner part of mold, called the inside form.", "An overhead funnel pours concrete into the cavity between the two mold forms.", "Powerful electrical vibrators shake the mold.", "This forces the thick concrete downward, filling the cavity.", "This process is called vibration forming.", "With either pipe-forming technique, the molded concrete is quite fragile, so the molds go off to the curing warehouse to harden.", "There, workers remove them, leaving the pipes standing upright.", "Steam hoses transform the curing warehouse into a sauna.", "The temperature rises to 140 degrees fahrenheit, the relative humidity 100%.", "The concrete hardens in about 12 hours.", "Concrete pipes buried underground have to be able to withstand the weight of the earth above them, so the company subjects sample pipes to extreme pressure to test their maximum resistance.", "Concrete pipes join together with watertight rubber gaskets." ]

{ "things": [ "Horseshoes", "Dishwashers", "Graphite Fly Rods", "Pizza" ] }

[ "Today on \"how it's made\"...", "Horseshoes...", "Dishwashers...", "Graphite fly rods...", "And frozen pizzas.", "Horses first wore leather and metal shoes around 500 a.d. to protect their hooves from wear and tear.", "Today, depending on the animal's vocation, horseshoes are usually made of steel, aluminum, or plastic.", "A farrier is someone who makes the horseshoes and carefully applies them.", "A horse's hoof has a hard outer wall like a fingernail, only much thicker.", "The farrier attaches the horseshoe to this wall with heat and lead nails.", "The horse feels no pain because the nails don't reach the sensitive tissues inside.", "Horses get new shoes about every five weeks.", "After removing the old ones, the farrier uses a file to trim the wall's growth since the last change-- about 1/3 of an inch.", "He measures the hoof's contour, marks the measurement on a steel bar, and cuts it to size with a rotary saw.", "Steel is the material of choice because it's affordable and durable.", "Next, he heats the bar until the middle's white-hot.", "He brushes off any dirt, then dips the bar in water to cool it.", "Then he hammers the ends to redistribute the metal toward the middle.", "This widens and thickens the part of the horseshoe that gets the most wear, since the front of the hoof hits the ground first and hardest.", "After reheating the bar, he hammers it again, this time with no cooldown.", "For larger shoes, two farriers take turns hammering so that it goes faster, and they can shape the steel while it's still hot and pliable.", "Using a drafting compass, the farrier gauges where two grooves for nails will go.", "He reheats the bar, then holds a sharp-ended tool against it, while another farrier drives it in with a hammer.", "The nails won't protrude when they're embedded in the grooves.", "These areas will also fill with dirt to give the horse traction.", "The farriers round the sharp edges of the horseshoe so the animal won't cut itself when it's lying down.", "They make the nail holes by first driving this tool into the grooves.", "Then they use another tool to perforate the steel, hammering it into the shoe over an opening in the anvil that lets the tool pierce through.", "The farrier then repeats these steps on the other side.", "It takes 2 farriers about 15 minutes to make a pair of horseshoes.", "The first farrier heats one shoe, while the second hammers the other.", "Like the hooves, the front and back shoes are differently shaped.", "The front pair are rounder, the back ones, more oval, because the horse's hind hooves have evolved to dig into the ground for traction.", "The farriers also hammer part of both curves, flattening the edges into raised sides called clips.", "These help the shoe fit onto the hoof.", "For larger workhorses like clydesdales, the farriers bend the ends downward to give the feet more traction.", "It's not uncommon for a 2,000-pound horse to have to pull twice its weight.", "Now time for the fitting.", "After heating the shoe, but not as much this time, the farrier uses it to melt the outer part of the wall.", "This makes an imprint on the horseshoe that later helps him place it properly on the hoof.", "Horses first wear shoes at about 3 years old, the age when they start working or competing.", "The farrier fine-tunes the fitting with a metal filing tool, curving the edges further to make them even safer for the horse.", "Next, he shines the steel with a metal brush.", "The shine will quickly fade once the horse takes its first steps.", "Depending on the foot size, the finished shoe can measure anywhere from 2.5 to 9 inches across.", "Now, to attach the shoe, the farrier first files the hoof to remove any dust or sharp edges.", "He slips on the shoe, then gently hammers as many as three nails into each side.", "The nails are about 2 inches long.", "They're made of lead-- a metal that's easy to bend-- and that's he'll do after hammering them through the wall.", "He clips off the ends and bends the rest in towards the wall.", "Then he uses other tools to gouge small crevices in which to bury the ends.", "This makes it easy to straighten out the nails and yank off the shoe when it's time.", "He also hammers the hoof against a template to stabilize the shoe.", "Next, he files the hoof so that it meets the angle of the shoe.", "And, finally, the horse is ready to stroll.", "So whether you've got a pony or a stallion, make sure the shoe fits.", "When it comes to horse footwear, function, not fashion, dictates.", "In 1886, an american woman invented the automatic dishwasher.", "Josephine cochran built a motorized wheel with wire compartments for dishes, turning inside a copper tank filled with soapy boiling water.", "It was a hit with restaurants and hotels, but it wasn't until the 1950s that affordable dishwashers for home kitchens came on the market.", "Building a dishwasher starts with a watertight container called the tub.", "Some high-end models have stainless-steel tubs.", "The rest have tubs made of molded plastic, usually polypropylene.", "Workers screw two pairs of plastic wheels to each side of the tub.", "They'll support the sliders on which the upper dish rack moves.", "The lower dish rack rolls along the bottom of the tub.", "This steel frame helps solidify the tub.", "They affix a steel plate at the bottom to shield the plastic from heat of the motor.", "Then they attach steel legs to the frame.", "Here, they install a rubber reservoir called the sump.", "It collects the water that flows to the bottom of the tub.", "They screw in a two-part ring to hold the sump in place.", "The heating element is a ceramic-insulated iron cable.", "This filter traps food particles washing off the dishes.", "After fitting an o-ring seal to make the sump leakproof, they secure the heating element by screwing ceramic insulators to the protruding connectors.", "Now for the polypropylene wash arms.", "This model has one at the bottom, with a tower that juts out for a larger spray span, and a second wash arm at the top.", "The motor pumps clean water directly to the bottom wash arm and, through this flexible hose, to the top wash arm.", "Once they connect the hose, they spin the wash arm to make sure there's no obstruction.", "Meanwhile, workers connect key components to the dishwasher's circuit board.", "This metal box is the timer.", "It controls the wash and dry cycles.", "For example, it activates this green cam lever to trigger the white lever to open the detergent dispenser at the right moment in the wash cycle.", "The detergent dispenser is located on a plastic panel that will line the dishwasher's door.", "They call this panel the inner door.", "This seal will prevent water from leaking out and also provide some soundproofing.", "A press runs over the inner door, driving in the seal evenly all around.", "Now they screw the inner door to the outer door.", "The assembled door hooks onto hinges at the base of the tub.", "This machine presses the hook and hinge together so that the door doesn't come unhinged.", "The dishwasher's motor is relatively quiet because it uses an inherently low-noise induction drive design.", "The white machine attached to the motor is a food disposer.", "It grinds up food particles so that they don't clog the drain.", "The last technical step is to connect the various wires.", "Before applying the finishing touches, workers conduct a seal test.", "They flush each tub with water to check for leaks.", "In this portable dishwasher, workers install cement blocks as a counterweight so that the washer won't tip forward when you open the door.", "And because a portable usually sits in full view, it also needs sides and a top.", "The top is decorative laminate on medium-density fiberboard.", "They screw it to what's called the wrapper, a three-sided panel made of painted steel that covers the sides and back-- a clean look to go with your clean dishes.", "Fishing may not be rocket science, but the graphite fly rod certainly is.", "Graphite is a space-age material-- lightweight, flexible, and strong.", "The very qualities that make it useful in space also come in handy at the river or lake.", "It explains why graphite fly rods are now popular in the fishing world.", "To make one, they start with a sheet of graphite.", "They cut out shapes, following precise measurements.", "One mistake here, and the performance of the rod will be compromised.", "This will be a three-piece rod, with a butt piece, midsection, and tip.", "They place a shape on a tapered steel mandrel...", "And peel away the paper backing.", "This machine rolls the graphite shape around the mandrel.", "They make all three sections of the fishing rod the same way.", "A graphite strip at the end reinforces it all.", "The graphite remains on the mandrel for the next step.", "They wind polypropylene tape around the graphite to squeeze out any air pockets between the layers.", "Then it's into the oven to cook at 257 degrees fahrenheit for an hour and a half.", "The tape won't melt, but resins in the graphite will, baking the rolled layers together.", "Afterwards, they remove the shrink tape and pull the graphite blank off the steel mandrel.", "Then the rod blanks go for a dip in a special finish, which turns it a deep blue.", "They bake on the finish for a half-hour at 257 degrees fahrenheit.", "Afterwards, they measure the rod sections and cut them to size so they all fit together.", "Bending without snapping is the graphite rod's strong point.", "They hot-glue the stainless-steel tip to the end.", "Then they piece together the retainer for the fishing reel.", "This locknut will allow the reel to be tightened.", "The plug will keep everything from sliding off.", "They glue cork rings together to make a handle.", "Then they shape it with a chisel and sandpaper.", "The line guides go on next.", "They keep things from getting into a tangle.", "They wind thread around it to secure it to the rod, one foot at a time.", "A final step ensures the handiwork doesn't unravel.", "They place the rod in a rotating jig and brush three coats of glossy epoxy onto the thread wrap.", "This not only protects it but gives it a nice finish.", "Now they slide a metal foot into a groove on the reel retainer, and it's ready for the reel to be attached.", "But before you can cast your line, there is some information that needs to go on the rod, like the brand name and serial number.", "A final inspection, and it's almost time to test the waters.", "The reel snaps into place, and it's easily adjusted with the locknut.", "The rest is a matter of luck and the right bait.", "Millions of pizzas travel daily from the frozen-food section of the supermarket to the family dinner table.", "Thick or thin crust, meat or vegetarian, their convenience makes them a staple in the freezer.", "But how do they end up tasting so fresh when they start out so frozen?", "Making frozen pizzas requires a maze of machines.", "To make the dough for the crust, they combine flour, salt, sugar, water, yeast, and oil in a large mixer...", "And they throw in a bit of cornmeal for flavor.", "The mixer turns the ingredients for about four minutes.", "This is one powerful machine.", "A truck transmission drives the steel bars that knead the dough.", "The dough rises for about half an hour.", "Then they feed it into a chunking machine, which divides the big blob into smaller pieces.", "The chunks travel to a sheeting machine that rolls them into a flat sheet one-inch thick.", "A light dusting of flour keeps the dough from sticking to the machinery.", "A series of rollers called quick reducers gives the dough an even consistency.", "A flour brush massages the dough, ensuring a smooth surface.", "Next, stainless-steel spikes pierce the dough with holes about a quarter-inch deep.", "These holes will stop air pockets from forming in the dough.", "A large plastic roller with several round forms cuts the circular shape of the pizza crust.", "The machine automatically separates the leftover dough.", "The factory remixes it with fresh dough for the next batch.", "A conveyor takes the dough circles to their next destination-- the oven.", "They bake for two minutes between 390 and 600 degrees fahrenheit.", "Six chambers inside the oven automatically control the temperature pattern to ensure that each one bakes evenly.", "Next stop-- the tomato sauce.", "A tank pumps a steady supply of sauce into a reservoir, drenching a roller turning inside.", "A plastic board then scrapes the sauce onto the crusts passing below.", "The excess sauce drips down, replenishing the reservoir.", "Mounds of preshedded mozzarella are ready to be added.", "A cheese-applicator machine controls the output so that the mozzarella forms an even layer.", "Large hoppers load heaps of pepperoni, sausage, and other meat toppings into a meat applicator.", "As with the tomato sauce and cheese, the meat toppings cascade down on the pizza crusts.", "The pizza is now ready for inspection.", "Workers take samples off the line and weigh the crust, sauce, cheese, and meat to ensure the equipment dispensed the right amount of each.", "Next, the pizzas enter a spiral freezer called a blast cell, where they spend about 20 minutes at minus-25 degrees fahrenheit.", "An overwrapping machine applies a clear layer of plastic around each pizza, automatically cutting the wrap to fit.", "A vision-control system takes a picture of every pizza, verifying the size, diameter, and checking for any imperfections.", "The machine automatically rejects any less-than-perfect pizzas by air-blasting them into a separate tub.", "Finally, an arm pushes each pizza into a waiting box.", "All that's left now is to heat it up and dig in." ]

{ "things": [ "Cheese Graters", "Hot Sauce", "Silver Jewellery", "Traditional Mexican Chairs" ] }

[ "Many recipes call for shredded ingredients, which is why a cheese grater is an indispensable kitchen tool.", "Depending on which type of blade or blades a grater has, you can coarsely shred to finely grate not just cheese but also potatoes and vegetables.", "Graters come in different sizes, shapes, and configurations, from flat models with one blade to box graters with a different blade on each side.", "The blades are made from a stainless-steel sheet that's just 1/50 of an inch thick.", "The sheet enters a shearing machine, where a die descends and cuts the blade shape, holes and all.", "The machine's dies are interchangeable, so when it's time to produce a different model, workers simply remove this die and install another one.", "Stainless steel is the ideal blade material because it's food-safe, durable, and rust-proof.", "For this model, the next step is to curve the blade.", "They insert it into a press that bends it with a rounded die.", "The press also turns over the edges along three sides, forming a channel for a handle.", "The handle is made of stainless-steel wire.", "A bending machine wraps it around a grater-shaped form...", "Then cuts the end free, releasing what is now a finished handle.", "Now for this model's final assembly.", "Workers slide a handle into the blade's channels.", "Next they put the blade in a press, which forces the channels closed, encasing the wire.", "With the handle and blade now locked together, the grater is finished.", "Another model has a built-in tray to collect the grated food.", "This machine forms the pivoting handle which enables the blade to stand upright in the tray.", "First the machine cuts a strip of stainless steel to the required length.", "It makes holes for a rivet on each side.", "Then it bends the piece to a \"u\" shape.", "Meanwhile, a forming press shapes the tray out of a stainless-steel sheet.", "The tray moves to the next press, which slices off the excess from the perimeter.", "The tray is now completely formed.", "All that's left to do is punch a hole on each side for the rivets that attach the handle that props up the blade.", "They take the handle and rivet it to one end of the blade.", "Next, they rivet the tray to the other end of the blade, and the grater is fully assembled.", "This company packaged certain models in blister packs.", "Workers put the grater in a clear plastic cover, then position a printed cardboard backing over it.", "The backing is coated with transparent, heat-activated glue.", "A few seconds under a hot press, and the plastic cover adheres to the backing, encapsulating the grater.", "From a basic version on up, a grater is an essential kitchen tool most cooks can't do without.", "When it comes to cuisine, some like it hot.", "A quick way to satisfy a picante-loving palate is with a splash or two of hot sauce, typically served with mexican food such as nachos, tacos, and burritos.", "It can also spice up everyday fare such as eggs, potatoes, and sandwiches.", "This american company has been producing hot sauce, also called a pepper sauce, since 1868.", "Its signature version is made from tabasco peppers, a type of chile pepper.", "The brand also comes in additional varieties, using habanero, chipotle, and green jalapeño peppers.", "The company has pepper fields at its home base in louisiana, as well as in central and in south america, using seeds harvested from the louisiana crop.", "The company president uses his experienced eye to select the best plants for seed extraction-- those with even and early-ripening, juicy peppers, well-formed, layered branches, and healthy, damage-free leaves.", "He marks his selection with a string.", "Then pickers harvest those peppers and send them to the seed extractor.", "The peppers are hand-picked for sauce production, as well.", "To determine which ones are ripe enough, the pickers use what cajuns call a petite baton rouge, french for \"little red stick\".", "If a pepper matches the color of the stick, they harvest it.", "If not, it stays on the plant.", "It's labor-intensive but ensures only the perfect peppers go into the sauce.", "Within hours of harvesting, the factory grinds the peppers and mixes them with salt.", "This creates a mash which then goes into oak whiskey barrels to ferment and age.", "Wooden barrels breathe, letting in just enough air to spur natural yeast growth-- the key to fermentation-- but not too much air, which would discolor the mash and produce a metallic flavor.", "After laying paper on top of the mash to prevent surface discoloration, workers seal the barrels.", "Then they spread a layer of salt over the top.", "The barrels now go to the warehouse, where the mash ferments and ages for three years.", "Fermentation releases carbon-dioxide gas, which forces liquid out through a vent hole in the top of the barrel.", "The salt absorbs the liquid and hardens.", "After the three-year fermentation and aging period, they break up the salt and open the barrel.", "What was once pungent and acrid is now aromatic, with a mellow, complex flavor.", "However, it still needs significant refining.", "So they pump it into large mixing tanks, add vinegar, then churn for three to four weeks.", "That's now long it takes for the vinegar to break down the pepper solids into smaller particles.", "During that process, the vinegar also takes on the color, flavor, and aroma of the peppers.", "The sauce requires no cooking whatsoever because the vinegar acts as a natural preservative.", "The next step is a two-stage milling process.", "The first mill extracts the pepper pulp.", "The second mill removes the seeds.", "The sauce is now finished.", "The quality-control department analyzes samples from every batch of sauce for viscosity, ph, salt level, and other criteria.", "Lab technicians also perform taste tests for flavor, clearing their palate in between with crackers and cooling the fiery heat with ice-cream bars.", "Once the batch gets the thumbs-up, it's pumped to the bottling line.", "The company uses glass rather than plastic because glass is a better barrier against oxygen.", "Oxygen penetration would adversely affect the flavor and color of the sauce.", "The capping machine twists on a plastic screw cap.", "Then the bottles travel to the labeler, which adheres the main product label, slips on a decorative neck band, and applies a clear plastic seal over the cap.", "Hot off the production line and ready to go.", "People have been making jewelry and other objects since about 4,000 b.c. silver remains popular today because of its beauty and its affordability compared to gold and platinum.", "Pure silver is rather soft, so it's traditionally combined with one or more metals to give it hardness and strength.", "The silver used in jewelry is traditionally sterling silver.", "Sterling is composed of 92.5% silver and 7.5% alloy.", "The alloy is usually copper or copper combined with other metals.", "This mexican jewelry manufacturer melts the standard ratio of copper and zinc alloy to silver...", "Then also remelts silver left over from the jewelry production process.", "At 1,760 degrees fahrenheit, it takes just seconds for these solid metals to become molten sterling silver, at which point workers pour it into a stainless-steel mold.", "The silver rapidly cools and hardens into a flat bar.", "Workers extract the bar and clean it with sulfuric acid, then pass it between two rollers and a press.", "The rollers apply more than 3,300 pounds of pressure.", "Workers feed the bar into the press repeatedly, each time turning the wheel to narrow the gap between the rollers to progressively thin it out.", "Rolling the bar scrambles its molecules, making the silver brittle.", "So they reheat it to rearrange the molecules into a regular pattern again and restore flexibility and malleability.", "The bar now goes through another rolling press to radically reduce the thickness.", "This 4/10-of-an-inch-thick bar becomes a thin strip a mere 1/100 of an inch thick.", "In doing so, it also lengthens dramatically from 10 inches to just over 4 yards.", "The strip now passes through a series of forming rollers, which progressively curl the edges up and inward until the strip becomes a hollow tube.", "Then the machine solders the edges, sealing the tube.", "The tube is still way too thick for making earrings and rings, so on it goes to another thinning operation.", "The machine grabs one end of the tube and pulls it through a series of circular dies which have progressively narrower diameters.", "Once the tube is the required diameter, a winding machine curves it.", "Some tubes then move on to a cutting machine which uses a diamond head to engrave a pattern in the surface.", "To make hoop earrings, an artisan steadies a piece of curved, engraved tube in locking tweezers and solders on an earring hook, then the latch into which the hook snaps.", "Some pieces of jewelry incorporate cubic-zirconia stones.", "In this design, a computer-guided laser machine has already cut two patterned pieces out of an ultra-thin silver sheet.", "A stamping machine then rounded each piece into a half-sphere.", "The artisan now solders the two halves together, encasing the cubic-zirconia stones inside.", "Then he solders the rest of the earring components made from silver tubing and silver wire.", "Here an artisan is making a pendant.", "He locks cubic-zirconia stones in between the front and back frame pieces.", "Then he positions the center piece within the frame, soldering it in four spots.", "Next, he solders a ring to the top of the pendant...", "Then the bail, the loop for the chain, around the ring.", "Next, into the finisher, a rotating barrel of abrasive powder that rounds edges and smoothes rough spots.", "A buffing with a cloth wheel then polishes the silver to a mirror finish.", "The same computerized laser machine that cut the sphere earrings can also etch an elaborate design on the surface of a piece.", "It can reproduce virtually any image that can be created or copied with software.", "The laser draws by pulverizing a microlayer of silver.", "As the laser works, a built-in suction device vacuums the silver powder away.", "Besides adding strength and durability, the alloy makes sterling silver less porous and, therefore, shinier.", "And the copper in particular has anti-corrosive properties which reduce tarnishing.", "The mexican barrel chair is sometimes called montezuma's chair, after the 9th aztec emperor who, as legend has it, enjoyed sitting in one.", "After the spanish conquest of the aztec empire, these chairs were deemed seats of honor for visiting v.i.p.s.", "Now considered more rustic than regal, anyone can sit in a chair like montezuma's.", "There are various versions produced in mexico today, many handcrafted using techniques that date back centuries.", "With a sharp, curved blade, the craftsman first splits a chunk of mexican rosewood into long, narrow pieces.", "He cuts 36 splints for the chair's distinctive lattice work.", "He pares down the ends of each splint, and he carves a round head onto each end.", "These heads will stop the rope from sliding off as he ties the splints together.", "He pulls the back away from a much longer piece of wood and then trims it to slimmer dimensions.", "This wood is fresh from a local shrub called guizema.", "It's so pliable, it's almost elastic, allowing the craftsman to bend it around his knee into a \"u\" profile.", "Too much force, and he could crack the wood.", "Too little, and the curvature won't be right.", "A thick nail used on railway tracks is now used as a hammer as he nails a linear piece of wood to a curved one, completing his chair base.", "He now loops plastic rope around the tips of the two splints and ties them together.", "He lays the tied splints to holes in the guizema wood base.", "He angles the top end of the splints diagonally and ties them together to create the chair's trademark lattice.", "He then arranges the rounded willow wood frame on top and lashes the tied tips to it.", "He reinforces the chair base with willow wood branches that have been scraped flat.", "He nails five of these poles to the base of the chair.", "The next craftsman secures a rounded bundle of willow branches to the protruding poles.", "This completes the back framework.", "Another worker now strings rope made of agave plant fiber across the seat framework and ties it to it.", "He creates a strong yet flexible webbing to support the seat.", "He now splits open some locally grown reeds and flattens them with a stone.", "Basket-weave-style, he interlaces the flattened reeds to create a plated material that will be the next layer for the seat.", "After cutting it to the exact shape and dimensions, he places it on top of the webbing.", "He then stitches a strip of leather along the border.", "His co-worker now reinforces the plastic ties at the chair base with leather rope.", "The leather ties also give the base a more finished look.", "He turns the chair on its side and trims the poles.", "He also carves slivers of wood from the base so that it's even all the way around, allowing the chair to sit level on the floor.", "The next worker drapes tanned and stretched pig-skin leather over the back framework.", "He trims it to the contours of the bent willow wood.", "He covers the reed seat with more leather from the same hide and cuts away the excess.", "Using a leftover swatch of leather, he applies wax made from pig and cow fat to leather rope.", "The wax allows the rope to slide easily through holes in the leather so there are no snags as he stitches the upholstery together.", "The leather upholstery is now tight and tailored.", "The next worker sprays mineral dye onto the leather.", "It's honey-colored for a warmer look, and it also hides any minor flaws.", "After the dye, he applies a protective coat of lacquer.", "They heat an iron stamp and apply it to the latticed base to brand the wood with the company name.", "And with that job done, it's time to take a seat.", "But with so many twists on this ancient design, it could be tough to decide which one." ]

{ "things": [ "Macarons", "Pine Needle Baskets", "Micrometers" ] }

[ "Today on \"how it's made,\" macarons...", "Pine-needle baskets...", "And micrometers.", "Meringue cookies with a flavored filling, macarons were first produced in the eighth century in venetian monasteries.", "In 1533, the recipe came to france with the pastry chefs brought by the italian noblewoman who arrived to marry the king.", "Macarons have been considered french ever since.", "Macarons are as much a treat for the eyes as for the mouth, with colorful meringue shells sandwiching a flavorful filling.", "To prepare what's known as italian meringue for the shells, the bakers combine sugar and water.", "They heat the mixture to precisely 222 degrees fahrenheit, slightly above the boiling point.", "In a mixing bowl, the bakers combine egg whites with dehydrated egg whites.", "Using a combination of liquid and dried egg whites reduces the amount of moisture in the meringue mixture.", "When there's less moisture, it's easier to control the baking.", "Workers mix the egg whites for about 8 to 10 minutes to make an emulsion, then add the boiling water and sugar.", "The combination mixes until the temperature drops to 104 degrees fahrenheit.", "No thermometer is necessary.", "Bakers can tell by the stiff texture of what is now meringue.", "The next step is to flavor and color the meringue.", "Workers weigh very precise quantities of almond powder...", "Then icing sugar.", "They transfer these ingredients to the mixer...", "And blend them thoroughly.", "The baker adds the blended almond powder and icing sugar to a mixture of egg whites and, in this case, red food coloring because these will be raspberry macarons.", "They resume mixing for another two or three minutes until everything is thoroughly blended.", "Then the baker adds this mixture to the meringue to color and flavor it.", "Five more minutes of blending, and the meringue is ready.", "It's time to form the meringue shells.", "A worker pours the meringue into the feed vat of the depositer.", "The depositer dispenses 5-gram disks of meringue, 60 disks per lined baking sheet.", "Using a micrometer, a worker measures each disk to make sure it's between 1.69 and 1.77 inches in diameter.", "Meringue expands with baking, so this ensures each disk will bake into a shell that's the correct size.", "Then, fans blow air to dry out the tops.", "Evaporating the moisture prevents the top of the disks from rising as they bake in the oven for 15 to 20 minutes at 249 degrees fahrenheit.", "When they come out of the oven, the baked shells are set out to cool.", "Meanwhile, the bakers prepare the filling, mixing chocolate with piping-hot 35% cream.", "As the chocolate melts, they blend the ingredients thoroughly.", "Then the baker refrigerates the filling for 12 hours at 48 degrees fahrenheit.", "When the filling comes out of the fridge, it's firm but malleable enough to be scooped up and put in a pastry bag.", "With filling and shells now ready, the baker can begin assembling the macarons.", "They squeeze about 5 grams of filling onto each shell...", "Then place another shell on top, pressing gently to spread the filling outward.", "The macarons fit perfectly into the slots of plastic retail trays, thanks to the careful measuring of the meringue disks prior to baking.", "The trays pass through a machine which seals them in a pocket of plastic film to keep out moisture.", "Then, each tray is packaged in a retail box.", "This colorful selection features five flavors of macarons-- raspberry, blueberry, lemon, cherry, and exotic fruits.", "When indigenous north americans needed containers, they looked no further than the pine needles that littered the forest floor.", "They wove the needles into sturdy baskets for their daily use.", "The making of these coniferous containers continues today, ensuring that it doesn't become a lost art.", "Pine-needle baskets are beautiful examples of resourcefulness.", "They prove that something substantial can be made from needles that would otherwise just end up on the ground and be trampled on.", "The norway red pine in the northern united states sheds needles in the fall.", "Just before they drop, they can be easily plucked from the branches.", "This forager also collects needles that have fallen to the ground.", "He tosses some pinecones into the bag too.", "Back in the studio, a craftsperson immerses the needles in boiling water and simmers them for five minutes.", "This softens the needles so that they're flexible enough to work with.", "She selects a pinecone and boils it for 15 or 20 minutes.", "This causes the scales to close up, and the cone shrinks.", "Here are the pinecones before and after boiling.", "The shrunken cone will serve as a handle for a basket lid.", "After winding waxed linen thread around the cone's base, the craftsperson loops thread around the strands to hold them firmly together.", "She now coils a bundle of pine needles around the cone and sews them to it.", "She sets the cone aside for now.", "Next, for an effect that is simply decorative, the craftsperson coils pine needles around a colorful piece of stone that's been sealed in acrylic.", "Holes around the edge of the acrylic envelope make it easier to stitch the pine-needle coil to the decorative center.", "The craftsperson gives each stitch a gentle tug to pull the coils snuggly so that it encompasses the acrylic edge.", "This decorative center is now ready to be used as a starting point for a basket or a lid.", "Using another technique, she crafts a basket center using only softened pine needles and thread.", "This will be a bit trickier.", "Using pliers, she pulls off the sheaths that hold the groupings of needles together.", "Without the sheaths in the way, it will be easier to work with the needles.", "The craftsperson now takes a bundle that's almost the thickness of a pencil and forms a small loop.", "She ties a knot at the cross point.", "She stitches the bundle all the way around, creating a spiral with a threaded pattern that radiates outward, like spokes on a wheel.", "The craftsperson continually tucks more pine needles into the tail of the spiral to make it thicker and more even.", "She then weaves a basket base from the center spiral outward.", "She stitches each coil of pine needles to the one before it.", "And she aligns the stitching to create a decorative pattern that adds to the appeal of the basket.", "The craftsperson now tucks in pine needles with the black sheaths still on, to add even more visual interest.", "She artfully arranges them around the basket base and stitches them to it.", "From start to finish, it takes about 12 hours to craft the entire basket.", "After completing the lid with the decorative stone, the craftsperson tests the fit.", "For an alternative embellishment, she weaves red dogwood twigs into a pine-needle basket.", "It's another way to be creative with the materials that nature offers up in abundance.", "Each one of these pine-needle baskets is an original, handcrafted by an artisan.", "And that makes them worth holding on to.", "A micrometer is a handheld precision-measuring tool typically used in manufacturing.", "A toolmaker producing parts for factory equipment or a machinist making parts for a product would use a micrometer to take precision measurements to make sure the part dimensions confirm to engineering specifications.", "Micrometers come in different types and ranges of measurement.", "This model is designed to measure the outside diameter of an object.", "The graduations are in imperial units up to 1 inch.", "The micrometer's frame starts out as a forged-steel part that needs to be machined to the final shape.", "Workers secure the part on a mechanical milling machine.", "The machine first squares the ends...", "Then slices the part down the middle, dividing it into frames for two micrometers.", "A computer-guided mill profiles the frame.", "This is the forged frame before this step and after.", "Another computer-guided mill reduces the inside and outside diameters of the frame's hollow stem.", "Workers insert a nut in the stem, then dip a piece of solder into a soldering chemical called flux and insert it through a hole in the stem.", "They hold the stem inside a soldering coil.", "The heat instantly melts the solder, fusing the nut to the stem.", "Workers remove excess solder with a wire brush.", "Then, they grind the stem to finalize the diameter.", "Here's what the stem looks like before this last grinding and after.", "Next, on the opposite end of the frame, they mill a notch.", "This is for the lock nut that locks the micrometer against the object while you read the measurement.", "Workers now sandblast the entire frame.", "This removes all traces of metal dust and machining lubricant, leaving the surface pristine, a requirement for the next step-- electroplating the frame with chrome.", "They complete the micrometer's frame by laser-marking the brand name and a reference chart of measurements in fractions of an inch and the decimal equivalents.", "This machine shapes a long steel rod into the micrometer's inside shell, which, in conjunction with the outside shell, displays the measurement reading.", "The machine first drills through the rod to form a hollow cylinder.", "Next, it reams the inside and grinds the outside to the required diameter.", "The same machine also shapes a steel rod into the micrometer's outside shell.", "It carves a diamond pattern onto it called a knurl.", "This textures the surface, making it easier to grip.", "Then the machines reams the inside to the required diameter.", "After sandblasting both shells, workers hang them on a rack, then dip the rack into a tank of chromic acid.", "Copper prongs on the rack deliver a positive electrical current to the shells while the chromic acid is charged with a negative current.", "This magnetically draws a chrome layer onto the surface of the shells.", "Then a computer-guided laser marks the brand name and the graduations on the inside and outside shells.", "This computer-guided mill shapes a steel rod into the micrometer's key measuring component, the spindle.", "The machine first profiles the outside.", "Then it drills a hole 1/2 inch deep and reams it to the correct diameter.", "It's critical that the spindle not wear down with long-term use, as this would effect the micrometer's measuring accuracy.", "To prevent this, they harden the steel through a heat-treatment process.", "First, workers put the spindles in a furnace at a temperature of 1,526 degrees fahrenheit.", "After an hour, they submerge the spindles in oil, then freeze them overnight to stabilize the steel.", "The next day, workers temper the steel by putting the spindles back in the furnace for an hour, this time at a lower temperature.", "Once the spindles cool, a machining tool grinds threads into them.", "The precision of that threading determines the micrometer's measurement accuracy.", "To use a micrometer, you place the object you're measuring against the stationary end of the frame called the anvil.", "Then you rotate the spindle on the opposite end until it's seated against the object.", "You turn the nut to lock that position and read the measurement.", "The spindle for this model has 40 threads per inch.", "So turning it one revolution in either direction moves it 25/1,000 inch.", "If the steel hadn't been hardened, those threads would wear down over time, causing inaccurate measurements.", "For the same reason, this disk they now prepare to solder onto the face of the spindle is made of tungsten carbide, the hardest type of steel.", "After fluxing the face of the spindle, topping it with the disk of solder, and positioning the fluxed carbide disk on top of that, workers place the spindle inside the hot soldering machine to fuse the carbide to the face of the spindle.", "They grind the diameter of the carbide disk to reduce it to the same diameter as the spindle.", "After this grinding, the disk becomes integrated with the rest of the spindle.", "They grind the face of the carbide disk flat.", "Then this lapping machine polishes the face to perfect the flatness and produces a mirror finish.", "They perform a quality-control check with an optical parallel made of sapphire.", "It projects bands of light which detect flatness to a degree the human eye can't perceive.", "This second test reflects light off the mirror-finish face.", "When rotating the spindle, the light should stand still.", "This indicates the face is perfectly perpendicular to the diameter.", "The micrometer's anvil, the fixed surface opposite the spindle against which you place the object you're measuring, is also machined from carbide.", "To assemble the micrometer, a worker places a spring in a recessed area of the frame stem, then the inside shell onto the stem.", "The spring applies enough tension to hold the shell in place.", "The inside of the stem will have female threads to match male threads on the spindle.", "This adjusting nut on the end of the stem controls the thread engagement between the two, enabling the spindle to move more tightly or loosely.", "The next step is cutting those female threads into the inside of the stem.", "First, a worker reams the stem to the required diameter, then switch the reaming tool on the lathe for a tapping tool.", "Tapping is the term for cutting threads.", "They put the stem back on the lathe and tap 40 female threads per inch.", "Now, workers can assemble the spindle to the stem.", "They mount the spindle on an automatic lapping machine.", "Then a worker slides the stem over the spindle, going back and forth multiple times to fit both sets of threads together.", "They lubricate the threads with instrument oil so they'll glide smoothly against each other.", "After assembling the lock nut in its notch, the worker cleans the spindle face with alcohol and glues the anvil to it temporarily.", "Then they rotate the spindle until the anvil reaches its adhesive-coated position at the opposite end of the frame.", "When the adhesive sets, the worker separates the spindle and anvil.", "Using an optical parallel, they check the spindle and anvil faces to make sure they're perfectly parallel to each other.", "The worker completes the assembly by fitting the outside shell to the frame.", "It covers the end of the spindle that's protruding from the stem.", "A steel ratchet locks it into position.", "A final round of quality-control testing ensures the device works smoothly and measures accurately.", "In this test, they measure four different-sized measuring blocks.", "In this one, they bring out those optical parallels again to check flatness and parallelism.", "They also perform a cosmetic inspection and check that the graduations are all legible because, of course, no one wants a micrometer that doesn't measure up." ]

{ "things": [ "Kitchen Knives", "Mannequins", "Socks", "Hypodermic Needles" ] }

[ "Today on \"how it's made\"...", "Kitchen knives...", "Mannequins...", "Socks...", "And hypodermic needles.", "Any good cook knows that you're only as good as your tools, so using the right kitchen knife for the job is essential.", "From chef's knives and cleavers to boning knives, filleting knives, and paring knives, a serious cook buys only quality cutting utensils and stores them in a block to keep their blades sharp.", "Today's blades are truly a cut above the stone tools the cavemen used.", "Knife-making is now a science, producing tools that really give you that edge in the kitchen.", "First, they roll out steel by the sheet from a big coil.", "Then this machine, called a press, cuts out the blades with a punch.", "And it really does pack a punch.", "It presses down with 110 tons of pressure in order to make these steel cutouts.", "Next, things get really hot.", "They roll baskets full of the blade cutouts into a high-temperature furnace.", "The blades bake at almost 1,600 degrees fahrenheit for 2 hours.", "This hardens the steel.", "Out of the fire and into the freezer, the blades chill out at subzero temperatures-- negative 56 degrees fahrenheit for two hours.", "This freezer is cooled by liquid nitrogen.", "Now we have what they call \"cold, hard steel\".", "Next, they douse each blade with water while a belt grinder smooths the back of the blade and sparks fly.", "Continuous water keeps the steel cool and hard while a sander smooths the back of the blade.", "Now a robot moves in.", "This robotic arm has vacuum grippers like an octopus.", "It picks up a blade by suctioning, then it transports it to a grinding machine.", "The machine grinds the blade to give it that cutting edge.", "Water flows continuously through the grinder, again to keep the steel cool.", "The robot keeps everything moving, putting a paring blade through the grinder every 12 seconds.", "The automated process for this bigger blade is a bit different.", "This robotic arm holds the blade in a grip, rather than through fast-action suctioning.", "That's because it takes more time to grind this big blade, called a cook's knife.", "So this arm holds onto this blade a few seconds longer.", "But if this makes you nervous, relax.", "The robot doesn't have a habit of dropping them.", "Some blades require a personal touch, like this shiny chef's knife, used for chopping vegetables.", "The worker runs the blade over the grinding stone very carefully.", "This gives it a very thin edge.", "Then a laser burns the brand name onto the side of the blade.", "Next, a piece of wood goes into a clamp, and a router shaves it into the shape of a handle.", "The end of the blade now fits neatly into the handle.", "A worker clamps the knife onto a riveting machine.", "Those things that look like bullets on an ammunition belt are actually the rivets.", "The machine forces the rivets into the handle from both sides.", "The rivets lock together inside the handle so they can never be taken apart.", "Now they grind down any protruding steel from the handle.", "This makes the wood flush with the steel from the blade.", "The piece of metal that extends into the handle is called the tang.", "It gives the knife weight and balance.", "Finally, they hone the knife between two stone grinding wheels.", "With this kind of an edge, these knives will slice paper.", "But these knives will do their best work on the cutting board, where they'll make the cook's life easier and meals tastier, no matter how you slice it.", "They strike alluring poses in store windows, motionless models flaunting the latest fashions.", "For clothing retailers, mannequins are a vital sales tool.", "They come in fixed or flexible versions, the bodies realistic or abstract.", "And they can be made out of a range of materials, from wood to fiberglass.", "Meet lady swing and mr.", "X-- not flesh and bone, but polyurethane foam.", "These fully flexible fashion figures start out as humongous blocks of soft polyurethane foam.", "Using a band saw, workers divide them into smaller blocks, about the size of a large refrigerator.", "A worker creates a pressed-wood mold using both a grinder and a sander to soften the inside.", "She applies a layer of putty over rough or damaged areas.", "This will harden and prevent the foam from clinging.", "She'll make separate molds for the arms, legs, head, and torso.", "A 3-square-foot slab of foam goes on top of the mold, then a slab of harder foam, called a pattern, on top of that.", "The foam layers and wood mold now go through what's called a pressure cutting machine.", "Pressure forces the slabs together, while a thin blade slices the excess foam away.", "Exactly how much pressure the machine applies is a closely guarded trade secret.", "The foam arms pop right out on the other side.", "For the head and torso, they use a foam slab measuring 58\"x17\"x5 1/2\", and a foam pattern that includes shapes for breasts and a belly button, and grommets to shape the nipples.", "This foam pattern is impressionistic.", "This mannequins are not meant to be anatomically correct.", "Here's the pressure-cutting machine close up.", "Nine rollers compress the mold, soft foam, and pattern slabs together, forcing them through a paper-thin opening, and slicing away up to six inches of foam.", "True to form, lady swing pops up on the other side.", "Her flexibility is her best trait.", "She and mr.", "X are often displayed on sports equipment, like snowmobiles and bikes.", "Their manufacturer first named them in the 1970s, and the monikers just stuck.", "Workers inspect the mannequin and trim the excess material.", "They extract her easily because they sprayed the empty mold cavity with lubricant.", "Next, a worker assembles a quarter-inch-thick steel skeleton to give the mannequin some structure.", "Workers will insert the skeleton between the half-sections of the foam body.", "A welder fuses together 16 joints in the ankles, knees, thighs, hips, elbows, and shoulders.", "Another worker sprays slow-drying, water-based glue on the skeleton and on the foam body sections that'll cover it.", "This will make them adhere together snugly.", "The hand skeletons are thin and pliable, like coat hangers, so they'll bend.", "A worker places the skeleton between the torso halves, positioning the foam so the edges meet evenly.", "These dummies don't come cheap.", "They sell for between $600 and $800 each, depending on the market value of the foam's main ingredient, oil.", "Still, that's a bargain compared to their more realistic-looking, but much less flexible, fiberglass cousins.", "They cost up to $2,000 each.", "After letting the parts dry and set overnight, a worker tests the limbs for flexibility.", "She joins together the lower leg portions.", "The skeleton protrudes at the heel so that it can be secured to the floor when the dummy goes on display.", "Now, here's a scene worthy of a horror movie.", "Using an electric carving knife, a worker slices of 2 1/2 inches from the front of the head.", "She glues on a hollow face mask made of plastic, using solvent-based glue for an extra-strong bond.", "Next, they spray the mannequin with a flesh-colored water-based glue, then sprinkle it with a fine powder made of tiny cloth particles.", "This is called flocking.", "It takes 12 hours to dry and gives the mannequin a protective fire-retardant skin.", "This factory's flocking comes in 18 different colors, from a variety of skin tones to several vibrant colors.", "Before lady swing makes her debut, a makeup session-- powder blush to color her lips and cheeks, and water-based paint on her eyes, lashes, and brows.", "They add a wig, and voilà-- she's ready for her date with mr.", "X. socks are something we put on without thinking.", "But consider this-- the very first socks were strips of cloth or hide wrapped around the feet.", "Imagine walking around in those.", "Thankfully, that's ancient history, and today's socks are much better for the sole.", "With so many styles and fibers for sock these days, it's no problem putting your best foot forward.", "But you have to step into this room of knitting machines to truly understand what a science sock-making has become.", "Here's a machine with the top open so we can get a view of the knitting action.", "An automated whirling cylinder pulls yarn from spools through holes in metal spokes.", "Little hooks on the needles grab the yarn.", "The hooks have latches.", "The latches open as the hooks snare the yarn and close as they knit so you don't lose a stitch.", "As you can see, this machine knits socks a lot faster than grandma, sometimes making over 360 pairs a day.", "As the layers are added, a sock emerges from a tube at the bottom.", "The knitting machine is fully computerized.", "It automatically switches to a different color of yarn to make a stripe or a company logo.", "Now the machine changes gears to make a heel.", "It does a half rotation instead of a whole one to knit the heel shape.", "The needles go up and down as the latches open, and the needles pick up the yarn, pulling it in.", "Knit one, purl two.", "Here it is in slow motion.", "This is about the speed at which a human could knit at, but this machine normally runs at a speed of over 200 revolutions a minute.", "A tension mechanism moves back and forth, keeping the yarn from going slack and getting tangled.", "Now a sock shoots out of a vacuum tube, and a worker turns it inside out.", "She sews the toe closed and cuts off the extra fabric.", "Then she turns the sock right side out again, and it's sucked up by the vacuum.", "Next, the vacuum tube deposits the sock into a bin.", "The trapdoor on the end of the tube ensures that vacuum pressure isn't lost.", "But there's more than one way to close a sock toe-- a more automated way.", "A worker slides the sock between two metal plates.", "Pressure holds them in place.", "Then a motorized conveyer system transports the sock to a sewing head.", "A blade cuts off excess fabric, and a needle goes up and down like an oil rig, stitching one row and then another as reinforcement.", "This automated system produces a finer seam than a sewing machine that's run manually.", "Now that the toe is closed, a robotic arm moves in and feeds the sock to a set of rollers.", "A blade pushes the sock down while the rollers turn the sock right side out.", "A vacuum chute fires the sock into a bin.", "Then it's on to the rotary dying machine.", "He loads 1,800 pairs or more, depending on the size of the dying machine.", "The socks toss around in a bath of dyes, chemicals, and softeners.", "For athletic socks, they add antimicrobial treatment to the mix.", "It will help prevent fungus or bacteria that cause foot odor.", "Now they slide the sock onto a foot form made of polished aluminum that won't cause snags.", "The aluminum leg forms stretch the socks to the prescribed size as they travel down a conveyer belt into a boarding machine.", "The boarding machine is like a gigantic iron, and the heat seals the stretch in the nylon so the sock stays that size.", "Once out, a robotic arm grips the sock and pulls it off the aluminum form.", "It's called a stripper.", "Then an automated rack with protruding pins collects the socks.", "The worker removes them a bunch at a time, and the socks are ready for packaging.", "And then, all you have to do is pull up your socks.", "A hypodermic needle is the proper term for a syringe and needle.", "It's used to draw blood or inject medication.", "This indispensable tool was invented back in 1853, but it wasn't until 1954 that mass-produced disposable syringes came on the market, developed for the vast immunization campaign against polio.", "A syringe may make you cringe, but the treatment it delivers could be a lifesaver.", "To make a hypodermic needle, they start with a flat strip of stainless steel.", "The milling machine rolls it into a tube shape.", "A laser welds the seam together.", "But what makes the steel stiff enough to use is something called cold-work, in which they press the tubing through a die several times.", "This also slims the tube dramatically, so now you have a thinner, tougher tube.", "It takes about a couple of days to turn this stainless-steel strip into a tube with needle potential.", "But it will have to be sharp to perform, and the next steps will focus on getting the steel tube to a point where it's more than just a blunt object.", "An electrically powered blade scores the walls of the tubes as rubber pads bear down and roll.", "This rolling causes the tubes to finally break at the score line.", "The tubes are being cut down to size-- about two inches long.", "The tubes fall into a bin, a tangled mess.", "The bin, driven by air pressure, agitates, and this shaking motion straightens them out.", "An operator bundles them together with a plastic band, but removes a few to check the specs.", "This micrometer uses laser light to measure the outside diameter.", "The tube is supposed to be 8/100 of an inch, and it's right on.", "Next, a mechanically driven drum rolls superadhesive tape onto the tubes.", "The tape will hold the tubes in place as more work is done on them.", "They razor cut five-inch strips of the tape tubes so that there are about 100 tubes per strip.", "Then they spray aluminum oxide on the ends of the tubes.", "This roughs them up so that the surface will be easier to work with.", "Now they place the strips of tubes into the grinding fixture, and then they snap it shut.", "Coolant flushes over the tube tips as the fixture moves across a grinding wheel.", "The wheel grinds through the tops of the tubes, shaping them into a rough point.", "This is only the first grind, so it's not yet needle-sharp.", "Now the fixture rolls and rotates the tubes.", "Then it's back to the grind.", "The angle of the wheel is changed so that it sands the sides of the tubes.", "These two secondary grinds sharpen the tubes into a finer point.", "This is how they look before grinding, and this is after, with their sharp needle tips.", "Now it's time for the big inspection.", "She pushes the ends of the needles with the back of her tweezers to make sure they're even, and then pulls out a needle for sampling.", "She measures the length of the grind.", "It should be a few hundredths of an inch long.", "Next, she sizes up the needle's outside diameter with a micrometer.", "Holding the needle between posts, it measures the space between them.", "Then she checks the inside diameter by inserting a plug gage into the tube.", "Now she inspects a whole bundle of needles for irregularities or burrs.", "Using tweezers, she removes one for a closeup look under the microscope.", "Once they pass inspection, it's on to the big wheel, or the automated assembly machine.", "Brass- and nickel-plated fittings, called hubs, drop onto pins on the wheel.", "Then needles fall into the hubs.", "Metal fingers align them so they fit together precisely.", "The hub is the piece that will connect the needle to the syringe.", "Automated crimpers press the needle into the hub.", "Sheer friction bonds them.", "Now two metal pads on the same wheel position the needle.", "A plastic sleeve drops down, encasing the pointed tip.", "Finally, a robotic arm lifts the needle off the wheel and drops it into a bin.", "The needles are now ready for you, but are you ready for them?" ]

{ "things": [ "Anatomical Models", "Jukeboxes", "Tortilla Chips", "Spark Plugs" ] }

[ "In the 18th century, anatomical models became widely used for educational purposes.", "However, they were unique pieces carved in wax, which made them expensive and fragile.", "Today, they're made of plastic-based resin and are found in medical schools, doctors' offices, even art schools.", "This model of a human torso has 20 removable parts.", "The front, sides, and back all provide different views of the body's inner and outer structure.", "Workers cast each part of the model using a plastic-based polymer resin.", "They pour the resin into nickel molds of the different parts, like this skullcap mold...", "Or this heart mold.", "Then they join the two molds that make up each part and clamp them shut.", "The molds go into a gas oven set to 437 degrees fahrenheit.", "As the heat penetrates the molds, the resin evenly coats the entire inner surface.", "After about 10 to 12 minutes, they come out piping hot.", "Workers spray them with water to cool them down before they unclamp the mold and release the warm casting.", "Here are some shoulder muscles fresh from their mold...", "The cross-section of a heart...", "An arm...", "And a leg that workers set to cool into shape on a form made of heat-resistant gypsum.", "Using a needle, a worker punctures the resin to release trapped air so the part doesn't shatter.", "Then he drills small holes for the pins that will hold the parts together.", "Each part is hand-painted to single out key features.", "An artist carefully paints in the veins in blue on this leg...", "And then uses yellow for the nerve endings...", "And red for the arteries.", "Even the toenails get some color.", "Before they can assemble the model, workers must first insert metal pins into each part.", "They help attach the parts to one another.", "Now the artist can finish painting in the arteries on this shoulder muscle.", "The gray areas indicate the ligaments.", "Next, she turns her attention to the head, painting in the eyes first to give the figure some life.", "It's all in the details.", "This final touch really makes the eyes come alive.", "The parts go into a warm oven for about 15 minutes to soften the plastic.", "This makes them easier to assemble.", "Here, a worker lowers the model's head onto a metal pin set in the torso.", "She puts the brain inside the model's skull and covers it with the skullcap.", "Next, she adds muscles to an arm, guiding the pin into a hole on the adjoining part.", "She adds the bicep, a muscle that helps flex the hand...", "And, finally, the deltoid, the muscle that lifts the arm at the shoulder joint.", "She tapes up the arm to keep all parts together as she attaches it to the torso.", "Nickel-plated hooks and fasteners hold the removable parts in place on the assembled model.", "This life-size muscular figure measures in at 4 1/2 feet.", "It has 45 separate parts, all anatomically correct.", "The human body-- truly an extraordinary structure.", "The jukebox actually started out as a memo-recording device for executives.", "That phonograph recorder was invented by thomas edison back in the 19th century.", "It evolved into a coin-operated music machine because music is a lot more fun to dance to than the boss' orders-- \"take a memo\".", "Put a coin in the slot and people will dance to your tune.", "Records replaced the phonographic cylinder early in the 20th century.", "Amplifiers were added in the 1930s and gave the big box a big sound.", "In the 1980s, compact discs came along, putting a different spin on the jukebox.", "With those smaller discs, manufacturers could pack a lot more music into a machine.", "Now compact-disc technology is becoming outdated, and the latest jukeboxes contain computers that download songs from the internet.", "To make a modern jukebox, they start with the door.", "They sandwich a red panel with swirled designs on it between layers of plastic.", "The assembler aligns them, then screws them together.", "He snaps the jukebox name into a snazzy piece of plastic, then fits it in one of the cutouts in the front of the door.", "Next, he installs aluminum framework around the door.", "He supports it at the corners with metal brackets.", "He screws a little metal wheel on the latch so the door will open and close smoothly.", "He mounts the touch screen in the big cutout on the door.", "He strings wiring for lighting around the perimeter of the door and fastens two long panels equipped with l.e.d. lights to the back.", "He plugs in the lights for a test, and it proves this door is flashy enough for the entertainment biz.", "He runs plastic trim along the perimeter of the door and screws a long metal hinge to one side of it.", "This jukebox door is now complete, and the rest is an inside job.", "The assembler installs an exhaust fan in the jukebox cabinet.", "He screws an audio amplifier to the back wall.", "The wireless router that allows the jukebox to connect to the internet goes in next.", "He mounts the power-supply system to the sidewall of the cabinet.", "He tucks the computer into a lower corner of the box.", "The power transformer for the amplifier goes on the back wall.", "He installs an audio-control system just below the transformer.", "He connects the amplifier to the audio-control system, and then he wires the computer to the router.", "He hooks up a communication system that passes information between all the devices in the jukebox.", "And he installs a transformer for the speaker system.", "Now the jukebox is ready for the showpiece-- that light-studded door with the touch screen.", "He screws the door's long hinge to the cabinet.", "He inspects his installation job and determines no adjustments are needed.", "So he fastens the bill box to the back of the door...", "And installs the computer hard drive in the cabinet.", "And, finally, the money test.", "He feeds the jukebox some cash and makes musical selections to check its function.", "At the jukebox factory, when the job is done, it really is party time.", "On their own, dipped in salsa or guacamole, or topped with chili and melted cheese, tortilla chips are the quintessential mexican snack, even though they're actually an american invention.", "In the late 1940s, a los angeles tortilla factory began cutting and frying leftover tortillas, selling the first tortilla chips.", "When the chips are down, they usually go fast.", "Tortilla chips start out as raw yellow corn.", "The supplier cleans the kernels and dries them to a moisture content of 14%, then ships them to the chip factory.", "There, the corn goes into large stainless-steel cooking kettles filled with almost-boiling water.", "Workers then add lime, an ingredient that does many things.", "It's antibacterial, it gives the corn a parched flavor, it helps loosen the hull-- the kernel's shell-- so it will come off later on, and lets moisture penetrate the kernel.", "Each cook kettle contains more than 650 pounds of corn and almost 200 pounds of water and lime combined.", "Next stop is a soak tank.", "The cooked corn sits there for 12 hours to further absorb water.", "Once the moisture content hits 45% and the hulls are soft and loose, a pumping system moves the corn to the washer.", "This machine strains the water so that what's left is just soft, hydrated corn.", "The next stop is the tumbler, a rotating drum with perforated walls.", "Water jets blow off the loose hulls.", "The corn travels on a conveyor from the tumbler to the mill.", "An auger feeds the corn into a stone grinder.", "It literally pulverizes the corn kernels between two stones, producing a soft corn dough called masa.", "The masa exits the mill through a narrow nozzle that shapes the dough into a thin sheet.", "The sheet then runs through rollers that have triangular dies on their surface.", "The triangles move into an oven heated to 644 degrees fahrenheit.", "They spend just 16 seconds inside, but that's enough time to dry the dough to the point where it won't break apart when handled.", "The heat also traps tiny pockets of moisture in the dough, creating little blisters.", "This gives the tortilla chips their trademark bumpy texture.", "From the oven, a conveyor belt transports the triangles to the fryer.", "The corn oil is 360 degrees fahrenheit.", "They take just 55 seconds to fry into chips.", "A mesh conveyor belt then lifts them out.", "As they leave, the excess oil drains back into the fryer.", "At the next stop, augers feed nacho-flavor seasoning into a tumbler.", "The seasoning's main ingredients are powdered cheddar, parmesan and romano cheeses, and spices.", "Nozzles spray the chips with corn oil to make the surface adhesive.", "Then the seasoning tumbles on and sticks.", "After exiting the tumbler, the chips travel to the packaging department.", "Chutes route them to different packaging machines.", "The packaging equipment represents technical choreography at its finest.", "Each machine has 14 bucket-shaped scales.", "When there's enough for one package, a trap door opens.", "The chips drop just as a forming device shapes a piece of foil and plastic film into a bag.", "The chips land in the bag.", "Then a heat sealer immediately closes the top and cuts it free while simultaneously sealing the bottom of the next bag.", "From bucket to bag to bowl.", "It takes a spark to get your motor running.", "The spark plug was invented in the 19th century to fire the internal-combustion engine.", "There are usually several in an engine, and they fit into the cylinder head.", "When the plugs are all working, it means your trip will have a good start.", "The spark plug produces what looks like a mini lightning bolt to ignite the gas that runs your car.", "To make spark plugs, they blend alumina ceramic powder and other ingredients with water.", "After a thorough mixing, the milky-looking brew drains into a big dryer, which converts it back to powder.", "The powder funnels into a mold.", "It closes to press the powder into the shape of spark-plug insulators, and a binding ingredient in the mix helps them keep their shape.", "An automated system loads them onto mandrels that spin the ceramic insulators against a grinding wheel.", "It grinds them into a more graduated shape and does a very precise job.", "These ceramic shapes are quite fragile, and they'll need to be baked in order to harden.", "But first, a tester double-checks the measurements with a laser tool.", "Then they bake in this very hot kiln until they're extremely hard.", "This takes up to 24 hours.", "While the insulators are in the kiln, tools ram steel through shaped cavities called dies.", "They're essentially punching out shells that will be the spark-plug casings.", "Other tools bore into the upper part of the shells to give them a hexagonal profile.", "This will later enable mechanics to wrench them into a vehicle's engine block.", "More tooling contours the spark-plug shells, and the result is quite a transformation.", "A conveyor now shuttles the spark-plug shells forward, as nickel-alloy wire unwinds overhead.", "An automated welder fuses the wire to the shells.", "This wire will serve as the spark plug's ground electrode, and it will be bent towards a firing electrode later.", "The space between them will contain the spark.", "Ridged rollers carve threads in the steel shells so they can be screwed into the engine block.", "The shell then gets a protective silvery finish.", "The ceramic insulators are now out of the kiln, and it's time to roll on the insignia.", "The insulators then brush by a rubber wheel that coats them with glaze as a protective finish.", "They install center electrodes in the insulators, and powder funnels into them to fill the space around the electrodes.", "The powder is a mix of glass and metal.", "Automated prongs compress it in the insulators.", "Grippers then insert the terminal studs into the insulator.", "The stud will act as the electrical connection to the center electrode.", "The insulators now go into an oven.", "The black powder melts around the studs and center electrodes to seal them inside the insulator cavity.", "Nozzles squirt oil onto the metal shells to lubricate them.", "The insulators funnel into the grip of robots which will install them in the shells.", "They slide in easily because of the lubrication job.", "Tools called shrinking punches apply an electrical current to each shell to fit it tightly to the insulator.", "A robot positions the assembly right side up with the side electrode protruding, then bends that side electrode towards the center one.", "The robot then collects the spark plugs and sends them down the line.", "It's time for an inspection.", "She looks for imperfections in the glaze, the inscription, and the nickel plating.", "She measures the space between the two electrodes before sending them over to the packaging department.", "And now these spark plugs are ready to keep your engine firing on all cylinders." ]

{ "things": [ "Pewter Flasks", "Potato Salad", "Hydrogen Fuel Cells", "Engineered Wood Siding" ] }

[ "Long before the plastic water bottle, there was the hip flask, carried in a pocket or strapped to the waist or hip.", "Unlike a water bottle or earlier canteen, the flask was used for carrying a very different type of thirst quencher-- several ounces of hard liquor.", "In the 18th century, it became quite fashionable for well-to-do europeans to carry elegant flasks crafted from silver or pewter.", "Today, flasks are typically given as gifts, often engraved with monograms or messages.", "Pewter is an ideal metal for flask making because it's so malleable.", "They begin with a sheet of raw pewter that's about 8/100\" thick.", "With a guillotine cutter, they slice a rectangular starting piece called a blank.", "They lay this blank onto a copperplate, which has the flask decorations on it in raised form.", "They feed the plate and blank through a rolling press.", "The compression stamps the design into the malleable pewter.", "Next, they place the imprinted blank in a hydraulic press outfitted with flask-shaped forming dyes.", "In a single strike, the press shapes the blank into half a flask.", "They transfer it to a trim press and clip off the excess pewter around the perimeter.", "They repeat the entire process to produce the other half of the flask, then solder the two parts together.", "They shape certain styles manually.", "A metalsmith heats the blank with a gas torch to make the pewter pliable, then wraps it around a flask-shaped aluminum block.", "He hammers the adjoining edges flat with a wooden mallet and removes the block.", "He fuses the edges by running a line of pure tin solder down the entire length of the joint.", "Meanwhile, on another press, workers stamp out pewter-sheet rectangles.", "The metalsmith solders one rectangle to the top of the flask...", "Then cuts it to the right shape with jeweler scissors.", "Next, he solders on a pewter thread for the cap.", "Before fusing a pewter rectangle to the bottom of the flask, he stamps it with a maker's mark.", "Then he dabs the bottom of the flask in flux, a chemical which helps solder run smoothly without globs.", "Then, just as he did with the top, he solders on the bottom, then contours it.", "Next, he puts a drill through the cap thread and bores a hole for filling and boring.", "Then, with an abrasive belt, he grinds all the solder seams flat, making them barely noticeable.", "Workers now fill the finished flask with water to check for leaks and rinse out the interior.", "Then they screw a pewter cap onto each thread.", "Now a buffer takes over.", "With a cloth wheel and pumice, he removes any surface imperfections, such as marks left by the abrasive belt they used earlier to grind down the solder seams.", "Once the buffing's complete, the flasks go through a dishwasher cycle to clean off pumice residue, then the finishing touch.", "A polisher shines up the pewter until it has a reflective-mirror finish.", "They pour out whatever water's still inside, emptying the flask for its new vocation.", "Unlike the flasks used to conceal liquor under clothing back in the days of prohibition, these modern-day pewter flasks are meant to be seen and treasured.", "In many families, a potato-salad recipe is a closely guarded secret passed down through the generations.", "The family barbecue just wouldn't be the same without it.", "But when there's no time to whip up a homemade batch, there's always the factory-made kind.", "The appeal of potato salad knows no boundaries.", "People around the globe have cooked up various versions of this dish over the years.", "There are so many different recipes, they could fill an entire cookbook.", "But no matter how you toss it, potato salad is always pure comfort food.", "Of course, it's all about the potato.", "At this factory, they use varieties with low water content so the potato salad doesn't end up soggy.", "They arrive fresh from the field and funnel out of the truck trailer onto a conveyer for an efficient and gentle unloading.", "They head up to a washer to clean off the dirt and remove stones and pebbles.", "The potatoes then bounce across rollers covered with fine grit abrasive.", "This scrapes off the skins.", "Once peeled, a worker inspects the white flesh for bruises or other flaws.", "They then tumble down a chute towards the dicing machine.", "It's equipped with these cutting cylinders.", "The blades are positioned vertically on one, while they're in a horizontal configuration on another.", "As they revolve in sync, they carve the potatoes into cubes.", "The blades can be adjusted to cut the cubes larger or smaller, depending on the recipe.", "Here they turn out medium chunks for a creamy, american-style potato salad.", "Workers roll trays full of potato cubes into a big pressure cooker to steam-cook for 6 to 10 minutes.", "Pressure cooking preserves the nutrients and original flavor of the potatoes.", "While the potatoes are cooking, they prepare the crunchy component-- the celery.", "The celery sticks first go for a sudsy ride to scrub them clean.", "Along the way, an inspector sorts out leaves and over-ripe pieces.", "They set cutting cylinders to dice more finely than with the potatoes.", "Out of the washer and thoroughly rinsed, the celery sticks tumble into the dicer, and it chops them into small bits.", "The minced celery exits into a vibrating trough and tosses about in a peroxide solution for a second cleaning.", "It's an extra precaution because the celery won't be cooked, and cooking kills bacteria.", "After another rinse, the soaked celery lands in a perforated drum that fits into another drum.", "The colander rotates within the drum to spin-dry the celery.", "The next ingredient is the eggs.", "They arrive at the factory already hard-boiled and de-shelled by the supplier, so all that's left is the slicing and dicing.", "The egg whites cube nicely.", "The yolk separates and crumbles completely.", "With so many yolk crumbs, their favor will permeate the entire potato salad.", "They're now ready to combine some of the ingredients.", "A worker adds finely cut onion to the egg, followed by diced red pepper and then celery.", "They weigh the mix with each new ingredient to confirm that the portions are right.", "And now for the dressing.", "They pump the ingredients out of big storage tanks.", "They include vegetable oil, sugar, vinegar, and egg yolks.", "Whipped into a frothy mayonnaise, the dressing flows into an enormous, steel mixing vat.", "They add the chopped-egg-and-vegetable combination.", "The now cooked potato cubes join the other ingredients in the vat.", "Blades spiral slowly for a gentle mixing to ensure the potato salad doesn't turn to mush.", "With the salad now ready, suctioning devices set plastic tubs on a track conveyer.", "Sensors signal their approach to dispenser nozzles, and the tubs stop right on cue for a fill-up of creamy potato salad.", "Suctioning arms then flip the lids onto the tubs, and once sealed, they're on their way.", "In just 40 minutes, they've manufactured enough potato salad at this factory to feed 500 people.", "It should be quite a picnic.", "A hydrogen fuel cell runs vehicles and other machines by directly converting the chemical energy in hydrogen gas into electrical power.", "Hydrogen is an abundant fuel source.", "It can be extracted from water, enabling almost any country to produce it domestically.", "Hydrogen-fuel-cell engines can power vehicles and run backup generators for large computer operations.", "They produce electrical power without any emissions.", "At the heart of the engine is a stack of super-thin hydrogen fuel cells.", "The engine's blower blows in air.", "The fuel tank feeds in hydrogen gas.", "Hydrogen and oxygen react and create electricity.", "Each fuel cell is made of five parts.", "On each end, there's a channelled plate made primarily of carbon, a material which conducts electricity.", "Hydrogen enters the cell through the first plate, which channels it through the next component-- a chemically treated paper which conducts both gas and electricity.", "Then the hydrogen enters this membrane, where it splits into protons and electrons.", "The protons react with the drawn-in oxygen, producing water.", "The water passes through another paper to the cell's outer plate, where a pump draws it away.", "Meanwhile, the electrons travel to the end of the stack of fuel cells to electrical wires.", "After assembling the stack, technicians compress the fuel cells in a hydraulic press.", "Compression helps the current flow smoothly from cell to cell.", "It also presses the rubber casket around each plate to the adjacent one, sealing the stack so that hydrogen can't leak out.", "The technicians run a quality-control test with nitrogen gas to verify the seal.", "Before releasing the press, they install high-strength steel rods to bind the compressed cells together.", "For a stack this size, the rods apply 3 1/3 tons of pressure.", "With a stack now off the press, they hook up an electric circuit board which monitors the voltage of each fuel cell.", "After securing the connectors to the stack with an adhesive strip, it's just a matter of connecting one to each fuel cell...", "And securing that connection with a special type of epoxy which contains silver to conduct electricity.", "Next, they mount the circuit board in a plastic cover to protect it.", "The fuel-cell stack is now fully assembled and moves to the factory's test area.", "A technologist mounts it on a test station and, simulating installation in an engine, hooks up a hydrogen line, an air line, and a water line for cooling.", "The testing machine runs a three-hour, automated performance test.", "They mount the stack onto the engine's structural frame, then install the hydrogen recirculation pump.", "Next, a water-recirculation pump, which cools the fuel cell by pumping in cool water.", "Then they mount the components, which feed hydrogen stored at high pressure in the fuel tank.", "That pressure pushes the gas through stainless-steel fuel lines to the cell.", "Next, the fan that blows outside air into the fuel cell to react with the hydrogen.", "This filter removes dust and other contaminants from the air the fan draws into the fuel cell.", "Meanwhile, technicians have assembled the computer that controls the whole engine.", "They now connect the wires from the fan, the pumps, and the other engine components to the computer.", "They hook up the fuel-cell output wiring, the wires which carry the current the fuel cell creates, and sends it to whatever vehicle or device the engine is powering.", "A tiny portion of the cell's output runs the pumps and other engine components.", "Now fully assembled, the engine undergoes extensive performance and safety testing.", "Once it passes every test, technicians perform a final visual inspection, then install the sheet-metal cover.", "The hydrogen-fuel-cell engine is now ready to be shipped to the customer and installed in the machine it'll be powering.", "Whether running a vehicle like this forklift or powering computer servers, the only by-product is waste heat and water, which is why hydrogen power is clean energy.", "Engineered wood siding is essentially clapboard reinvented.", "With its rough grain, it resembles natural wood.", "Each board contains wood strands that are resin-bonded for strength and durability.", "They're also treated to resist rot and termites.", "Engineered wood siding is a chip off the old block-- or a lot of chips, for that matter.", "But how do they transform a bunch of wood chips into a solid piece of wood?", "It starts with aspen and other kinds of wood.", "They transfer the logs to ponds to maintain a consistent moisture content and temperature until production.", "The logs land soaking-wet on a conveyer.", "Grooved rollers feed them into a debarker.", "It shaves off both the tree bark and the cambium-- the soft, green layer beneath the bark.", "This exposes the white aspen wood.", "The logs land on the next conveyer in a horizontal configuration.", "Circular saws cut the logs into smaller chunks, known as bolts.", "The bolts head towards a machine called the waferizer.", "Here's a look under the waferizer hood.", "A 10-ton steel disk holds 48 razor-sharp knives.", "When the disc spins, the knives slice the bolts into wafer-thin chips, known as strands, in just seconds.", "The strands are the same length, but slightly different widths.", "Most are roughly the size of a business card.", "They remain flat and don't curl up because of the stability of the aspen wood itself.", "A conveyer delivers the wood strands to big, steel bins, and from here, they're fed at a controlled rate to a dryer one floor below.", "Heated by a furnace, the cyllindrical dryer is superhot.", "It rotates to tumble-dry the aspen strands.", "A blender coats the strands with resin adhesive, wax for moisture resistance, and a preservative to ward off rot and termites.", "They spray a release agent onto the next conveyor to keep the strands from sticking to it.", "Rotating disks orient the first layer so the strands all land in the same direction.", "The next layer lands in a more random configuration.", "The third layer is again uniform and parallel.", "The result is a loosely interwoven mat of wood.", "Layering the strands will provide dimensional stability in the finished siding boards.", "A carriage now moves a large, circular saw back and forth to cut the mat into sections approximately 16 feet in length.", "The sections transfer to a faster conveyor that pulls them forward.", "A steel carriage stretches a sheet of heavy, industrial-grade paper across the mat of wood strands.", "The paper has been coated with a primer and saturated with a durable adhesive that bonds with the wood strands.", "A multitiered press closes to compact the mats and bake them.", "The heat and residual moisture activate the resins to turn wood strands and paper into one solid piece of engineered wood.", "At the same time, the press embosses the paper topping with a deep, cedar-like grain.", "The press opens, revealing the cured and compacted composite sheets.", "The thickness has gone from roughly 4\" to just under 4/10\" a conveyer doubles as a scale to confirm the content of each sheet is exact.", "Saws trim the sides and slice the sheets in two.", "A pusher pushes then shoves the smaller sheets forward, and another saw trims the ends.", "The trimmings don't go to waste.", "They're ground up and used as fuel for the dryer.", "They now have a stack of 40 engineered wood sheets.", "They're ready to be turned into siding boards.", "Rollers push the sheets one at a time into saws that slice them to siding dimensions.", "Now separate strips, they exit in a cluster and separate.", "A paint gun coats the trimmed edges with primer.", "This seals any exposed wood from the elements.", "After a trip through the oven to dry the primer, the engineered siding boards head towards an inspection station.", "Here, a worker scrutinizes each board for blemishes or damage.", "If he finds any, the board is rejected.", "The siding will be painted postproduction to the homeowner's preference, and once installed, this engineered wood product is sure to fit into the neighborhood." ]

{ "things": [ "Scalpels", "Oil Paints", "British Police Helmets", "Ice Axes" ] }

[ "Today on \"how it's made\"...", "Scalpels...", "Oil paints...", "British police helmets...", "And ice axes.", "The scalpel is the surgeon's trademark tool.", "Its short blade is razor-sharp and designed to slice swiftly and cleanly.", "This little knife may seem like a simple instrument, but its incredible precision, along with a surgeon's steady hands, is key to a safe and accurate medical procedure.", "Scalpel handles are made from rods of stainless steel.", "The blades are made of either carbon steel or stainless steel.", "They're sterile and designed for one-time use only.", "The blade steel is extremely thin, less than .", "02 of an inch.", "It arrives at the scalpel factory in coiled strips.", "The first machine feeds the strips into a press.", "A die inside punches out unfinished blades, called blanks.", "Blades will vary in size and contour, but they all have the same center slot for attaching the handle.", "When you flex a blank, it bends entirely out of shape.", "That's because the steel still needs to be tempered.", "The blanks pass through a furnace for about 30 seconds.", "The heat alters the molecular structure of the metal, hardening it.", "Now the blank has the flexibility a scalpel blade requires.", "Next, the blanks move through a punching tool that pops them from the strip...", "And stacks them on a peg.", "A worker threads a metal ring through the slots to keep them together, then sends the whole set of blanks for surface polishing.", "This process will restore the metal's original sheen, which was dulled by the heat treatment.", "Next, workers visually inspect every blank, discarding any defective ones.", "They transfer the blanks from the ring to a metal rod using a gauge to measure out the right number.", "From here, the rods are mounted onto grinding machines.", "Each one picks up a blank with a magnet, then places it in a holder.", "The holder runs the blank against a wheel coated with diamond particles.", "This powerful abrasive shapes and sharpens a cutting angle, transforming the blank into a blade.", "As the blades come off the grinder, they cling together because the magnet that fed them into the machine magnetized them.", "To cancel this effect, a demagnetizing machine passes an electromagnet behind the stacks of blades.", "After a thorough washing in an ultrasonic cleaning tank, the blades move on to final inspection.", "Wearing protective rubber gear, workers carefully scrutinize the cutting edges, discarding any blade that's less than perfect.", "Each and every blade passes through two different inspectors.", "In the packaging department, a machine covers each blade with a brown paper strip that contains an anti-corrosion chemical.", "This provides extra protection against rust.", "A second machine slips each blade into a foil packet, then cuts the packets apart.", "Each packet bears the blade model number and tracking code.", "As the blades come off the packing machine, an inspector does one last quality check.", "Then he counts the blades and boxes them.", "Of course, it's critical that surgical blades be sterile, so the boxes go into a cobalt radiation chamber for about six hours.", "This obliterates any lingering contaminants.", "When the boxes exit the chamber, they're hospital-ready.", "In the operating room, it's simply a matter of sliding the blade onto the protruding part of the handle, called the bayonet.", "Surgeons make the most of their dexterity by choosing a handle that best fits their hands and best suits the procedure their hands will be performing.", "Coming up, mixing up a wide palette of colors at an oil-paint factory.", "Oil paint dates back to ancient times when artists mixed minerals and other elements with wax or oil.", "In the 1400s, they discovered that linseed oil was ideal as a pigment binder because it allowed blending and glazing in layers.", "Centuries later, the colors in those paintings are still vibrant.", "Today, many oil paint pigments still come from natural sources, though most are synthetically made.", "Factories buy both types of pigments in powdered form to make their paints.", "Cuttlefish ink yields brown pigment, lead produces a specific yellow, and mercury ore makes red.", "In the past, pigments have also come from stones, tree bark, plant gum, ground up glass, and even arsenic.", "This company's research laboratory spends about two years developing a color recipe.", "A chemist mixes specific amounts of linseed oil and pigment into a machine called an automatic mueller.", "It rubs the ingredients together, dispersing the pigment particles throughout the oil.", "For each sample, the formulation is altered slightly in search of the perfect result.", "The research team compares the resulting colors and selects the best one.", "To produce a color on a large scale, workers start by pumping a specified amount of linseed oil into a mixer.", "Then they add the precise amount of pigment.", "Most colors are made with just one pigment.", "The precise mixing time and speed depends on the kind of pigment formulation being created.", "Next, the mixture is spooned into a mill.", "Three dispersion rollers rub the ingredients, separating pigment particles and coating them in oil.", "The recipe specifies how much pressure the rollers apply, how fast they turn, and how long they work the mixture.", "Milling can take hours or even days, depending on the texture of the pigment.", "The quality-control lab takes samples from each batch coming off the mill and subjects them to a series of tests.", "Technicians scrutinize paint from both sides of the mill to ensure the mixture is being processed evenly.", "First, a spread test.", "A heavy brass weight goes onto a blob of paint for a prescribed period of time.", "Then, inspectors evaluate the volume of color and measure the distance it spread.", "If it doesn't spread far enough, it needs more milling.", "Next, a dispersion test.", "The markings on this gauge indicate the size of the paint's particles in microns, millionths of a meter.", "If the particles are too big, the paint hasn't been milled enough.", "Finally, inspectors time how long it takes the paint to dry to the touch.", "Each color has a specified drying time, ranging from two days to two weeks.", "The factory produces a chart that displays its 120 paint colors.", "Workers brush each color onto a primer-coated paper.", "When the paint dries, they cut each bar into rectangular swatches called chips.", "The chart is assembled using this mounting machine.", "The bottom has a section for chips of each color.", "And the top contains a cardboard chart coated in glue.", "As the machine closes, each chip aligns perfectly with its designated spot on the chart.", "Back in the production line, the factory packages one color at a time in toothpaste-style tubes that will be finished off with twist caps.", "Once the labels go on, the tubes make their way to the filling machine.", "There, the tubes have their tops screwed on.", "A nozzle squirts in the paint.", "Then clamps flatten the edges shut.", "A roller folds over the edge to strengthen the seal against squeeze pressure.", "Now these oil paints are finally ready to meet the canvas.", "When we return, a new twist on the traditional british police helmet.", "British bobbies are used to standing tall because of their distinctive hats.", "These traditional police helmets are almost a foot high.", "That added height can't hurt when you're staring down a bad guy.", "Bobbies' helmets have looked the same way for a century and a half.", "Today, hatmakers use a metal mold to create that signature shape in fortified plastic.", "The mold descends into an oven.", "A worker places a sheet of plastic overhead.", "He lowers the lid and slides the heated cover over it.", "It takes a couple of minutes for the heat to soften the plastic.", "The mold rises.", "A vacuum below pulls the plastic into shape.", "It hardens almost instantly.", "A firm tap with a rubber mallet releases the shell from the mold.", "A band saw slices away the excess plastic along the brim.", "And now the helmet is ready to be covered.", "For that, the factory uses water-repellant wool.", "The helmet pattern is cut out in two pieces.", "These halves are stitched together, making a raised seam, which gives the helmet a smoother line.", "The insides of the fabric covers are covered with glue.", "Then they're steamed.", "A coating of glue is brushed all over the helmet's shell.", "The fabric cover has now reached the perfect dampness, making it easier to pull over the glued surface of the plastic helmet shell.", "The fabric gets stretched a bit so it'll fit tightly without buckling.", "Then, a wooden tool is used to smooth away any remaining air bubbles.", "The excess fabric is trimmed away.", "Then, rubber piping is sewn around the brim to reinforce it and give it a neater edge.", "The prong ends of the helmet's decorative metalwork are dipped in a chalky powder, which mark its positioning on the crown.", "Holes are drilled through the markings.", "Then the ornament is installed and its prongs are folded against the inside of the helmet.", "Next, workers stitch together strips of tape, plastic, and foam to make the helmet's harness and chinstrap.", "They fit the harness assembly inside the helmet, then secure it with an industrial stapler.", "Metal banding is wrapped around the helmet and pinned down.", "Not only does this banding hide the staples, it gives the helmet a snazzier look.", "An ornate helmet plate featuring the police department's insignia goes on the front.", "Next, a sponge liner is tucked inside the helmet to protect the officer in the event of a blow to the head.", "Ventilation holes are punched in the sides.", "Now it's time to size the helmet with a special gauge.", "Any excess fluff is tweezed away and the wool is brushed to bring up the pile.", "Finally, workers attach the label that assures the product meets all specifications.", "This police helmet is now ready to report for duty.", "It takes about half an hour to make one of these helmets, but it should keep a bobby on the beat safe and stylish for much, much longer.", "Up next, ice-axe production begins with a little heat.", "When it comes to mountain climbing, the ice axe is a fundamental tool.", "Ice axes were invented in the mid 19th century to help mountaineers get a grip on slippery slopes, pull themselves to the summit, and stop a fall.", "They're designed for peak performance.", "Talk about a steep learning curve.", "Climbing with an ice axe takes a bit of practice and a lot of courage.", "Production of an ice axe starts with an aluminum rod.", "A powerful press bends it into a curve, giving it the basic contour of an ice axe.", "It's flattened and shaped in two fiery dies.", "Each die has a top and a bottom half, which are lubricated between forgings.", "The hot forging transforms the metal rod.", "It starts to look a lot more like the shaft of an ice axe.", "The long ridges add strength to the metal while other indentations mark where the attachments are to go.", "The forging creates a lip around the perimeter of the shaft.", "They call this excess metal flash.", "This press takes care of it in a snap.", "Now, the ice-axe shaft has a cleaner edge and it's quite a bit lighter than the original rod, an advantage when you're toting it up a mountain.", "That aluminum rod has gone through quite a few stages, and now it has a whole new profile.", "This tub of vibrating ceramic cones will smooth the shaft's rough edges.", "Here, a computerized drill makes holes into recesses that were stamped into the shaft earlier.", "These holes will be used to attach other parts.", "The machine changes the drill bit to a circular blade.", "Then, guided by the computer, it cuts a slot for the ice-axe pick.", "Next, the saw moves to the other end and thins out the area where the handle will be attached.", "Using another drill bit, the saw carves out a hole for the adjustable finger rest.", "Here's a shaft that's already been milled and drilled compared with one yet to undergo the process.", "The shaft gets a protective coating.", "Then, it's time to bring all the pieces of the ice axe together.", "A worker applies epoxy to the inside of the rubber handle and slides it onto the shaft.", "The handle has an open end.", "He beads a little more epoxy onto it and inserts a steel spike.", "The spike is then riveted to the ice-axe shaft.", "This spike will come in very handy on the mountain side.", "Plunging it into a snowy slope can help a climber maintain his or her balance on a slippery uphill trek.", "Next, the adz slides into the slot at the head of the shaft.", "Climbers use this tool to chop steps in hard snow and ice.", "The worker secures the adz with nuts and bolts, and then he installs the pick.", "This hooked and jagged attachment will help get the climber up a mountain of hard ice.", "The bolts are tightened with a torque wrench.", "After all, a solid job here could be a lifesaver.", "And finally, the adjustable finger rest is screwed to the shaft just above the handle.", "And now you have a tool that can help you scale new heights." ]

{ "things": [ "Hearing Aids", "3" ] }

[ "Today on \"how it's made\"...", "Hearing aids.", "We're turning up the volume for this one.", "3-d puzzles-- a traditional pastime enters a new dimension.", "Rubber mats-- we bring you a step-by-step explanation.", "And toilets-- this fascinating report leaves us flushed with pride.", "When you stop and listen to all the sounds around you, you suddenly realize how easy it is to take your hearing for granted.", "If you ever develop a hearing disorder, you'll undoubtedly feel the loss.", "Thankfully, though, hearing aids are tinier and more effective than ever before.", "Loss of hearing causes a serious handicap, but, happily, it can be remedied thanks to hearing aids.", "But before fabricating the aid, the degree of hearing loss must be precisely measured with this apparatus called an audiometer.", "So they make a mold of the ear canal.", "To protect the eardrum, an autoblock is inserted.", "The next step is to pour in a silicon impression-making material.", "It solidifies and is then removed from the ear.", "This congealed mass representing the ear canal is then soaked in warm wax to obtain a positive imprint.", "Then the silicon container is filled.", "The silicon hardens in only 10 minutes.", "The hardened silicon block is removed, and the excess of the imprint is trimmed away so that only the essential part is retained.", "The imprint must slip easily into the ear.", "It's now the molding stage for the hearing aid.", "Acrylic is poured into the mold before placing it into this ultraviolet oven.", "Without emitting any heat, this oven hardens the acrylic.", "Here is the raw prosthesis without its electronic components.", "This plan details the electric circuit of the amplifier.", "Holes are pierced for the volume control.", "These components are tiny.", "Here is the volume control...", "The miniature microphone that captures sounds...", "And the earphone, which functions as a speaker.", "This tiny braided wire of seven conductors is soldered to the amplifier and other parts of the prosthesis with pewter.", "The hybrid circuit is inserted into a silicon casing, which assures its protection.", "Then the wires are soldered to the speaker.", "And they verify the proper functioning of the volume control.", "A hearing aid must be very discreet.", "That's why they cut the excess with a diamond disk.", "They also remove the roughness with fine sandpaper.", "The holes we see here are used to vent air from the earphone.", "This silicone tube is used to make the vent.", "Acrylic is poured onto the tube to form a tunnel.", "Ultraviolet light is used to harden the acrylic.", "Afterwards, the tube is removed.", "This hole is used to position the fastener, a small wire which allows for removing the hearing aid from the ear.", "Then the battery is installed.", "Only a few parts, such as the microphone, remain to be put in place.", "Then everything is delicately assembled into the interior of the prosthesis.", "The two parts of the hearing aid are then glued together.", "Ultraviolet hardens the glue.", "The plate used to position the prosthesis components is cut away with the drill.", "Then the hearing aid is manually polished to make it perfectly smooth and comfortable.", "The prosthesis is now completed.", "There remains one important step-- verifying its electroacoustic characteristic.", "It's with this analyzer that they validate that the hearing aid conforms to the original prescription.", "These minute prostheses allow us to solve the main hearing problems.", "Microfabrication of a single unit requires a little more than two days of work.", "Remember spending lazy afternoons putting together simple 60-piece jigsaw puzzles?", "Well, put that image out of your mind, because today's sophisticated puzzles can have 1,500 3-d pieces that go up, down, and even sideways.", "Are you up for the challenge?", "Flat puzzles are well known by everyone, but 3-d puzzles present a different challenge.", "These 3-dimensional puzzles are first conceived with computer software.", "Good blades are needed to cut puzzle pieces.", "Here are the blades for the master die which will cut out printed sheets of different models.", "This rubber will be used to eject the die.", "The master cutting die is unique to each puzzle.", "It is the specific pattern used to make the puzzle.", "They measure it meticulously to obtain a perfect register.", "It's imperative that the die not move during the cutting, otherwise the pieces would be cut at the wrong points, so they very firmly secure it in place.", "The carbon of the die is positioned.", "It's somewhat like printing the master.", "Alignment is again verified, a highly important step which assures the quality of the final product.", "Finally, they install this large metallic plate, which is the cutting base.", "It will be on this surface that the master die will strike.", "Once measurements are finished, the drawer of the die is slid into place.", "This press cuts the pattern seen on the puzzle.", "Here's how it works.", "The sheets, or printed cardboards, go into the drawer one by one, where they are cut according to the master model.", "We clearly see the press making the cut in the puzzle sheet.", "The cut sheets pile up on one another.", "At this checkpoint, they verify the precision of the cut.", "They make sure that every piece is correctly shaped.", "Now they go to the foam support of the puzzle.", "This guillotine is used to cut the polyethylene sheets onto which they will glue the cut images.", "Foam sheets are inserted into this laminator heated to 450 degrees.", "The sheet with the design on it is glued onto the foam with a thermosetting adhesive.", "Now they glue the printed sheet onto the foam sheet.", "Once the adhesion is finished, the puzzles are stacked on one another, and they proceed to the unbuckling operation.", "By pulling, they remove the surplus cuttings.", "The same design is printed several times on a sheet, so they must separate each puzzle.", "This step is called the reduction of the models.", "Now the pieces have to be separated.", "This decorticator handles this task and sends the pieces down a chute.", "Packing cartons arrive already made up, and the puzzle pieces are placed in their boxes.", "No less than 15,000 puzzles are produced here each day.", "Since it began operations, the company has created more than 300 different puzzle models from quite simple ones to much more complex designs.", "The largest of them contain a total of more than 3,000 pieces.", "And you need real patience for this one.", "Ever wonder what happens to the millions of used tires we throw out every year?", "Well, you'll be relieved to know that burning tires is a thing of the past.", "Today's tires are often given new life as rubber mats.", "Some are even big enough to cover whole arenas.", "Now, that's recycling.", "Used tires are a real source of pollution.", "This pile represents about 100,000 of them.", "At any rate, these tires will have a second life.", "They'll be recycled to make rubber mats.", "Each day in this factory, they recycle 15,000 tires into mats.", "Tires have to be reduced to little granules, but first this conveyor feeds the tires into the washer.", "Tires are washed with a water-based biodegradable preparation.", "Then they're sent to the shredder.", "The shredder has two rows of large teeth.", "These grind up the tires into pieces.", "This shredder is able to cut up almost 1,000 tires an hour.", "They come out as fairly good-sized pieces of tires, which are then shredded a second time.", "Metal is magnetically separated from the rubber, and the metal pieces are recycled at another factory.", "Other components of the tires, such as fiberglass and nylon, also have to be separated.", "They use a sifter to get out unwanted rubbish.", "Recuperated rubber particles purged of foreign materials measure about 1/10 of an inch.", "Some 16 tons of tire particles are piled up in this recycling depot.", "But the particles are still too large to be used.", "They're sent to a secondary shredder supply tank, where they'll be reduced even further.", "This tractor feeds the secondary shredder.", "Grinding action produces a kind of rubber powder.", "The powder is spread out on these enormous molds.", "This mold has a length of 23 feet and a width of 4 feet.", "Thickness varies according to the product being made.", "The molds filled with rubber powder are stored in this loading magazine of the press.", "Once full, the molds are sent to the rubber-mat press.", "Here's the mat press.", "The powder has to be cooked at a very high temperature for about 30 minutes.", "Cooking time depends on the product being made.", "The cooked mat goes to the unmolding unit before being sent off to cool.", "The rubber mats are still extremely hot.", "They're cooled with jets of water for a period of several minutes.", "The cooled mats can now be sent to the next department.", "This conveyor in the cutting center positions the mat before it's cut.", "The mat is vibrated to eliminate any surplus water.", "Each rubber mat is now cut up into three pieces.", "The cut mats are then stacked into a pile and stored before being shipped.", "The company also makes mudguards.", "These are fabricated the same way as the preceding mats.", "After having been cooled in water, but while they're still warm, they remove the surplus rubber.", "This operation is called \"notching\".", "Hard rubber rings are also produced at this facility with the same fabrication methods and, as always, from old, used tires.", "Over a 12-hour period, this facility makes no less than 12,000 rubber mats from old, recycled tires.", "This translates into good news for our environment.", "We tend not to put much thought into this humblest of household appliances as long as it keeps doing what it was built to do.", "But like most of the machines we've invented to do our dirty work, we may take it for granted, but it's next to impossible to imagine life without the toilet.", "The first public restrooms appeared in ancient rome when the emperor vespasian built latrines.", "Such public urinals became widely known as vespasiennes by 1840.", "In 1775, the invention of a water-flush system created toilets somewhat resembling today's convenience.", "The valve and siphon were added in 1784 and the septic tank in 1896.", "A toilet is an everyday object whose fabrication requires several days of work.", "It involves assembling several molds called \"tools\".", "Each new product requires the design of a master plaster mold from which they will produce a plastic tool.", "This latter will be used to create plaster duplicates used as production molds.", "The plaster production mold of a toilet is made from six different tools which have to be assembled.", "Their life-span is only two months.", "The process begins with a mixture of water and plaster according to a precise recipe.", "Then the liquid is poured into this filling hole of the tool.", "Once the plaster hardens, they can proceed with unmolding.", "They strike the end at the junction of the plaster mold and the tool with a rubber hammer so as not to damage the plaster.", "Pieces are gently assembled.", "The toilet softly takes its shape.", "It is in this same mold that they will later color the clay.", "Then they install tensioning straps.", "Little blocks are inserted between the mold and the strap to increase the tension.", "The mold will soon be filled with liquid, and they thus prevent any distortion.", "Here a new recipe is being prepared.", "This time it's a slurry, a composite of clay and silica.", "This preparation is spread out over 48 hours.", "Now they install the core, the upper part of the mold.", "They can now proceed with the filling.", "This copper distribution pipe connected to the tank containing the slurry permits the filling of several molds at a time.", "They need about 45 pounds of the mix per bowl mold.", "After an hour, the slurry has attained a thickness of 4/10 of an inch.", "The plug is pulled to allow the excess slurry to run out.", "They can now unmold the still-fragile piece.", "This thicker slurry is used to adhere these two pieces together.", "They cut the holes and unmold the ensemble.", "The toilet is now molded.", "Then, to obtain a perfect appearance, they remove the little fillet formed by the surplus adhesive slurry.", "The toilets air-dry for 36 hours, then in a warm-air dryer for 12 hours.", "Finishing must be impeccable.", "They carefully sand the surface to make it perfectly smooth.", "A vacuum draws up the dust.", "Then, with a jet of compressed air, dust and debris are blown away.", "Bowls are hand-painted in a special room.", "As for the water tanks, they are painted by an automated robot.", "This truck carries the different parts to the final fabrication stage-- baking.", "The toilets remain in this oven at the very high temperature of 2,150 degrees for 23 hours.", "It takes this long to fuse the clay and silicone.", "The paint then becomes hard and shiny, and it's all done.", "The toilets and the different bowls now take on shapes more elegant than in the past, but the fabrication of each one of them will have the same basic construction steps involving 45 pounds of slurry and almost 4 days of labor." ]

{ "things": [ "Motorcycle Sidecars", "Frozen French Toast", "Refrigerator Compressors", "Superchargers" ] }

[ "A sidecar is a passenger attachment that bolts to a motorcycle.", "Sidecars are aftermarket products, meaning a separate company-- not the motorcycle maker-- manufactures and markets them.", "You buy a model that's compatible with your motorcycle.", "A motorcycle sidecar carries one passenger or two, if they're small children or pets.", "Manufacturers typically produce several models, designed to fit the most popular bikes on the market.", "This one has a fiberglass body, surrounded by a steel perimeter chassis.", "Workers construct the chassis using several sections of steel tubing.", "They form each section to the required shape on a hydraulic bender, measuring as they go.", "There are sections in the front and back, along the sides, and underneath.", "Once the sections are each bent to specifications, workers clamp them into a jig, which aligns them all in the correct configuration.", "The smaller-diameter sections fit into adjoining larger-diameter ones.", "Once all the parts are in position, a welder fuses them.", "The structure of the perimeter chassis is now complete and ready for a coat of baked-on powder paint to prevent the steel from rusting.", "Next, workers mount the suspension and wheel to the chassis, then install a fiberglass mudguard that has a reflector, a taillight, and a turn signal.", "They make the sidecar's fiberglass body with upper and lower molds, first painting each one with gel coat, a polyester resin that creates a smooth and shiny surface over fiberglass.", "When the gel coat dries, about 45 minutes later, they lay fiberglass mat over it, then saturate the fiberglass with resin.", "They lay two fiberglass layers in most parts of the mold and a few extra layers in areas that need a bit more strength to support attached components.", "In the lower mold, they re-enforce the floor with plywood and, in specific locations, bond in steel mounting plates for bolting components to the fiberglass later on.", "24 hours later, once the resin has cured, they extract the upper- and lower-body halves from their respective molds, trim the rough edges, and join the halves on the inside with more fiberglass and resin.", "Then they place the now-assembled body inside the perimeter chassis to check the alignment.", "But they don't connect the chassis just yet.", "First, to snazz up the body, they mount a nose badge made of stainless steel and anodized aluminum.", "Then they attach aluminum strips to the nose badge, affixing them to the fiberglass with rivets.", "They gently tap the strips with a mallet, shaping them to the contour of the body.", "Then they set a rubber insert into each strip.", "This adds a decorative touch, while hiding the rivets.", "Next, the sidecar's windscreen.", "It's made of polycarbonate, an ultra-thin yet strong type of plastic, encased in a durable aluminum frame.", "They finish off the body by installing carpeting and an upholstered vinyl seat.", "Workers position the sidecar so that its wheel is turned slightly inward.", "This ensures the bike and sidecar handle correctly.", "Then they bolt the chassis to the bike frame with four steel arms-- two at the front and two at the back.", "Next they fit a steering damper.", "This prevents the sidecar from causing a wobble in the steering.", "The final step is to connect the electrical wiring to the lights and the mudguard.", "The perimeter chassis is now ready to receive the body.", "They thread bolts into the holes of those mounting plates that were bonded in with the fiberglass during the molding process-- two bolts at the front and two at the back, through the floor.", "With that, this motorcycle sidecar is ready to hit the road.", "Love french toast for breakfast but don't have the time or patience to make it from scratch?", "That's why there's ready-made frozen french toast that you simply pop into the toaster-- no cracking eggs, pouring milk, or dipping bread required.", "Just pour on the syrup and enjoy.", "A breakfast favorite for generations, it's easy to get sentimental about french toast.", "To get that traditional taste without the traditional mess, there's frozen french toast.", "They go from your freezer to your breakfast table in just minutes.", "French toast starts with freshly baked bread.", "A local bakery supplies this factory with custom-made 16-inch-long loaves.", "When those fresh-baked loaves arrive, workers load them horizontally onto a conveyor belt.", "The belt winds its way to the first machine on the production line-- the slicer.", "The slicer has several vertical blades, crossed in a figure eight over two drums that drive them.", "Because each blade crisscrosses, it cuts two slices at once.", "For this production run, the slicer cuts each loaf into 28 slices almost half an inch thick.", "At the output end of the slicer, workers discard the two end pieces.", "However, these heels, as they're called, aren't wasted.", "They're used for animal feed.", "Workers load the cut loaves into side-by-side vertical columns.", "The slices drop down onto a wire conveyor belt.", "The spacing between rows and slices is perfectly positioned to align with the upcoming stations, which will transform them from bread to frozen french toast.", "First, the slicer enters the batter station, which bathes their underside in a mixture of eggs, milk, water, and sugar.", "The slices then pass under a batter waterfall, which thoroughly coats their top surface.", "The slices exit the batter station onto a wire belt, which feeds them onto cast-iron griddle plates.", "Gas flames underneath heat the plates to 275 degrees fahrenheit.", "After several seconds, the underside is cooked, and a row of automated spatulas, appropriately called flippers, turns the slices over to cook the reverse side.", "Seconds later, the fully cooked french toast slices are removed from the griddle plates...", "And deposited onto a conveyor belt.", "All of the single-file conveyors now converge on a larger conveyor belt, which transports the slices into the freezer.", "The temperature inside-- negative 4 degrees fahrenheit.", "After a frosty 23-minute ride, the french toast is completely frozen.", "It exits the freezer, ready to be sorted into packaging portions.", "For this order, workers stack the slices in fours.", "Each package will contain two stacks.", "The packaging machine inserts each portion into a continuous plastic-film pouch.", "Then, at both ends of each portion, it simultaneously heat-seals the film and cuts the pouch free.", "An automated arm picks up each pouch and inserts it, either into small retail cartons destined for supermarkets or into large boxes for bulk orders to cafeterias, hospital kitchens, and restaurants.", "All packaging, warehousing, and shipping occurs in temperature-controlled facilities to keep the product frozen until it's time to toast this breakfast tradition.", "Behind every chilled beverage, there's a compressor, a crucial component in refrigeration systems.", "It pressurizes and pumps refrigerant to the condenser so the cooling process can begin.", "With a well-functioning compressor, a refrigerator is more likely to keep its cool.", "Behind the glossy exterior of a supermarket refrigerator, there's a substantial compressor doing its part to chill the merchandise.", "They often remanufacture old compressors to save resources and money.", "They immerse the cast-iron body in a chemical bath to remove the grime and rinse off the residue with hot water.", "That old compressor already looks a lot less tired.", "A worker polishes the cylinder bore with an abrasive pad attached to an air drill.", "He sands the surfaces around the openings so that all the parts will fit without leaking.", "Smaller parts bounce around in a vibratory bowl with steel pellets and cleaning compound for a good scouring.", "Out of the bowl, a worker places a valve plate on a magnetized turntable to keep it in one place, as a grinder smoothes the surface.", "This makes it look new.", "He screws two new valves to the plate.", "These valves will open and close to move refrigerant in and out of the compressor.", "The next worker assembles the terminal plate for the compressor's electrical motor.", "Most of the components have been reconditioned, including the lugs for the wires.", "He slots the lugs in the terminal plate from the back and flips the plate around.", "He slides new rubber seals onto all the lugs...", "And then installs rubber insulators and metal washers.", "He secures the lugs with screws, using a precisely calibrated torque wrench.", "The compressor's original crankshaft has also been thoroughly cleaned.", "As it now spins in a chuck, a worker polishes it until it's completely smooth.", "This will allow bearings and connecting rods to operate efficiently.", "He measures the shaft to confirm that the circumference is right.", "With many parts now reconditioned and partially assembled, they're ready to reconstruct the compressor.", "The worker installs new bearings and the refurbished crankshaft into the compressor body.", "He inserts the connecting-rod and piston assemblies.", "Moved by the crankshaft, these pistons will compress the refrigerant gas to pump it through the system.", "He slides the rotor part of the motor into the compressor, and it links up to the crankshaft.", "He aligns the rotor to the crankshaft with a long pin.", "He secures the rotor to the hub with a substantial bolt.", "The next part is the stator.", "It's the magnetized mechanism that drives the rotor and, subsequently, the crankshaft.", "He connects protruding wires to the lugs on the terminal board we saw reassembled earlier.", "He sets the terminal board flush to the compressor and bolts it to it.", "He fits the valve plate on the cylinders, adjacent to the terminal plate.", "He places the cylinder head over the valve plate and bolts it to it.", "The remanufacture of this compressor is complete.", "To test the compressor, they pump dry nitrogen through it.", "A machine measures the suction and discharge pressure, as well as the electrical draw.", "And still running dry nitrogen through it, they immerse the compressor in water and check for bubbles that would indicate leaks.", "They make repairs if needed and then spray the compressor with enamel paint to protect it from rust.", "Remanufacturing this refrigeration compressor has taken 24 hours.", "It's given it a whole new lease on life.", "An engine naturally takes in air from the atmosphere to burn the fuel with oxygen.", "If you're looking to give your car a boost, a supercharger compresses air and force-feeds it into the engine.", "The increased mass of oxygen burns more fuel, giving the engine more power.", "A supercharger is particularly popular in drag-car racing.", "It attaches with a belt to the engine's crankshaft, and, voilà, the car's on steroids.", "They begin with a plate that forms the rear of the supercharger's aluminum housing.", "Using a press that applies several tons of pressure, they install two steel ball bearings.", "These will enable the supercharger's two rotors to spin, which is what compresses air and forces it into the engine.", "After bolting the steel cap over each bearing, workers insert steel dowels into holes along the perimeter of the plate.", "These dowels, which they now fully seat with the press, will align with receiving holes on the adjoining housings.", "They take the plate that forms the front end of the housing and press a steel ball bearing into it.", "This bearing will enable the supercharger's input shaft to rotate and, by doing so, spin the rotors.", "They press a rubber-lip seal on top of the bearing to keep oil in and dirt out.", "Next, they apply a retaining clip to hold the seal in position.", "Using the press, they seat the clip in its groove.", "Next, they insert the input shaft.", "Its flanged end will protrude out of the supercharger, where a belt and pulley will rotate it so that it turns gears which spin the rotors.", "A computer-guided mill machines each rotor out of extruded aluminum.", "Once both rotors are ready, workers take the central section of the supercharger housing and apply sealant to one end of it.", "They affix the rear plate containing the two bearings for the rotors.", "They secure the plate to the main housing using socket-headed screws, which they tighten with an air driver.", "Flipping the housing to the other side now, they install the first of the two rotors, inserting its shaft into the first bearing in the just-attached rear plate.", "Then they install the second rotor, inserting its shaft into the second bearing in the plate.", "The second rotor lies perpendicular to the first.", "This positioning allows the spinning rotors to capture air at the top of the housing, compress it, and force it downward to the bottom of the housing.", "They close up the housing with another plate which also contains bearings for the rotor shafts.", "However, on this end, the shafts protrude beyond the bearings in order to receive gears.", "Then to this, they'll attach the housing containing the input shaft, which, driven by the belt and pulley, rotates these gears to spin the rotors.", "Before continuing further, the team puts the supercharger through a performance test.", "The machine, called a dynamometer, assesses the ratio of speed to air flow to ensure the rotors are compressing air the way they should be and therefore outputting the required boost.", "If the rotors pass the test with flying colors, workers then hand-polish the aluminum housing to a shiny finish.", "A key component in the supercharger is a feeler gauge-- that fan-shaped part shown on the lower left.", "It ensures that the distance between the rotors is correct, which is critical, because if the rotors are too far apart, they don't compress air adequately.", "And if they're too close together, they jam.", "It's the customer who, when installing the supercharger, attaches a pulley to the end of the input shaft, then a belt onto the pulley.", "The other end of the belt loops around the car engine's crankshaft pulley, connecting the supercharger to the engine for a mega boost of power." ]

{ "things": [ "Power Steering Pumps", "Asian Bowl Meals", "Walking Canes" ] }

[ "In the first half of the 20th century, power steering was not an option.", "Prototypes were too expensive for production.", "During world war ii, the british and american armies began to use power steering in heavy vehicles like armored cars, and auto makers soon began adding it to passenger vehicles.", "These hydraulic steering pumps are the steering muscle in muscle cars, providing a power assist to give the driver more control.", "Using computer software, manufacturers design the pumps to fit specific classes of vehicles.", "They print a plastic model using a 3-d printer.", "This is a time-lapse video of the process.", "The designer removes the plastic model and he sends it, along with the computer design, to a casting facility, which produces aluminum pump-housing parts.", "Back at the factory, a worker mounts 12 of the castings in a machine with computer-controlled tooling.", "He activates the system, and it moves the rack of castings into position.", "The tools machine the face of the castings.", "They bore center-bearing holes and drill threaded holes for bolts.", "This is precision work, which will now be double-checked by a device known as a coordinate measuring machine.", "A worker clamps the pump housing in the machine.", "Then, a ruby-tipped probe scans its dimensions.", "The machine analyzes the information.", "It verifies that every part of the housing meets the precise specifications.", "With that confirmation, he unclamps the part.", "This is the pump housing in the various stages of production.", "Other tools turn a solid aluminum dowel into a fitting for the pump's pressure bore.", "They sculpt the circumference and carve a complex geometry in the center for controlling the flow of power steering fluid.", "Another tool carves the thread to screw the fitting into the pressure bore, and the final one drills the fluid bypass hole.", "A blue anodized coating protects it from corrosion.", "A worker now locks the pump housing in a honing machine.", "The machine floods the pressure relief bore with lubricant as the stone hones the inner diameter to a precise tolerance.", "He then transfers the pump housing to a press.", "He inserts a bearing and shaft in the center bore.", "He places an aluminum tool over the bearing and shaft to align them correctly as he manually presses them into the bore.", "Once the bearing has been solidly entrenched, he removes the tool.", "He inserts a metal snap ring in a groove to retain the bearing and shaft.", "He turns the power steering pump over an installs o-rings to seal the pressure section.", "Then the worker installs the cam ring and the rotor with the veins.", "As the rotor spins, the veins will move in and out, collecting hydraulic fluid.", "This process adds pressure, taking the load off the steering wheel.", "The worker installs this critical sub-assembly in the pump housing.", "He screws the device in place in the four corners.", "He turns the power steering pump over and seals the end of the pressure bore with an aluminum plug and copper washer.", "He now tucks the pressure relief valve in the open part of the pressure bore.", "He secures it with the special flow fitting we saw machined earlier on.", "He tightens the fitting with a torque wrench.", "He turns the power steering pump onto its side.", "He attaches a fitting to the intake port for the hydraulic fluid.", "The power steering pump is now equipped with all the working parts.", "Here's a look at the transformation.", "A display model with a cutout offers a peak inside.", "At the test station, a technician makes all the connections and runs it as if it was in an actual racecar.", "A computer measures its performance and confirms that it meets all the technical requirements.", "The power steering pump is now ready for the twists and turns of professional racing.", "Across asia, rice bowl meals are an enduring tradition.", "By combining protein and vegetable elements with rice in a bowl, people have a meal.", "It's asian comfort food, and somehow it just tastes better in a bowl.", "And people around the world are discovering the appeal of these one-bowl meals.", "Asian bowl meals start with the rice.", "Then people add whatever they want.", "At food bars like this, there's any number of choices.", "The bowls can be served up fast, and the food is healthy.", "Because there are many possible combinations, these one-bowl meals never get boring.", "Preparations start with the rice.", "This food worker measures enough for 40 portions.", "After rinsing the grains repeatedly, he adds it to a rice cooker.", "He then measures the water for cooking.", "He adds it to the cooker.", "It will steam the grains so they cook uniformly for one hour.", "While the rice is cooking, the food worker then pours peeled garlic cloves into a food processor.", "He adds a half cup of vegetable oil.", "The garlic will flavor several dishes in the asian food bar.", "The food processor chops the garlic to a fine consistency.", "Using a mandolin vegetable slicer, he slices slivers of carrots.", "Along with chopped onions, the carrots will enhance the flavor of fried rice.", "He now removes some rice from the cooker, in order to make fried rice.", "He separates the grains so they'll fry more uniformly.", "The food worker is now ready to fry.", "He heats the wok to a very high temperature.", "He adds cooking oil, and it starts to sizzle.", "He tosses in the carrot slivers, chopped onion, garlic and frozen peas.", "He constantly stirs the ingredients, and the flavors sweeten and deepen.", "He turns down the heat a bit an adds the rice.", "He mixes the rice with the other ingredients as the cooking continues at a slightly lower temperature.", "He measures the temperature.", "For food safety reasons, it needs to be over 143 degrees fahrenheit.", "The food worker pours soy sauce onto the hot wok.", "It trickles down to permeate the rice, adding flavor and color.", "That completes the fried rice component of the food bar.", "Next up are the vegetable and protein choices.", "The food worker cubes sushi-grade tuna.", "It will be marinated with a spicy saucy shortly.", "He places the tuna in a food bar container.", "He peels cucumber and then juliennes it.", "The cucumber will be a raw food choice that will offset the strong flavor of the tuna.", "The food worker then prepares the tuna's spicy marinade.", "He adds chili sauce and a smaller amount of chili oil to mayonnaise.", "It's hot stuff.", "A seaweed salad dish is another refreshing choice that will cool the palate.", "He adds the chili mayonnaise to the tuna.", "And he turns up the heat a little more with some extra chili oil.", "A thorough mixing completely saturates the raw fish with the spicy sauce.", "Next, the food worker prepares the dressing for a cabbage salad.", "He starts with a white miso paste.", "A generous amount of soy sauce follows.", "Sushi vinegar and vegetable oil are the next ingredients.", "After adding some sesame oil, he blends all the components.", "He coats the shredded cabbage with the miso dressing.", "He sprinkles black sesame seeds onto the cabbage salad.", "Teriyaki beef is the next option.", "The main ingredients are shaved filet steak, chopped ginger, and shredded onion.", "The food worker sautés the onion and ginger to provide a flavor base.", "He adds the shaved steak, and as it cooks, it takes up the essence of the onion and ginger.", "The soy-based teriyaki sauce provides the final layer of flavor.", "With this dish now complete, it's time for the fun part-- mixing and matching components for the asian food bowl.", "There was a time when an elegant walking cane was a status symbol for fashionable gentlemen.", "Today, a cane is no longer considered an accessory, but rather a utilitarian medical aid for people with mobility issues.", "However, one can still find canes which combine both function and fashion.", "Walking canes can indeed be stylish, with straight or crook handles made of exotic wood or bone, elegant knob handles, or elaborate figurative handles.", "This family enterprise has been hand-crafting walking canes since 1909.", "Making a crook handle requires bending the handle material.", "After heating a curved steel form in a fire, workers insert a square stick of ebony in a steel spring and mount it on the central axis of the machine.", "The clamp the machine's guide wheel against the form, then clamp the part of the stick that will remain straight.", "Using their body weight, the worker forces the machine's lever forward, wrapping the top part of the stick around the hot, curved form.", "It's critical to do this slowly to prevent the wood from snapping.", "Workers then lock the bent stick against the form with a brace...", "And remove it from the machine.", "They set it aside for a week.", "One week later, they remove the brace and spring and mount the curved stick on a lathe.", "As the stick spins, a carriage moves a saw down the straight part of the cane, known as the shaft, reducing the diameter and rounding it out.", "This is the shaft before and after this step.", "A worker runs the handle against a coarse grit sanding belt to pare it down and begin rounding it out.", "He uses a router to refine the shape and works on the harder-to-access inner part of the curve.", "Once the handle is rounded, and its diameter equal to that of the shaft, he performs a final fine sanding.", "Then he polishes the entire cane with polishing compound against a cotton buffing wheel.", "Slowly but surely, this makes the ebony sleek and lustrous.", "All wooden canes-- these here are made of maple-- warp a bit during woodworking.", "Another worker heats the cane to make the wood flexible, then inserts it in a v-shaped holder and peers down the length of the shaft to assess the direction of the deformity.", "Then he manually straightens out the cane.", "These canes undergo a final step to add a decorative feature.", "A worker sands off some wood on the crook handle, creating a flat, oval surface.", "He applies glue, then he adheres a piece of cow horn.", "Once the glue dries, he grinds the horn flush with the surrounding wood.", "The result is a horn inlay.", "Wooden canes also need protection against moisture and wear.", "The factory submerges them in varnish for a half hour, so that the varnish deeply penetrates the pores of the wood.", "Hanging the canes to dry would leave varnish drip marks, so the factory uses this ingenious pulley-driven contraption that dates back to the 1900s.", "With its wood wheels and leather belts, the machine continuously rotates the canes to prevent the wet varnish from dripping as it air dries.", "That's how to make a wooden crook-handled cane.", "As you'll see next, fancier walking canes require additional steps.", "Whether it's decorated with ornately carved wood, sleek horn or gleaning metal, brandishing a fancy walking cane is like wearing a bold pair of eyeglasses.", "What might otherwise be a bland necessity can be elevated to a fashion statement.", "Elegant canes can have horn or knob handles, or silver-plated figural handles.", "The figural ones are molded two at a time.", "After placing a screw mechanism in each cavity, a worker closes the mold and places it in a centrifuge machine.", "As the mold spins, he ladles pewter into a funnel that feeds the channels leading into the mould cavities.", "The centrifugal force shoots the pewter onto the cavity walls in an even layer, where it cools and solidifies in about five minutes.", "Then he stops the machine and removes the mould.", "The worker opens the mold and extracts the two pewter castings, each with it's screw mechanism securely embedded.", "One is a cobra handle.", "The other is a dog and boar handle.", "They require a bit of refinement, so the next step is to remove the excess metal with a rotating wire brush.", "A worker then shines up the surface with some polishing compound and a cloth buffing wheel.", "He washes off the polishing compound and silver-plates the pewter.", "The handle will top an equally elegant ebony shaft.", "A worker places the square stick of ebony in a lathe, which rounds it.", "The shaft goes through several sanding and polishing steps.", "Then a worker drills a two-inch-deep hole in the top of it.", "He puts some glue in the hole and screws in the handle.", "If silver-plated cobras aren't your style, how about a handle made of white cow horn?", "First, a worker heats all but the tip of the horn in a fire.", "This destroy the nerves in the bone inside the horn's shell.", "This horn will be shaped into a crooked handle using the same bending machine the workers use for wood crook handles.", "The base of the horn is hot, so they use a small block of wood as a buffer.", "After clamping the machine's guide wheel against the middle of the horn, they use their body weight to move the lever forward, and wrap the top half of the horn against the curved form.", "Before heating the horn, the worker drilled a small hole through its tip.", "Now he inserts a thin steel wire through that hole and ties the wire tightly around the opposite side to hold the horn to the round form.", "He sets it aside for a week.", "A horn handle undergoes the same multi-step sanding process as a wood handle, however, a worker drills a hole into the bottom and screws in an aluminum rod.", "This makes the handle easier to hold while sanding.", "The worker removes the final traces of the outer layer with a router and finalizes the crook's shape.", "He removes the handle from the metal rod and finishes it off with a fine sanding.", "The horn surface is now as smooth as silk.", "He then polishes the handle on a cotton buffing wheel using a polishing compound specially formulated for horn.", "That brings out the color and sheen.", "Then the worker screws and exotic-wood shaft into the same hole used for the metal rod.", "This fashionable cane, which has taken 4-6 hours to craft, is ready to be modeled on the walkway." ]

{ "things": [ "Upright Pianos", "Flags", "Wet" ] }

[ "Unlike a grand piano, an upright piano is vertical, so you can place it against a wall.", "Uprights come in various heights.", "The taller ones have longer strings and a larger soundboard, so their sound is closer to that of a grand piano.", "Around four feet tall, this is the largest upright piano on the market.", "It's designed for those who lack the budget or space of a grand piano.", "A piano technician spends several days calibrating the pre-assembled action stack.", "It has 88 wooden hammers with heads wrapped in felt.", "Pressing a piano key causes the corresponding hammer to strike a particular string.", "The string vibrates, producing a specific musical note.", "A damper stops the string vibration a split second later, ending the sound.", "Each key has two slots called mortises.", "They are lined with a felt bushing to protect the wood from wear.", "At the back of each key, there's a height adjustment rod called a capstan.", "Each key has an embedded lead disc.", "This disc equalizes the pressure that's needed to play an individual key.", "Without this pressure equalization, you would have to press harder on the bass keys because their hammers and strings are heavier.", "The soundboard is already installed in the piano cabinet under a cast iron frame.", "The technician checks the clearance between soundboard components.", "He verifies that each steel string is properly wound to a tuning pin at the top, loops over a hitch pin at the bottom, and passes over a wooden bridge in between.", "After making necessary adjustments, he measures the pressure of each string over the bridge, a critical factor producing fine tone.", "then he tunes below the bridge, adjusting string tension as needed.", "the technician assembles the keyboard by aligning each key with corresponding pins on the key frame.", "He uses round spacers called punchings to equalize height so the black and white keys are level.", "He checks the tightness of each key's bushings.", "If a key needs to be loosened, he compresses the bushing and widens the mortise.", "Then he installs the action stack directly above the keyboard, attaching it to bolts mounted on the cast iron frame.", "He presses each key a few times to make sure it functions properly.", "If it doesn't, he adjusts the capstan to better strike the key.", "Then he connects the pedals to the components they control.", "The right pedal pulls the dampers away from the strings to let the sound continue.", "The left pedal draws the hammers closer to the strings, which reduces the volume of the sound.", "Then several more calibrations-- each hammer to make sure it moves correct, each backcheck so that it doesn't rebound and strike again.", "And finally, each key is checked to ensure that the pressing depth is identical across the keyboard.", "If a key needs adjustment, he adds or removes punchings.", "They come in a range of thicknesses from heavy felt to ultra-thin tissue paper.", "He plays with different combinations until the pressing depth is perfect.", "now he strikes a tuning fork to sound an \"a\" and tunes the corresponding \"a\" key.", "Then he tunes all the other keys in relation to that note, tweaking each tuning pin with a special wrench.", "an assembler completes the piano by mounting the remaining sections of the cabinet.", "This cabinet is made of wood and laminates, coated in high-gloss polyester resin-- an elegant yet simple exterior, enclosing very complex internal workings.", "Flags bring strangers together to support a cause or a nation.", "For many centuries, a flag fluttering above the fighting was a visible communication signal.", "Flags eventually became patriotic symbols away from the battlefield.", "And today there is one for every country and almost every cause.", "Flags bring strangers together to support a cause or a nation.", "Rippling in the breeze, flags have a kinetic energy that draws people to them.", "At this factory, they make flags from special polyester.", "It's extra strong, but it's also translucent to make the design visible from both sides.", "A machine unwinds the fabric over rollers that pull it straight and tight.", "It then enters a digital printer.", "The first printing head lays down the image and a second one deepens it.", "Printing in two steps keeps the dyes from running.", "The employee transfers the printed fabric to the next machine.", "He loops it through guide rollers and secures the end.", "The flag material travels over a larger cylinder that's heated to 419 degrees.", "This bakes or fixates the dye into the fabric.", "At the wash line, a worker aligns the flag with a sheet of leader fabric and trims the end.", "A sewing machine stitches the fabrics together in a chain lock configuration.", "This seam is tough enough to withstand a series of wash cycles.", "The first wash removes any excess dye that wasn't fixated on the fabric.", "They add special chemicals to this wash because ordinary soap isn't strong enough.", "The second bath contains chemicals that neutralize the cleaning substances.", "Finally, the fabric travels through a rinse station to remove the residual chemicals.", "Pressurized rollers wring out the water.", "The damp fabric travels over steamed heated cylinders that dry and iron the fabric.", "The flag material winds around rollers before reaching the cutting table.", "The worker first cuts out the color code printed on the side of the fabric.", "She uses a spectrometer to confirm that the colors are correct and haven't faded during the wash.", "Then she cuts out the flags using a pair of industrial scissors.", "The polyester material is strong and doesn't unravel or fray during the cutting.", "The next worker stitches a sleeve onto the fabric for the banner hardware.", "She also hems the other three sides.", "At another station, a machine installs a grommet on the front and a washer on the back to make an eyelet.", "An employee inserts a fiberglass rod in the sleeve and threads a bungee cord through the eyelet.", "He inspects the fit and confirms that the flag will withstand strong winds.", "From conception to completion, it takes about three days to manufacture flags.", "Then the sky's the limit.", "You can use a wet/dry vacuum both inside and out, to clean up messes that an ordinary cleaner can't handle.", "This powerful picker-upper can suction everything from leaves to small pieces of wood, and if you remove the filter bag from the tank, it can vacuum liquids, too.", "A wet/dry vacuum is lightweight, yet can handle heavy-duty pickups that would ruin an ordinary vacuum cleaner.", "Most of the components are plastic.", "This machine produces them by shooting molten plastic into molds, then cooling it to a solid state.", "A robot extracts the finished parts.", "All the vacuum's parts are injection-molded except for the electric motor.", "The motor has two fans.", "One cools the motor itself with ambient air and the other creates a vacuum to suck debris through the hose.", "The vacuum fan is in a separate chamber so that liquid never comes in contact with the motor's electrical components.", "Workers place the motor in a plastic housing with the drive shaft facing upward.", "They put a spacer on the shaft, then mount the vacuum fan, securing it with a nut.", "They close up the housing with a grid plate.", "This prevents fingers from accidentally touching the fan.", "They now take the head assembly to a testing area.", "They'll run the motor for up to 10 minutes to make sure everything functions correctly.", "Then they plug it into a second test station, which verifies that there's adequate suction and no electrical short circuits.", "If everything checks out, they send the head assembly to the packaging area.", "There, workers assemble the rest of the vacuum.", "At the first station, a press locks the inlet securely in a hole at the front of the tank.", "At the next stop, a worker places a package of screws, an instruction manual, and four casters to be installed by the purchaser in the tank.", "Next, workers take the head assembly and add it to the vac's top cover.", "They load the vacuum's lid onto a carousel along with a pleated paper filter.", "The filter prevents dust and fine debris from getting into the vacuum fan chamber.", "Then they mount the head assembly on an automated screw-driving machine and place the lid on top after first removing the filter.", "Once the lid is screwed to the head assembly, they put the filter back on.", "Now they place the assembled lid onto the tank...", "And snap down the latches to secure it.", "The final stop on the line checks the suction power, the electrical system, and makes sure the on/off switch works correctly.", "If the vacuum passes testing, a robot picks up the unit and places it in a retail box.", "Workers add extension wands, a nozzle, and a hose, then finally a filter bag is added, which is only used when vacuuming up dry debris.", "Consumer wet/dry vacs come in several tank sizes, from 1 to 24 gallons.", "During the medieval era, axes were more than tools.", "They were terrifying weapons that could inflict very deep wounds.", "Today, craftsmen still make battle axes for use in the entertainment industry.", "The medieval battle ax was a brutal weapon.", "With a single blow, it could break through a knight's armor and fatally wound him.", "To produce an authentic replica for movies and tv shows, the blacksmith consults reference books.", "He sketches the ax head design on paper, roughing out the details to the desired scale.", "He cleans up pieces of old carbon steel, which he'll combine with other metals.", "In total, there will be 75 metal strips of varying composition.", "To complete the mix of metals, he cuts an old blade made of nickel steel alloy into equally sized strips.", "He loads 37 strips into a vice.", "He tightens the vice and tack-welds them together.", "He sands the welded stack.", "He rubs oil into the stack to prevent oxidation.", "Now, exposed to intense heat, the metal layers forge together.", "He spreads a mix of borax and other minerals called flux onto the surface.", "This deters oxidation as the forging continues with a pneumatic hammer.", "The hammer slams the layers together to become a solid laminated block.", "It's ready to be transformed into the ax's cutting head.", "Repeated strikes pinch the metal in the center.", "He sprinkles the flux mixture onto the surface of the metal form, heats it again, and folds it into a \"c\" shape.", "After a reheat, he inserts a layer of carbon steel in the center for the blade.", "He hammers the \"c\" shape flat, leaving the pinched section round for the handle.", "The 75 strips have been forged into one.", "Next, the power hammer refines the handle knob.", "He drives a steel stake called a tapered drift into the center of the knob.", "This forms an opening for inserting the wood handle.", "Using the power hammer, he now flattens the blade end of the ax head substantially.", "He flares it to form a cutting edge and removes the excess with a plasma cutter.", "He saws it off, and the result is fierce.", "The ax head has taken shape, but it needs some refining.", "He hammers the handle area to spread it wider.", "And dips the ax head in water to cool it down.", "Then he grinds the blade thinner using a belt sander and rinses off the residue.", "He grinds it again to get rid of any hammer marks or oxidative scale.", "The different metals react when dipped in acid, creating a swirled pattern on the surface of the head.", "The first bath was contaminated, so he polishes it off and gives the ax head another rinse in clean acid.", "After heat treating and tempering, he polishes the face of the ax and hones the edge.", "Next, he grinds spiral grooves into a piece of oak for the ax's handle.", "A colleague stains the entire handle to accentuate the carved spirals and enhance the grain of the wood.", "Once it dries, the blacksmith wedges the ax head onto the handle.", "A few strikes against a steel block improves the fit.", "Finally, he hammers upholstery studs onto the handle to simulate the rivets that reinforced the original medieval ax handles.", "This medieval ax is ready for action.", "Medieval ax replicas are authentic props for any tv show or movie.", "Handled carefully, no one will get hurt." ]

{ "things": [ "Airstream Trailers", "Horseradish", "Industrial Steam Boilers", "Deodorant" ] }

[ "In 1931, airstream founder wally byam sold plans to build your own travel trailer.", "In response to a growing demand, he decided manufacturing was the better way to go.", "He then introduced the airstream trailer, with its familiar modern design that has withstood the test of time.", "The airstream trailer is a recreation vehicle that can take you to the most remote areas, yet still enjoy a fully functional living space.", "They can also be hooked up to outside services, so you can stay as long as you like in the comfort of home.", "To start, an operator puts a sheet of aircraft-grade aluminum into a press that punches the rivet holes.", "A worker then rivets the sheets together to make the walls of the trailer.", "Here they're assembling the end shells, the rounded end sections for the front and back of the trailer.", "They apply sealant to all the seams.", "Technicians then rivet the two ends to the components that make up the trailer shell, including the floor, the walls, and the roof.", "A worker uses a router and a template to cut out window openings from the walls.", "He puts the windows in the openings and secures them in place.", "Another worker applies a weatherproof sealant to all the interior seams, then smoothes it out to ensure good coverage.", "Using a crane, they lower the shell onto the chassis.", "At this point, they thread some of the wiring into the shell.", "Next comes the plywood floor, which a worker attaches firmly to the chassis.", "Another associate puts the door in place.", "He rivets the door to the shell.", "He takes extra care to protect the aluminum from being damaged by the force of the rivet gun.", "The trailer then goes into a rain-test booth that simulates hurricane-strength rain.", "The test lasts about an hour, during which a technician makes sure the shell is watertight.", "Next, they apply a water-based adhesive to the interior and install insulation throughout the shell.", "Now they bring in the interior skin.", "It's the same aircraft-grade aluminum used on the outside.", "They trim the walls for the window openings then lay down the vinyl floor covering.", "An installer trims the vinyl and uses the old-fashioned way to make it snug against the shell because a standard carpet stretcher would poke holes in the vinyl.", "A worker installs the fiberglass shower stall and hooks up the drain and plumbing.", "He cuts a hole in the fiberglass then installs all the shower-control components and the showerhead.", "He finishes off this residential-style shower with a frosted-glass door.", "Next, they put in the convertible couches and beds and all the other amenities of home, including a gas stove.", "Finally, a technician performs quality-control checks to make sure the electrical and mechanical systems work flawlessly.", "Only then is an airstream trailer ready to hit the road and continue the time-honored tradition of discovery and adventure that makes this iconic recreation vehicle an american original.", "Horseradish has a hot history.", "The ancient greeks used it as an aphrodisiac.", "They also rubbed it on sore body parts to alleviate pain.", "During the renaissance, eating horseradish made its way from central europe to england.", "By the late 1600s, it was customary among the british to eat horseradish with beef and oysters.", "At the root of this hot condiment is a root.", "You peel away an outer skin to access a thick white flesh.", "Chewing or grinding the flesh releases enzymes, which produce horseradish's heat-- the plant's natural defense mechanism against predators.", "Horseradish is a leafy, flowering plant with a thick central root, called the mother root, and smaller offshoots called sets.", "After culling the mother root, farmers re-plant the sets, each of which will spawn a new plant.", "At harvest time, the first farm machine chops down the plants to ground level and rakes the leaves out of the way.", "Then a horseradish harvester digs up the roots.", "As the roots bounce onto a mesh conveyer belt, most of the soil breaks off and falls back onto the ground.", "You have to keep horseradish cold to keep it hot.", "So the roots go directly into a cooler.", "The temperature is just above freezing and the humidity high so the roots retain their moisture.", "To grind them fresh from the field would produce horseradish with a grassy flavor, so the roots spend about a month in the cooler.", "Only then are they ready for processing.", "At the horseradish factory, a machine washes the roots in cold water.", "Then a conveyer belt runs the roots through a final rinse.", "Workers carefully inspect the roots.", "They pick out any debris and discard any dark roots that would sully the whiteness of the final product.", "Next, the roots travel to the automated grinding system.", "The conveyer belt has built-in scales that control how much goes into the grinder at a time.", "The grinder works like a giant food processor.", "While grinding, it automatically feeds in a specific amount of vinegar.", "This stops the enzyme reaction, preventing heat from escaping.", "The grinder also automatically adds water and salt brine.", "The salt adds flavor and keeps the horseradish from browning.", "Next, the horseradish moves into a blender.", "This is where the factory adds the extra ingredients for specialty flavors, such as fresh cream for cream-style horseradish.", "A pumping system transfers it from the blender to a holding tank.", "Inside the tank, mixing blades continuously turn to prevent the ingredients from separating.", "En route to the filling station, the inside of every single glass container gets a blast of air to blow out any debris.", "The filling process is entirely automated.", "The machine grabs each container, aligns it under a nozzle, then squirts the horseradish inside.", "The filled containers move on a conveyer to the capping machine.", "There a spinning head descends, screwing a plastic cap to the container.", "Next, the containers move to the labeler.", "It applies glue to the back of the labels, then slaps one on to every container.", "From there, the containers go off to cold storage until shipping time-- shipping via refrigerated truck, of course.", "Prepared horseradish has a seven-month shelf life, thanks to the vinegar and salt, which act as natural preservatives.", "Those critical ingredients maintain the color, flavor, and heat until you're ready to eat.", "Industrial steam boilers heat water to produce steam to do such things as sterilize surgical instruments, cook food, and heat or humidify buildings.", "They are even used for dry cleaning.", "The water inside an industrial steam boiler is heated by natural gas, oil, or electricity.", "Industrial steam boilers are usually found deep inside buildings, where they inconspicuously create valuable steam and heat.", "It starts with a plasma torch that cuts holes in a solid sheet of steel.", "The thickness of the steel used depends on the operating pressure of the boiler.", "Using a hydraulic bending machine, a worker shapes the metal into what will become the inner shell of the boiler.", "This inner shell will contain the water that gets heated inside the boiler to create steam.", "He stops the rolls and prepares an edge of the shell for welding.", "He continues shaping the metal to a preset diameter, and then he grinds the other edge to prepare it for welding.", "The shell shape is now fully formed and ready to be welded closed.", "A submerged arc-welding machine deposits a special granular material that protects the weld from air contamination.", "He removes the protective granular material, leaving behind a perfect weld.", "Next, a worker welds what's called a boiler head to the shell.", "He fits steel pipes into the boiler heads located at both ends.", "He welds the pipe securely in place.", "Workers then insert a combustion chamber into the shell.", "Later, a burner, used to heat the water, will be fitted into the combustion chamber.", "A worker then tests the fully assembled pressure vessel, as it's now called.", "He fills the space between the combustion chamber and the shell with water to ensure it doesn't leak.", "Workers then wrap the pressure vessel in insulation to help the boiler retain heat.", "They wrap an outer jacket around the pressure vessel and secure it in place using sheet-metal screws.", "All boilers then receive a blower, which feeds air into the burner and the combustion chamber.", "Next, a worker attaches what is known as a water column.", "This apparatus supports various control devices and sensors, as well as a visual indicator that shows the water level inside the boiler.", "A worker connects the electrical-control panel, so he can test the safety and operation of the boiler.", "He powers up the unit and fires the burner that is installed inside the combustion chamber.", "He opens a steam-outlet pipe on a test line and makes sure all the control devices, including the water-level indicator and the blower, are working properly.", "This boiler passes the test.", "It generates the correct amount of heat and steam.", "Finally, a worker applies the appropriate labeling on every boiler, whether it's a smaller unit, the type used in a dry-cleaning business, or one of the larger boilers used in a food-processing plant.", "Before bathing became common, people used heavy colognes to mask unwanted odor.", "It wasn't until the late 1800s that chemists created the first commercial deodorant.", "Today deodorants are available in a variety of forms, from natural alternatives, like body crystals, to antiperspirants that use chemicals to reduce perspiration.", "Almost everyone applies deodorant at some point during the day.", "Convenient packaging helps make application easy.", "First step to making deodorant-- mixing up the batch.", "Workers pour a blend of ingredients into a kettle mixer, then add powdered wax-- the main ingredient that holds everything together.", "They also add silicone for a smooth texture.", "Steam heats the mix to 167 degrees fahrenheit, melting the ingredients.", "A standard recipe for deodorants includes wax, active ingredients that prevent perspiration, dimethicone-- a blending agent, silicone, and fragrance to mask odors.", "Deodorants, like all personal-care products, must meet strict quality-control standards.", "The chemists in this plant's laboratory perform a variety of tests to ensure their product meets the highest standards.", "To make sure that the product has the right consistency, this chemist will perform a viscosity test.", "She stirs a sample at a constant speed, then verifies that the force required is within the accepted range.", "These containers will dispense the deodorant.", "They're mechanically unscrambled on a rotating platform that sends them spinning into individual pockets.", "Sensors overhead detect the ones that aren't lining up properly.", "A blast of air sends them back onto the platform to repeat the process.", "Now that they're all right-side-up, they move along to the filling station.", "There, a system of levers raises them up to align with filling nozzles that dispense the mix.", "A system of rotating wheels keeps the containers moving.", "One wheel conveys them to the next for filling, and then a third wheel leads them out.", "It's best to fill using hot mix that flows freely.", "But the deodorant must cool in order to harden.", "An overhead rake evenly lines up the containers inside a refrigerating tunnel.", "Once it's full, workers set the cooling system to 14 degrees celsius.", "The deodorant will remain here for several hours.", "Next, chemists perform a hardness test on a cold sample of deodorant.", "A force meter measures the amount of pressure required to crush the sample.", "It has to be just right.", "Too hard, and the deodorant crumbles without spreading.", "It must be able to flow smoothly out through this perforated dome that will cover the deodorant.", "Each container gets one over at the doming station.", "Again, a system of revolving wheels works together to convey the containers through the station.", "At the center wheel, cappers overhead lay the perforated dome on top of each one.", "The containers then move to the next station, where they each receive a strip of adhesive plastic that covers the dome's surface-- a safety seal that protects the deodorant.", "Back to the doming station.", "The containers pass through once more as the cappers now snap a plastic cover onto each one.", "Now they're ready for the final step-- labeling.", "The containers roll past a plate that lifts off adhesive labels from a continuous strip and applies them.", "A brush smoothes over the labels.", "That's the final touch.", "Now the deodorant is ready for shipping to customers.", "Good things do come in small packages of all kinds." ]

{ "things": [ "Turbochargers", "Enchiladas", "Watches" ] }

[ "A turbocharger harnesses a vehicle's exhaust gases to compress fresh air, forcing the pressurized air into the engine's combustion chamber for a turbocharged performance.", "With it, a small engine can be as powerful as a larger one, using energy that would otherwise disappear out the tailpipe.", "The exhaust gas turbocharger is an invention that dates back over a century, but in recent years the concept has literally been picking up speed.", "Design tweaks and the use of lighter materials mean a bigger boost to engine output so a small engine can be as powerful as a larger one without guzzling extra fuel.", "Production begins at the foundry, an overhead sprayer blows sand into the shaped cavity of this box.", "The spraying action activates a binder applied to the sand.", "This causes a chemical reaction that solidifies the particles.", "The worker extracts the hardened sand shape from the box.", "The shape is called a core.", "It will be used to mold the inside of the turbocharger's housing.", "He files down any little bumps and rough edges.", "He then pipes adhesive around the border of a second sand mold and glues the first part to it to build up the core.", "He applies a putty-like compound to the seam to plug any gaps.", "Meanwhile, another worker uses a different technique to make smaller cores.", "He rocks the box, and this causes sand to flow into a shaped cavity.", "The sand has been mixed with heat-sensitive chemicals.", "He aims a flame at an opening in the box as burners warm it from the sides.", "This triggers a reaction that hardens the sand inside so it takes the shape of the cavity.", "The result is another smaller turbocharger core.", "These snail-shaped sand cones are now ready for casting.", "He places the cores in a mold which is also made of hardened sand.", "Machinery lifts the bottom half of the mold to the top half, essentially closing the mold.", "He pours molten aluminum into it, and it flows into the spaces between the cores and outer mold.", "The aluminum solidifies in a minute, and the molds tumble onto to a conveyor, revealing the cast turbocharger parts.", "They are connected by hardened flow lines.", "After separating the parts, they ship them to the turbocharger factory.", "Here, computerized tools carve and contour the aluminum part to specifications so precise, they are measured in thousandths of an inch.", "This is the turbocharger housing before the work was done...", "And after.", "Using a computerized probe, a technician looks for irregularities.", "Even miniscule ones will need to be fixed.", "It's now time to assemble all the parts.", "The worker inserts a bearing into one end of the iron center housing.", "He lubricates a second bearing and slots it into the other end.", "These bearings will ultimately support a shaft with a turbine on one end and a compressor on the other.", "He adds a metal collar and a third bearing to the assembly.", "He caps the bearing parts with a metal plate.", "It will keep lubricant from spilling out when the turbocharger spins.", "He flips the center housing around and installs a metal heat shield on the bottom.", "He inserts the shaft and turbine wheel assembly.", "He installs the compressor wheel on the other end of the shaft.", "He heats the wheel briefly, causing it to expand, which allows it to be pushed further down the shaft.", "Once cold, it shrinks to the shaft for a tight fit.", "Next, a machine called a vibration sort rig spins the compressor at a high speed as a computer analyzes it for vibrations.", "Even the slightest tremor indicates an imbalance.", "The computer also detects the source of the problem so it can be fixed.", "He grinds the compressor nose ever so slightly to balance the part.", "He now nestles the compressor into the curled aluminum housing.", "It's a shape that's designed to funnel air into the engine.", "He secures the compressor to the housing with a metal ring.", "He fits the turbine end into its housing.", "It, too, has the distinctive curl to pipe the exhaust gases in the right direction.", "A blast of air now simulates the effect of those exhaust gases, spinning the turbine to power the compressor.", "It takes about 15 minutes to build one of these turbos.", "Once installed in an engine, it's full speed ahead.", "\"enchilada\" means dipped in chili in spanish.", "And true to its name, these stuffed corn tortillas are typically smothered in sweet and mildly spicy chili sauce.", "First cooked up by native mexicans centuries ago, enchiladas are an ancient food, but they are definitely not passé.", "In modern times, the enchilada has become a metaphor for having it all.", "\"the whole enchilada\" means there's no holding back.", "There are numerous enchilada recipes today.", "This black bean and veggie version starts with a filling sauce.", "It's a chili-flavored tomato puree.", "They add organic corn, a firm variety that's mildly sweet.", "That means the flavor won't clash with the chili spice.", "Spiraling blades fold the corn into the filling sauce.", "The mixing action is gentle to keep the kernels intact.", "The next ingredient is tofu, diced into cubes.", "Like the corn, it's a firm type for a more substantial texture.", "The firm tofu is also quite porous, so it readily absorbs the flavors of the enchilada filling sauce.", "They green up the sauce with chunks of organic zucchini, uniformly diced with the skins on.", "Black beans are next, already cooked with the juices drained.", "This completes the enchilada filling sauce.", "They cool it to preserve its thick consistency and overall freshness.", "And now they are ready to wrap.", "They pump measured amounts of the black bean and vegetable mixture onto each tortilla.", "And here the chilling of the filling pays off.", "A warmer, runnier sauce would spill out and make a mess, but this cool, thick sauce stays where they put it, in the middle of the tortilla.", "Workers now roll the tortillas around the black bean and veggie mix.", "There is a trick to this.", "If the tortilla is rolled too tightly, there could be leakage.", "Too loose, and the enchiladas could come undone.", "A perfectly rolled enchilada fits neatly into the trays.", "They place the enchiladas seam-side down in the container.", "Elsewhere in the factory, they sauté various chili powders in flour and oil.", "They liquefy this flavorful mix with vegetable broth.", "Mixing blades blend the simmering ingredients, and the flavors intensify.", "It thickens to a gravy-like consistency.", "And as one would do with gravy, they strain out any lumps or impurities.", "What exits the sieve is pure enchilada chili sauce.", "Next, it flows into a dispenser.", "The nozzle head is the exact same length as the enchiladas, ensuring complete coverage as the sauce is pumped onto them.", "The enchiladas are now swimming in chili sauce, imbuing the dish with mild spice.", "The chili sauce also serves to keep the tortillas moist during cooking.", "They sprinkle on freeze-dried chives.", "This herb adds an onion-y nuance to the dish.", "Every few minutes, they pull a tray off the production line and weigh it to confirm that the portion size is right.", "They churn out 53 enchilada entrees a minute at this factory.", "Next, it's into the freezer to preserve the enchiladas at arctic-like temperatures.", "It's a new day and a new shift of workers.", "They place the enchiladas on a conveyor en route to the packaging line.", "It takes just one minute to wrap and box 75 frozen enchilada entrees.", "Technology and humans team up to get the job done fast.", "Enchiladas have come a long way over the centuries-- from a simple meal first whipped up by the mayans of mexico to a mass-produced frozen meal.", "Today, they are consumed in countries around the world.", "And with these frozen versions, mealtime is no trouble at all.", "Just heat and eat.", "The mechanism inside a wristwatch that measures time and moves the hands accordingly is called the movement.", "High-end watches typically use traditional, very intricate mechanical movements.", "Such premium watches are made up of a multitude of components, requiring hundreds of manufacturing and assembly operations.", "Luxury wristwatches are made of top-quality materials, often precious metals.", "They are crafted with painstaking precision, partly by traditional watchmakers, partly by high-tech machines.", "The main section of the watch case starts out as a block of metal-- stainless steel for this model.", "A press stamps the preliminary shape, which a computer-guided milling machine then finalizes.", "Another computer-guided machine drills a hole on the side for the stem and crown, the manual watch-winding mechanism.", "This tool refines the edges.", "Next, using an abrasive tool, they manually etch the surface to give it a brushed metal finish.", "Then they apply some polishing compound to a felt buffing wheel and polish the entire surface.", "Certain models undergo a second polishing performed by a robot.", "The two other parts of the watch case, the back and the ring around the watch face, called the bezel, are made the same way as this main section.", "To produce the movement, they cut a square brass plate and stamp it into a preliminary shape.", "This computer-guided mill then refines it to the correct thickness.", "The next computer-guided machine makes several slots and holes.", "This part, called the main plate, is the base upon which all the movement's components will be assembled.", "The milling process leaves behind traces of metal dust and oil on the surface, so the main plate undergoes a thorough washing with water and solvent.", "Once dry, a computerized inspection device examines the plate from three dimensions, verifying that every last detail is precisely as it should be.", "Then the last machine cuts the final circular shape.", "The main plate is now technically perfect.", "Only finishing steps remain.", "First, to remove tool marks, they sand-blast the surface to give it an even matte finish.", "Here's what the plate looks like before sand-blasting and after.", "Another computer-guided tool etches tiny circles onto the main plate surface to produce a pearl-like effect.", "This next component, called the bridge, covers most of the parts assembled onto the main plate, and itself holds a number of parts.", "After a laser engraves the company name, they fill the lettering with varnish.", "They put the bridge into an automated machine that etches a brush finish and wipes off the varnish.", "Some varnish residue remains inside the letters, making them more visible.", "Next, a robot sets a jewel into each hole in the main plate.", "Jewels are tiny, cup-shaped synthetic rubies.", "Each jewel will hold one of the movement's moving parts in a drop of lubricating oil.", "After installing two barrels containing a spring each, the watchmaker positions four wheels.", "These form the gear train that moves the hands of the watch.", "Next, he mounts the auxiliary main plate on top.", "This sandwiches the barrels and gear train, holding them in place.", "Then the escapement, the regulating mechanism.", "Winding the watch fully coils the springs inside the barrels.", "The escapement paces the springs as they slowly unwind and turn the gear train.", "Now a robot takes over, squirting a drop of oil in each jewel.", "Meanwhile, a laser engraves the watch brand name and logo into the oscillating weight.", "This component is a heavy metal disk first stamped in a press, then refined by high-precision computer-guided tools.", "The oscillating weight is an automatic winding mechanism.", "This weight, located on the back side of the movement, automatically winds the watch as it's on your wrist.", "Therefore, the more often you wear the watch, the less often you have to wind it manually by turning the crown.", "The watchmaker connects the oscillating weight to the springs which move the gear train so that the weight will shift backwards and forwards with any wrist movement, automatically coiling the springs.", "On the front side of the movement, he screws in the date indicator and the dial.", "The dial is comprised of two brass plates, the top one coated in oxidized copper with cutouts to show the bottom one, which is painted with this company's secret formula of glow-in-the-dark pigments.", "Next, a machine mounts the brass hour and minute hands.", "This operation is automated because applying even slightly too much pressure could damage the tiny, delicate hands.", "Now for the watch case.", "After twisting an arched ring called the bezel onto the front of the main case, he slides a plastic gasket into it...", "Then positions the main case onto to a press...", "Cleans the crystal...", "Then presses it forcefully into the bezel.", "The gasket seals the minute gap between the crystal and the bezel so that water can't seep inside the case.", "Next, the stem and crown.", "Then on the back of the case, the casing circle, a ring that comes between the movement and the case.", "Here, too, a gasket seals the gap to make the case water-resistant.", "He installs the ring in crystal that form the back of the case.", "He applies grease so that it twists on smoothly.", "He closes it tightly with a tool.", "Then the fully assembled case goes off to be tested for water-resistance.", "If it passes, it comes back to the watchmaker to receive the movement.", "He removes the crown and the case back, cleans the movement, then places it in the case.", "Next, he squirts grease in the crown hole and reinstalls the crown.", "This time, because the movement is in place, the crown stem connects to the two springs so that turning the crown now winds them.", "The watchmaker affixes the movement in the case with several tiny clamps and screws.", "Then he closes up the back for the last time.", "After checking that the movement works properly, he has just one last component to assemble to the watch head.", "This particular watch company has developed a unique protective device that goes over the crown.", "A computer-guided mill shapes it out of the same type of metal as the case so that, aesthetically, it blends seamlessly.", "The watchmaker screws the device to the case so that it bridges the crown.", "The device has a lever, the tension of which the watchmaker carefully adjusts with the help of this gauge.", "The lever closes the device tightly over the crown, immobilizing the crown so that it can't be turned accidentally.", "Finally, they mount the watch head on an automated machine which closes the back tightly.", "This is critical for water-resistance.", "Every single watch head this factory manufactures must pass several quality-control tests to ensure time-keeping accuracy and water-resistance.", "For water-resistance, they first test using air pressure.", "Then actual water tests.", "First a low-pressure test in 4 inches of water.", "Then a high-pressure test in 410 yards of water, which far exceeds the 328-yard depth to which the watch is guaranteed to be water-resistant.", "Finally it's time to assemble and attach the watch strap, either a link bracelet in matching metal or a strap made of fine leather, a fitting finale to this luxury wristwatch, the elegant product of precision technology and time-honored tradition." ]

{ "things": [ "Pipes", "Rock Climbing Gear", "Leather Bike Saddles", "Luxury Sports Cars" ] }

[ "When christopher columbus discovered the americas, he also discovered the tobacco pipe.", "The pipe was an important part of native culture to be shared during times of negotiation and celebration.", "Columbus and other explorers brought the concept home, and the rest is history.", "Since the 19th century, pipes have been made from briar, a hard, fire-resistant wood from the root of a mediterranean heather shrub.", "After the briar has cured for several months, the pipe-maker saws it into a rough pipe shape.", "Using a lathe and chisel, he rounds the larger block to approximate the shape of the pipe bowl.", "He bores through the center to carve out the tobacco chamber.", "Then he slims down the stem, marking the center for drilling later.", "The pipe-maker finalizes the shape by hand.", "He now sands both the inside of the tobacco chamber...", "And the outside of the pipe bowl.", "Next, the pipe's mouthpiece takes shape.", "The pipe-maker pierces a piece of hardened rubber called vulcanite to establish the center and then drills a channel through it.", "Using a grindstone, he sculpts one end, taking it from round to oval, a shape that fits more comfortably between the lips.", "He checks his work with a sizing template...", "Then shaves the exterior of the mouthpiece, reducing it considerably.", "He shapes the other end to form the tenon, which fits into the pipe stem.", "He polishes the tenon with a special compound.", "The smoother surface makes this part easier to join to the pipe stem.", "Using a series of sanding disks with progressively finer grit, he gives the exterior of the mouthpiece a sleek finish.", "Then he steadies it in a clamp and widens the hole in the center of the mouthpiece to broaden it into a funnel-shaped cavity.", "Attention now turns to the seam between the rubber and wood parts.", "He sands it to make them perfectly flush.", "Hand-filing removes blemishes and adjusts the thickness for a more comfortable bite.", "The thickness can be customized for individual preferences.", "He drills a tiny hole into the top of the mouthpiece...", "Then dips a thin plastic rod in glue and inserts it in the hole.", "He sands it down, leaving a white spot, a marker that indicates the mouthpiece is right-side-up.", "For bent or curved pipes, the mouthpieces are heated in an oven at 320 degrees fahrenheit.", "This makes the vulcanite flexible enough to be shaped by hand.", "The pipe-maker bends the mouthpiece to the desired shape, and a quick cool-down in water re-hardens the vulcanite, fixing its curve.", "Next, he buffs the wooden part of the pipe.", "This removes fine scratches and brings out the wood grain.", "It also gives the wood a glossy finish.", "But for a different finish, a craftsman sand-blasts the briar wood, giving it a ripple texture.", "He stains it darker with an alcohol-based dye, working the stain into every crevice.", "And now for a neat trick.", "He sets it on fire, and the alcohol burns off to set the stain.", "The pipe doesn't go up in flames, proving it's truly fire-resistant.", "He burns up to 10 layers of stain into the pipe, depending on the effect he's trying to achieve.", "Finally, he stamps the company name and other information into the pipe.", "After a final quality inspection, this handcrafted briar pipe is on its way to making a statement at the country club.", "Rock-climbing is no pastime for the faint-hearted.", "Scaling natural rock formations or manmade rock walls requires a certain fearlessness, along with good physical conditioning, balance, agility, and you must be well-trained in climbing techniques and use specialized equipment.", "Climbers usually work in pairs, using a system of ropes and other devices to catch them if they fall.", "A key piece of gear is the spring-loaded camming device.", "The climber pulls the trigger to contract the cams and position it in a crack then releases the trigger to expand the cams, which securely grip the rock on either side, then attaches a rope through a device called a carabiner.", "Climbers typically carry several types and sizes of cams, carabiners, and other devices.", "The equipment must be as lightweight as possible, yet, at the same time, strong enough to save a falling climber.", "Which is why this manufacturer uses aircraft-grade aluminum.", "To make carabiners, automated saws cut aluminum bars into pieces the required length.", "Then a bending machine forces each piece around a form in the basic shape of the carabiner.", "Carabiners come in various sizes and shapes.", "Workers simply mount the appropriate form on the machine.", "Next, they place the roughly formed carabiner onto a hot die.", "Another die slams down on it with up to 800 tons of force, forging the final shape.", "Then the most critical part of the manufacturing process-- a multi-phase heat treatment to harden and strengthen the aluminum.", "Next, they use a clipping press to slice off excess metal along the perimeter.", "This leaves rough edges, which they now smooth out using an abrasion process.", "The carabiners go into a vibrating tub, where they rub against porcelain chips for the next 20 hours.", "Next, workers drill holes for the rivets on which the spring-loaded opening mechanism will hinge.", "That mechanism, called the gate, has channels which align with these holes.", "Assemblers slide a spring and spring-pusher into the gate, then insert the rivets through the aligned holes and channels.", "A riveting machine locks each rivet in place by rounding and widening the head.", "Then they adjust the carabiner's frame until the alignment is perfect.", "After a thorough inspection, a laser etching machine inscribes product information and a unique serial number.", "Random samples undergo strength and other quality-control tests.", "Elsewhere in the factory, camming device production is under way.", "Computer-guided equipment machines the same aluminum alloy to a preliminary shape, saws off slices, then machines each slice to the final shape of a cam.", "An assembler attaches a wire to each cam...", "Then takes four cams and joins their wires to the trigger wires with a metal crimp.", "The cams, by this point, are different colors.", "That's because they've undergone chemical treatment to make them corrosion-resistant.", "This process can, in fact, produce various colors.", "So, at the same time, the company can color-code the different models.", "As assembly continues, they thread the cams onto an axle-like component called the spindle, positioning a spring in between each cam.", "The springs provide the resistance required to expand and retract the device.", "A cone-shaped washer on each end of the spindle holds everything together.", "This time, the riveting machine locks in the components by flattening and widening the end of the spindle to fill the hole in the washer.", "With that, the camming device is finished.", "This is how camming devices, carabiners, and other climbing gear all work together to catch climbers who lose their foothold.", "Not only do they keep the climber safe, they also protect nature, because they attach to the rock face without damaging it in any way.", "Leather bike saddles feature a leather top suspended on a metal frame.", "With time and use, the leather molds itself to perfectly suit the rider's anatomy and their cycling style.", "And just like a pair of leather shoes, the saddle becomes very comfortable.", "Leather bike saddles look almost the same as they did 100 years ago.", "They are still made by hand and by some machinery that is sometimes over 60 years old.", "Saddles are made exclusively of metal and leather, traditional materials that retain the style and quality of the early days.", "The first step is making the steel wire springs for saddles that have a suspension.", "The machine coils and cuts the wire to the proper length.", "Liquid lubricant keeps everything running smoothly.", "Depending on the saddle's model, some springs are then chromed.", "This machine folds and curls steel or titanium wire to form brackets.", "It's adjustable, so it can make brackets of different sizes and shapes, depending on the model being produced.", "A technician assembles the springs and brackets to form the saddle's frame.", "He attaches the clamp so that the saddle can be attached to the bicycle's seat post.", "Saddles come in different sizes and shapes, with or without suspension springs to accommodate various riding styles-- racing, mountain biking, or city commuting.", "Now for the saddle's leather top.", "Using a hydraulic clicking press, the worker cuts the leather with a sharp blade.", "The blade cuts ventilation holes at the same time.", "Tanneries provide leather in any color required by the factory.", "After the tops are cut, they soak in tepid water for 20 minutes to an hour, until the leather is completely saturated.", "The wet leather top then goes to a press, which applies 2,000 pounds of pressure per square inch.", "Using a leather cushion, the technician pads the leather piece to help reinforce the shape, especially in the narrow front end.", "Because the top is wet, it retains the shape and does not bounce back.", "They carefully sand the leather to get a smooth edge.", "The tops now go into the oven for three hours at a maximum temperature of 130 degrees fahrenheit.", "Now they're ready for the finishing process.", "A worker rivets a name plate to the rear of the saddle...", "Then stamps a trademark on each side.", "Each saddle model has its own trademark.", "They attach the nose to the front of the saddle using solid copper rivets.", "They hammer each one down carefully to follow the contours of the leather without scratching it.", "This machine now rivets the frame to the back of the saddle.", "They insert a tension pin between the frame and the nose.", "This pin will allow the rider to adjust his saddle if the leather starts sagging after a few years.", "It takes about three days to make a leather bike saddle.", "And with careful care, it can be used for years to come.", "Luxury sports cars are coveted by people around the world, and with good reason.", "The extraordinary skills and materials that go into making them were developed from a long racing heritage.", "Each one of these automobiles is born from expert craftsmanship and a passion for racing.", "Underneath the beautiful exterior of these cars lie a chassis and power train capable of delivering remarkable performance.", "The aluminum frame is engineered to be lightweight, yet rigid, and provide crumple zones that can evenly distribute force in the event of an impact.", "It takes highly skilled technicians to perform these complex welds.", "On the factory floor, robots transport the body panels that will later be fitted onto the chassis.", "Once the frame is completed, technicians use a pneumatic hoist to position and attach exterior panels and doors.", "Door panel cutouts reduce the car's weight while retaining a high degree of structural integrity.", "The elongated cutouts on this model will house its stylized headlights.", "Next, they coat the car in a compound which fluoresces under a special lighting system.", "This helps technicians detect any minute imperfections.", "These imperfections are then filed down by hand.", "Here, a robot fully immerses and rotates the chassis in a galvanizing solution that prevents corrosion.", "Once the body has been primed, it passes through a device that dusts off the entire body with ostrich-feather brushes.", "Next stop, the paint room, where robots spray the car body with a smooth, even coat of paint.", "Once the paint dries and cures, the robots apply several coats of varnish.", "The final step in body prep is a meticulous waxing by hand to remove any remaining blemishes.", "Moving on to the chassis, a technician uses a hoist to position and fasten the engine and gearbox in place.", "Here, robots transport the completed power train to the assembly area...", "Where an automatic crane gently lowers the car body onto the chassis, which includes the fully assembled suspension, gearbox, and engine.", "This step is known as the marriage.", "Next, a worker installs the wheels with some help from a hydraulic lifting system.", "At the next station, technicians test all the dashboard components.", "This vehicle features a combination of analog and digital displays.", "A master computer runs the electronics and information systems.", "Again with the help of the crane, technicians install the finished dashboard.", "The next step is the steering wheel.", "Assisted by a special assembly jig, a technician positions and tightens it onto the steering column.", "Workers lower the trunk cover and convertible hardtop into position, which is particular to this model of car.", "A worker double-checks the installation of the hydraulic mechanism.", "This beautiful road machine is the culmination of years of racing history, modern engineering, and dedicated craftsmanship.", "Now watch this.", "This is one of the few cars that features a fully automated convertible hardtop.", "This beauty is now ready for the sun, wind, and the open road." ]

{ "things": [ "Racing Shells", "Stainless Steel Sinks", "Leather", "Pedal Steel Guitar" ] }

[ "Today on \"how it's made\"...", "Racing shells...", "Stainless-steel sinks...", "Leather...", "And pedal steel guitars.", "The racing shell is a high-tech rowboat that's built for speed.", "Long and exceptionally narrow, it's designed to cut through wave drag and leave the competition in its wake.", "Racing shells are made for single rowers, called scullers, for pairs, or entire crews.", "They're custom-made to precise specifications.", "Racers need to travel light to maintain speed, so these boats are made from reinforced carbon fiber, which weighs a lot less than wood.", "First, several of these carbon-fiber sheets are layered in a mold and trimmed along the edge.", "Textured thermoplastic called honeycomb gets a spray of glue and is then pressed onto the carbon-fiber plies.", "Sandwiched between layers of carbon fiber, the honeycomb will serve as the shell's core, lending some lightweight reinforcement to the delicate hull.", "Next, the entire boat is wrapped in breather cloth and a plastic bag so that the air can be vacuumed from between the layers.", "The breather cloth is a permeable layer that prevents the plastic from sticking to the mold and creating air pockets.", "Next, the shell goes into a long oven, which melts the glue that's been impregnated in the carbon material, fusing the layers together.", "The shell bakes at 210 degrees for 8 hours.", "Then the plastic and breather cloth are pulled away.", "And the boat is pried out of the mold using plastic wedges.", "The hull comes out in one solid piece, and a primer paint sprayed into the mold earlier has adhered to the shell's surface.", "Workers check the weight, which has to be exactly what the customer ordered.", "Next, they reinforce the boat's cockpit with several carbon-fiber bulkheads.", "Foam is glued on the inside rim of the racing shell, using a piece of wood as a guide.", "Glue is applied around the bulkheads.", "Then the cockpit panel is lowered so that it adheres to the glued areas and rests on top of the foam that's been installed along the edges.", "Next, a computerized tool drills holes for the hardware and riggers and workers trim the rim from stern to bow.", "They smooth the holes' finish with a grinding tool.", "And now it's over to the paint station for some sanding and priming.", "Any flaws are marked for repair because the slightest imperfection could affect the boat's ability to speed through the water.", "Once the boat is perfectly smooth, it gets a high-gloss urethane coating.", "Next, a fin is installed for a little stability.", "A laser guide helps align it into perfect position.", "A rudder goes into the bottom of the boat.", "The system of ropes that's attached next will allow the rowers to steer.", "This boat comes with special shoes and sliding seats that allow rowers to put a lot of leg power into their strokes.", "Finally, the rigging equipment for the oars goes in.", "Now this sleek racing shell is ready to hit the water.", "When we return, turning stainless steel into a sparkling new sink.", "The stainless-steel sink is an invention born of patriotism.", "It evolved during world war ii when sinks were often made from copper-nickel material called monel.", "When that material was needed for the war effort, stainless steel was drafted for use on the home front, and it's still on kitchen duty to this day.", "Stainless steel is lightweight and heavy-duty, which makes it great for sinks.", "The process begins with a large sheet of stainless steel, uncoiled and sliced into pieces called blanks.", "Each blank goes under a 1,000-ton press.", "As the press descends, a punch rises from below, stretching the steel into a rough sink shape.", "This process also transforms the steel on a molecular level, hardening it.", "Workers brush lubricant in and around the sink bowl to make it easier to stretch it again.", "The bowl goes under the same punch press a second time for more precise shaping.", "This second working of the steel hardens it even more.", "Now the sink goes under a different punch device that cuts out a drain hole and forms a lip around it.", "As coolant flushes the sink, an abrasive belt grinds the surface to give it a brushed look.", "Next, a sink bowl slides into a welding machine.", "A second sink bowl is lined up against the first one.", "Inside, an electrode welds the two sinks together.", "Using enormous force, a roller moves across the seam to flatten it.", "A grinding belt behind the roller sands it down.", "Now that the seam joining the two sinks is level and smooth...", "It's time to give the sink's rim some shape.", "This die forms recesses along the sink's perimeter.", "These recesses give the sink a sleek look and collect water runoff.", "Another press trims the rim and gives it a bevel finish, which softens those rough edges.", "Now, using a punch cutter, workers pierce the back rim of the sink to make holes for faucets and a soap dispenser.", "Then they grind and buff the sink to a fine finish.", "It's a very intensive process that takes about 25 minutes.", "The company's trademark is embossed on the sink.", "Then the sink's drains are plugged and a substance similar to latex paint is sprayed onto the outside.", "The finish will muffle the sound of clattering dishes and protect the outside of the sink from condensation.", "It takes about 2 1/2 hours to make a stainless-steel sink-- a functional and stylish addition to any kitchen.", "Coming up, turning hairy cowhides into buttery-smooth leather.", "Leather production dates back to primitive times when humans rubbed fats into animal skins to preserve them.", "Times have changed, but leather endures.", "From footwear to furniture, this tough material remains an integral part of our lives.", "This leather comes from the hides of cows killed for meat.", "Without tanning, these cowhides would go to waste.", "Converting them to leather is a kind of recycling.", "The first step is to cut each hide in half.", "The hides are draped over a sawhorse, stamped with an identification code...", "And sliced down the center.", "Two smaller pieces will be easier to handle and process than one large hide.", "Hundreds of these hide halves are loaded into a modified cement mixer for some serious hair removal.", "As the mixer fills with water, a worker dumps in a combination of sodium sulfydrate and lime.", "A chemical reaction strips the hair from the hides.", "The hairless hides now get an acid bath to prepare them for the tanning process.", "The tanning itself happens inside big wooden drums with prongs to keep the skins from getting tangled.", "Chrome salts turn the hides a robin's-egg blue as they bind to the collagen fibers of the skins.", "The hides have now been preserved into leather.", "Next, the pieces are fed grain-side up into a machine that slices the leather to an even thickness.", "The cutoffs won't be wasted.", "They'll be recycled into suede.", "Workers check each piece of leather with a gauge to confirm that the thickness is uniform.", "Now it's back into the wooden drums for a second tanning, this time using a solution of vegetable extract, tree bark, and water.", "Dye is added along with a chemical that will make the leather water-resistant.", "The solution binds to the leather, giving it a brownish tone.", "It's a gentler process than the first tanning, and it softens the leather.", "Now a mixture of starch and water is brushed onto the tanned hides.", "This paste-like solution allows the hides to be pressed onto big glass frames, which also have been moistened with the same starchy mixture.", "This process allows the leather to dry flat...", "Prevents it from shrinking...", "And stops the edges from curling up.", "After four hours in a dryer, it's time to remove the leather.", "It easily peels away from the glass.", "A revolving paint-gun system dyes the leather.", "And now it's time for the finishing touches.", "A glazing jack pulls a glass cylinder over the leather, and the abrasive action polishes it.", "This glass is very strong, so it can do this vigorous work without shattering.", "Finally, huge heated rollers smooth out any wrinkles.", "It's the end of the production line for this big pile of leather but just the beginning for so many other products.", "Fashionable and tough, it's no wonder this ancient material continues to be one of our favorite products today.", "Up next, an instrument that's almost as tricky to build as it is to play.", "Playing the pedal steel guitar takes quite a lot of skill.", "You slide a steel bar up and down the strings as you pluck them, all the while operating a system of pedals and knee levers below.", "This means using both hands, both feet, and both knees.", "But a pedal steel guitar's unique sound and impressive range are worth all the effort.", "to make one, a guitar maker first carves the neck of the instrument from hardwood.", "He beads glue around the edges of the neck and applies strips of intricate wooden inlay.", "Once the fretboard design is silk-screened onto the top, the guitar neck is complete.", "The guitar maker then outlines a design onto aircraft-grade aluminum and cuts it out to make an end plate for the guitar frame.", "He pops the end plate out of the holding device.", "Then he welds it to the rest of the framework and polishes everything to a mirror finish.", "Next, the part of the guitar called the steps is machined.", "The holes in the steps will be used to attach tuning pegs.", "There's one for every string.", "The steps are attached to the neck just above the fretboard.", "This is the pickup plate.", "It will hold the device that transfers sound to the amplifier as well as a series of metal fingers.", "The fingers are made from several aluminum pieces that are machined and assembled together.", "The fingers pivot to raise and lower the pitch of the strings.", "All of the fingers are fitted into the pickup plate and secured with screws.", "The guitar maker double-checks the fingers' movement, then he hooks springs to the end of each one to maintain the proper tension.", "A little grease ensures that this next step goes smoothly-- the production of the guitar's cross-shafts.", "Then it's on to the guitar's undercarriage and the system of foot pedals and knee levers that will move the fingers.", "The guitar maker screws several cross-shafts, one for each pedal, into the undercarriage.", "He attaches bell cranks to the cross-shafts...", "Then connects thin steel rods from the fingers to the bell cranks.", "This system will allow the performer to tighten or relax strings while playing, which gives the instrument its characteristic sound.", "The guitar maker tests the knee lever.", "Here he's winding copper-coated wire around a cartridge thousands of times to make the guitar's pickup, which transfers sound from the guitar to the amplifier.", "He takes two of the wire-bound cartridges and places a magnet between them to complete the pickup.", "Then he fits it into the other slot in the pickup plate just above the fingers.", "Now, using a gauge and a level, he adjusts the pickup.", "It has to sit low enough in the slot that it won't interfere with the strings.", "There's no room for error here.", "The positioning must be exact or the guitar won't sound right.", "10 to 12 strings are attached to the guitar neck.", "Some instruments have two necks to add even more dimension to the sound." ]

{ "things": [ "Western Revolver Replicas", "Arc Trainers", "Used" ] }

[ "In the american wild west, the gun ruled, and that gun was usually a six-shooter revolver.", "Today, replicas of those revolvers can take you back to dodge city, and they do at cowboy shooting competitions.", "It's a chance to engage in a little old-fashion gunslinging for old time's sake.", "With its six-shot cylinder and innovative cocking mechanism, the 1873 colt was carried by the likes of jesse james.", "They start these automatic replicas by shaping and machining the gun's frame.", "A computerized blade carves the cylinder.", "It cuts slots for the ammunition and notches for rotating the cylinder after a shot is fired.", "A technician files down rough edges so the parts will fit together perfectly.", "He then screws the curved grip and the trigger guard to the frame.", "He assembles the wooden grip casing to the metal back strap and attaches them to the grip.", "Once he confirms it's a good fit, he removes the casing the writes the gun's serial number inside.", "He stamps a matching number onto the grip and polishes it and the gun's frame to a glossy finish.", "He now rolls the model number and other identifying information onto the gun's barrel.", "To add a bit of flourish, an artist engraves designs copying the artwork on an original colt.", "Another worker now dips the parts in hot salts, then in cold water.", "A reaction occurs that both hardens the parts a bit and tints them.", "In this case, they turn a bronze color.", "This is called color case hardening.", "The grip and trigger guard have been removed from the gun frame for color casing.", "This makes it easier for the technician to install the cartridge loading gate on the frame.", "He files down the mechanism for rotating the cylinder to make the dimensions perfect.", "He then inserts a bushing and a pin in the cylinder's center.", "He uses that pin to install the cylinder in the gun frame.", "The pin will also serve as the axis for the cylinder to revolve on.", "He slides a couple of test slugs into the chambers to confirm the gap between the cylinder and gun frame is spot on.", "He then fits the gun barrel to the frame.", "And, using a special measuring rod, he checks the alignment of the cylinder and barrel.", "He tightens the barrel to the gun frame, using a stick as a lever.", "The technician aims the assembled gun and eyeballs the alignment of the barrel to the frame.", "Once he's certain the configuration is right on target, he installs the gun's hammer and trigger.", "He pops the cylinder back into the gun frame and inserts the rod for ejecting spent ammunition.", "He screws a spring into the side of the hammer and cocks it in its three different positions to verify that it's in working order.", "He then reattaches the grip and trigger guard.", "He assembles a flat spring to the curved grip.", "This is the main spring.", "It transfers energy from the trigger to the hammer to cause the revolver to fire.", "Then it's over to a government testing facility called the proof house.", "Behind bulletproof glass, special equipment fires ammunition at three times the usual operating pressure.", "If the gun can handle this, it's deemed safe to operate.", "After a few more parts have been color cased, this revolver replica is ready for its target market.", "And that would be history buffs who are interested in a real blast from the past.", "Arc trainers can give you a full-body workout.", "They provide a number of exercise programs to choose from, like strength training, weight loss, and cardio.", "They monitor such things as heart rate and calories burned.", "Like any piece of exercise equipment, using one properly is the key to a safe and healthy workout.", "Arc trainers are made to give you a wide range of incline and resistance levels to let you train as easy or as hard as you like.", "To start, a tube laser machine-cuts and profiles the steel tubing that will make the arc trainer's side frame.", "A worker cleans the steel tubes, then runs them through a computer-controlled roll-forming machine.", "This machine shapes all the steel used to build the arc trainer's frame.", "They use a robot to weld all the parts together because robotic welding is more consistent and accurate than hand-welding.", "The completed frames then get a surface preparation, giving the steel a uniform finish that is now ready for powder painting.", "Workers then paint the frames using an electrostatic paint process.", "These guns spray electrically charged paint particles that are drawn to the grounded frames in a smooth and even coat.", "The frames then bake in an oven for 40 minutes to cure the paint.", "Next come the handlebars.", "A worker then makes them by lubricating a rubber tube and sliding it onto an assembly frame.", "He then locks a preformed metal tube in place and lubricates it, as well.", "He turns a handwheel, which brings the two tubes together, forming the handgrip.", "He completes the assembly by screwing on an end cap.", "Meanwhile, a worker assembles the control panel by putting on the overlays for the user interface.", "She then hooks up the printed circuit board that controls the unit.", "She closes the housing but leaves the connectors exposed for connection to the mainframe later.", "A worker then attaches a steel support fixture onto the frame.", "Next comes this drive-wheel assembly, which he bolts onto the support fixture.", "He puts a drive belt around a pulley that provides various resistance levels for the user and rolls the belt onto the drive wheel.", "He then uses a pneumatic tool to tighten down the pulley, which stretches the drive belt and sets it to the appropriate tension.", "Next, he attaches the computer board that controls the various fitness programs.", "A worker then installs the leg bars onto the arc trainer's frame and attaches a foot pedal onto each leg bar.", "He installs linkage bars onto the drive-wheel assembly.", "Then he aligns the drive wheel and puts on the molded front housing...", "Followed by the protective side covers.", "He connects a linkage bar that extends from each leg bar to the drive wheel, then connects one linkage bar to each arm handle.", "He makes sure all the linkage bars are working properly.", "Finally, he tests the free-floating foot pedals and the dual-action arms, as well as all the other functions and features.", "These arc trainers are high-tech exercise machines.", "Some models even come with a tv.", "Used-oil furnaces generate heat by burning used oil without having to refine it.", "These furnaces are found in automobile shops, maintenance facilities, and construction sites.", "Transport fleets and trucking companies also use them to turn the used oil they produce into heat for their facilities.", "It takes a special furnace to burn used oil.", "Used oil is thick and dirty compared to residential fuel oil and must be turned into a fine mist to burn properly.", "It all starts with a computer-controlled laser making what's called the front and rear flue plates out of steel.", "The plates for this hot-air furnace are made of stainless or hot-rolled steel depending on the size of the unit.", "A worker then makes what's known as the heat exchanger by joining the flue plates together with steel tubes called flue tubes.", "This device is called a swagger machine.", "It expands just the ends of the flue tubes, binding them in place with the flue plate.", "Next, he assembles the section in which hot gases collect after passing through the flue tubes on their way out of the furnace.", "He then sets a combustion chamber on the top of the heat exchanger and welds them together.", "He completes the heat-exchanger assembly by welding on a base equipped with two air-deflector plates.", "These square plates help direct the ambient air as it enters the furnace and circulates around the combustion chamber.", "Meanwhile, an electrostatic powder-coating machine paints the outside covers for the furnace.", "Next, they put on inner air deflectors, then assemble the cabinet.", "They bolt everything in place, then put on an insulated door.", "Now he hooks up a blower control box.", "This electrical box regulates when hot air is sent into a room.", "A worker then connects a tester box to the temperature controls that measure the temperature inside the furnace.", "He runs a number of tests to confirm that both the blower and the burner will turn on or off when they're supposed to.", "He verifies the operation of the door that allows for cleaning out ash residue.", "A technician installs a 100-watt pencil heater inside a brass nozzle adaptor, then threads a thermostat into it.", "This nozzle adaptor heats the oil and turns it into a fine mist so it burns properly.", "She then attaches assembly fittings to the adaptor so she can later mount it inside a burner housing.", "She checks these fittings with a leveling tool to ensure the adaptor will go on straight inside the housing.", "She also installs an assembly that controls oil flow, temperature, and air pressure.", "Then she mounts the nozzle adaptor and covers it with a retention head that shapes the flame for optimal heat, completing the burner assembly.", "A worker then hooks up the used-oil and compressed-air lines to begin testing the burner.", "He turns on the oil, ignites the burner, and looks through an observation port to verify the burner is working properly.", "A closer look shows the flame is at the right intensity for optimal heat with minimal emissions.", "The furnace is now ready to turn used oil into useful heat.", "Top-of-the-line pizza cutters and vegetable peelers can be a pleasure to use.", "They make preparing and serving your favorite foods quicker and easier and are ergonomically designed for style and comfort.", "They are also easy to clean and guaranteed for life.", "Vegetable peelers and pizza cutters work like a charm, making straight cuts without damaging your pans or your fingers.", "Quality pizza cutters start with cutlery-grade, high-carbon stainless steel from which a stamping press punches the cutter blades.", "The blades go through a three-step heat-treating process.", "First, they enter a high-temperature furnace.", "Then it's into a deep freezer to maximize hardness and corrosion resistance.", "Finally, they go into a tempering oven, which increases the durability of the metal.", "A polishing machine with two buffing heads then polishes both sides of the blade, giving it a protective and cosmetic finish.", "A worker than loads the blade onto a bevel-grinding machine that thins out the edge of the blade.", "It grinds a beveled edge that is thin enough to cut pizza but not sharp enough to cut your finger or damage a cutting surface.", "A worker puts a steel-bar insert into an injection molding machine that makes the soft-polymer handle.", "He then cools it down in water.", "He puts the handles on an extraction fixture which removes the inserts, making the handles ready for assembly along with all the other molded parts.", "He then attaches what's called a swing arm to the blade holder, and he secures it in place with a screw.", "He dips the tip of the blade holder into lubricant and uses a pneumatic-assembly fixture to insert the blade holder into the handle permanently.", "Using the swing arm, he snap-fits the blade onto the blade holder and hides the swing-arm screw with a cover cap.", "Finally, he ensures the blade rolls properly and safely so it will cut through pizza with ease.", "The finest vegetable peelers also do their job quickly and effectively.", "They also start with cutlery-grade stainless-steel blades that undergo tempering to ensure the metal is durable and corrosion-resistant.", "After cleaning and polishing, the blades are dried in a vibrating medium of ground corncob, then removed from the tub by a magnet.", "The blades are now ready for sharpening.", "A worker mounts the peeler blades on a computer-controlled edge-grinding machine.", "The grinder sharpens one edge of each blade at a time.", "Once both sides of the peeler blades are fully sharpened, they're ready for assembly.", "Meanwhile, an injection molding machine makes the blade holders.", "A worker dips each blade holder into lubricant and inserts it into the molded soft-polymer handle, joining them together permanently.", "Finally, he attaches the blade by deflecting the holder just enough to insert the tip of the blade into a tiny hole.", "These top-quality vegetable peelers are sold individually or in combination with other kitchen utensils like pizza cutters, and they sure are handy in the kitchen, even if you're not." ]

{ "things": [ "Pre" ] }

[ "Today on \"how it's made\"...", "Pre-inked stamps...", "Cranberries...", "Cotton yarn...", "And road signs.", "\"paid,\" \"rush,\" \"approved\" are some of the terms routinely stamped onto documents.", "Professionals, such as engineers, have their official stamps, too.", "For years, you had to dab the stamp on an ink pad for each impression.", "Nowadays you can get stamps with the ink built right in.", "The process begins with a design that either the stamp company or its customer creates with standard graphics software.", "They print the stamp design onto paper using a high-quality laser printer, then place the printout under an imaging camera.", "They feed in a blank sheet of negative film...", "Then photograph the printout.", "30 seconds later, out comes the negative.", "The design is light, the background dark.", "Now they can begin making the mold for the stamp.", "They apply the negative to a plate of light-sensitive polymer-- a plastic-like material.", "Then they vacuum out the air to prevent defects in the mold.", "Then they expose the polymer plate to ultraviolet light for approximately three minutes.", "The u.v. penetrates through the light part of the negative-- the stamp design-- and hardens the polymer underneath.", "The rest of the polymer is shielded by the dark portions of the negative, so it doesn't change.", "A wash cycle then scrubs away this unhardened polymer, leaving behind a perfect mold in the shape of the stamp.", "Now they cover the mold with a sheet of synthetic resin called bakelite and put it into a machine called a vulcanizer.", "The machine heats the bakelite to just over 309 degrees fahrenheit, then forces it into the mold using 2 to 3 tons of pressure.", "After four minutes, the bakelite stamp is ready.", "To be more productive, the factory actually molds several stamps at a time.", "Next comes the built-in ink.", "They screw the bakelite stamp into what's called the pre-ink mold, then pour in a mixture of ink and gel.", "They cover the mold and vacuum out the air, a process that takes 12 minutes.", "The mold then goes into a heat press for 17 minutes.", "The press applies 2 tons of pressure to expel excess ink and heats the ink gel to about 260 degrees fahrenheit, transforming it to roughly the consistency of a marshmallow.", "So it won't overcook, the mold goes onto a special cooling table for 12 minutes.", "Next, it's set out to cool for another 45 minutes, this time on newspapers, which soak up more excess ink.", "Finally, they wrap the mold in paper towels and newspapers and vacuum out the last drops of excess ink.", "Then they quickly seal the back of the stamp to lock the ink in.", "Now they can cut apart the individual stamps.", "They glue the stamps by hand onto the base of the stamp handles.", "Before they're shipped out to the customer, all stamps undergo a quality-control check to make sure they'll leave a lasting impression.", "Cranberries are one of just a handful of fruits that are native to north america.", "Before the europeans arrived, the indians used them for food and medicine.", "The cranberry vine is well-suited to a harsher climate.", "It thrives in low temperatures and loves acidic soil that's scarce in nutrients.", "Cranberries are ripe for the picking in late september.", "At harvesttime, farmers flood their fields to make the cranberries float to the surface.", "Then they use a machine called a beater.", "It generates underwater turbulence, pulling the berries off the vines.", "The beater is suspended from a mobile bridge that's computer-guided to systematically work its way through the entire field.", "The beater cuts a swath about 23 feet wide with each sweep.", "Workers move the floating cranberries to one corner of the field...", "Where a pump transfers them to a waiting truck.", "Along the way, the berries get a preliminary rinsing to remove branches and leaves.", "At the factory, the truck unloads its cargo.", "The cranberries travel along the water canal and onto a conveyor belt, then through a cleaning station, where workers use brushes and water jets to get rid of any remaining leaves and branches.", "Then they dump the cranberries into large bins to be frozen for up to several months.", "To produce cranberry juice, they defrost the frozen berries in hot water, then mash them-- skins, seeds, and all-- into a puree.", "They add special enzymes to break up the pectin molecules, making the puree less viscous and therefore easier to press.", "The press processes almost 9 tons of puree at a time.", "That's the weight of 1 1/2 elephants.", "It takes three to four pressing cycles to extract all the juice.", "The juice then goes through a sophisticated filtration system.", "The 216 filters remove any plant particles or bacteria larger than one micron.", "A micron is about 25,000 times smaller than an inch.", "Then they evaporate the water until the juice is 10 times more concentrated.", "Cranberries not destined for juice go through a grading process.", "Undersized berries drop down through the holes of a giant sifter.", "The bigger cranberries move on to the grading table, where workers remove any that are substandard.", "An electronic sorter then scans the remaining cranberries for color, signaling an air gun to blow any reject berries off the production line.", "The rest move on to the packaging department or continue down the line to be dried.", "Cranberries destined for drying are automatically seeded, cut in half, and pressed, then soaked in a sugar-and-water solution to make them sweeter.", "The side-to-side motion of the conveyor belt spreads the berries thinly so that they'll dry evenly.", "The hot-air dryer subjects them to temperatures varying from 86 to 176 degrees fahrenheit.", "After about three hours, the cranberries come out looking like this.", "As you sip your cranberry tea, ponder this-- cranberries are a source of potassium and vitamins \"a\" and \"c,\" and drinking cranberry juice can prevent and treat urinary tract infections.", "Twisting plant or animal fibers into yarn dates back to ancient times, when people fashioned primitive spindles out of sticks.", "Around 500 b.c., the spinning wheel was born in india.", "Today's factories have fully automated spinning machines that work on the same principle as the spinning wheel.", "This is a 2-ply commercial yarn, the kind factories use to weave fabric for making jeans and tops.", "It's made from large bales of raw cotton.", "Cotton comes from a plant, so, naturally, some leaves and stems are mixed in with the cotton fibers.", "To remove them, the first machine passes over the bales and removes a layer of cotton .", "2 of an inch wide...", "Then sends it through a duct system to the blending and cleaning machine.", "The machine processes half a ton of cotton per hour.", "The cotton comes out evenly blended and cleaner, but still not clean enough, so it goes into a second cleaning machine, which finishes the job.", "Now the cotton goes through what's called a carding machine.", "It has huge rollers with wire teeth.", "They comb out the tangled fibers and line them up in parallel rows.", "The machine also discards any fibers that are too short to process.", "Next stop-- the coiler.", "This device takes the rows of fibers and forms them into a thick and loose first-stage yarn called sliver.", "The slivers move on to the drawing machine.", "It lines them up six at a time and draws them out, stretching them to form a second-stage yarn.", "Then a machine called a roving frame stretches this second-stage yarn, strengthening it by thinning it out...", "Until it looks like this.", "This third-stage yarn is called roving.", "Depending on the type of yarn they're making, it's anywhere from 3 1/2 to 16 times thinner than sliver.", "They now stretch the roving up to 30 times thinner, which strengthens it even more.", "The yarn is finally finished.", "Now they have to transfer the yarn from all these small spools onto huge, industrial-size cones-- 20 spools to a cone.", "One transfer method uses the winding machine.", "It winds the yarn from the first spool onto the cone.", "Then it automatically takes the back end of that yarn and attaches it with a knot to the front end of the yarn from the next spool.", "It winds it onto the cone, then attaches the back end to the front end from the next spool and so on.", "As each spool empties, the machine automatically discards it.", "And while all that winding is going on, the machine's optical sensor-- that white object you see crossing the screen-- does a quality-control check.", "If a portion of yarn doesn't meet specifications, the winding stops, the machine cuts off the offending portion, then reconnects the ends and resumes winding.", "This is air-jet spinning, another method of making yarn from slivers and winding it onto giant spools known as tubes.", "A suction tube grabs the front end of one spool and connects it to the back end of the previous one, again with a tiny knot.", "Before fully automated machines like this were invented 50 years ago, all that knotting had to be done by hand.", "The thin, finished yarn is 200 times lighter than the thick, first-stage yarn that came out of the carding machine.", "From start to finish, spinning this yarn has taken 48 hours.", "You might not have noticed, but road signs have undergone a subtle change in recent years thanks to advances in technology.", "Today's signs are more reflective than ever.", "You can actually read them in the dead of night, even when the only source of illumination is your car's headlights.", "The earliest road signs were crude-- a stick in the ground or a heap of stones to mark a route.", "In the roman empire, stone posts were erected along roadsides at regular intervals, indicating the distance to rome.", "Centuries later, stone-marker systems gave way to wooden cross signs pointing in several directions at once.", "The international system of road signs we know today came out of the first international road congress, held in 1908.", "The process of manufacturing a road sign starts with a computer.", "The government strictly regulates the specifics of the design and requires a certain degree of reflectivity.", "The computer's specialized software guides a machine to cut the design on a sheet of film.", "Once the design is cut, workers carefully peel off and discard the pieces.", "What's left is a film stencil of the sign-- in this case, a french stop sign.", "They inspect it for defects, then prepare a screen of polyester fabric that they'll later use to print the sign.", "They start by coating it with a thin layer of light-sensitive emulsion.", "Once the emulsion is dry, they adhere the film stencil using vacuum pressure to flatten it and get rid of any creases or air bubbles.", "Then they expose the screen to an intense, 6,000-watt light for seven minutes.", "This activates the emulsion on the lettering and area outside the octagon-- what's not shielded from the light by the film stencil.", "This exposed emulsion hardens, plugging the minute holes between the screen's fibers.", "After rinsing, you see the result.", "Elsewhere in the factory, workers cut the aluminum panels on which the signs will be printed.", "Using a punch press, they round out the edges.", "They make holes for the bolts that will later attach the sign to the post.", "They stamp on the company name and the year of manufacture for warranty purposes.", "They immerse the panels in a chemical bath to remove grease and other residues.", "Then they rinse off the panels and dip them in an acid solution that seals the metal to make it better withstand harsh weather.", "Next, they laminate the aluminum panels with a film containing miniscule glass particles.", "This film will make the sign reflect in the dark when light hits it.", "Then they cut the panel to the final shape.", "Now they can finally print the sign.", "The process they use is called silk-screening, although the fabric screen, as you saw earlier, isn't actually silk.", "It's polyester.", "The machine forces the ink down through the screen onto the panel.", "The ink penetrates through the open fiber holes of the octagon, printing the red background on the stop sign.", "But it can't penetrate through the blocked fiber holes of the lettering and the area outside the octagon, so those remain white.", "The freshly printed signs pass through a dryer at about 150 degrees fahrenheit for 5 minutes.", "To produce street signs, workers first laminate aluminum panels with reflective film for the background color...", "Then either silk-screen the street name or apply self-adhesive reflective lettering.", "But it's back to the silk-screening process for printing multicolored signs.", "Workers print them one color at a time with a drying cycle between colors.", "All the film stencils are carefully stored for future use.", "The printed signs go into an oven for a final curing at 349 degrees fahrenheit-- an hour for a one-color sign, a half-hour per color for a multicolored sign.", "The ink is transparent enough not to block the reflective film underneath.", "Therefore, the entire sign, not just the lettering, is highly reflective.", "That maximizes the sign's visibility, thereby minimizing the excuses drivers can come up with for not heeding it." ]

{ "things": [ "Tasers", "Canned Soup", "Jaw Harps & Mouth Bows", "Diving Boards" ] }

[ "A taser device fires bursts of electricity to deliver a high-voltage, low-amp shock that temporarily disables the subject.", "Invented in 1969 by an american aerospace scientist, the taser has become a weapon of choice for police forces around the world.", "Today, when an officer reaches for his or her gun, it's often one without bullets.", "From a cartridge on the front, the taser fires electrified darts, which, on impact, cause muscle contractions in the target's subject.", "The subject is immobilized but usually recovers in a few minutes.", "This metal capsule contains the propellant, pressurized gas.", "A robotic arm inserts the capsule in a plastic chamber.", "The next robot places a part, called the primer disc, on the capsule.", "It contains chemicals to generate a mini explosion that will drive pins into the capsule, releasing the gas.", "Another robot adds a protective screen.", "That's the primer disc on the left and the screen on the right.", "They punch out a round piece of foam, and the robot thrusts it into the chamber and tamps it down.", "After welding it in place with ultrasonic vibrations, a robot flips the unit up and into a second plastic chamber.", "The placement leaves just enough space between the inner and outer chambers for wire bundles to be inserted later.", "A robot then tucks the assembly into the plastic cartridge.", "It has slots for other components, like insulated copper-wire bundles.", "A machine winds the wire in a tight figure-eight formation.", "This wire will electrify the darts as they're deployed, and the figure-eight winding reduces the possibility of tangling.", "A worker places two bundles in the designated spaces in the cartridge.", "He tops each bundle with a piece of strong polyester film.", "It keeps the wire pack from spring apart as he slides it off the fork and presses it into the cartridge.", "He's now ready for the barbed taser darts.", "He threads the end of each wire bundle through one and knots it.", "He installs the darts in the cartridge, using a special tool to seat them correctly.", "He selects plastic wedges-- one for each wire-- and wraps the other end of the wires around it.", "He attaches electrodes to facilitate the flow of electricity to the cartridge.", "The next part is called the blast door.", "It will blast apart and break in two as the taser darts are deployed.", "The robot snaps it in place on top of the cartridge.", "The door is color-coded to signify the range of the dart probes.", "Yellow indicates five yards.", "With the compressed-air cartridge complete, they now focus on the taser's deployment mechanisms.", "A technician installs a laser system and two l.e.d. lights in the plastic casing.", "The laser is an aide for aiming the electrified darts, and the lights will illuminate the target.", "He adjusts the laser's aim to sync it with one of the darts, using a bull's-eye target as an alignment aide.", "Next, they immerse the high-voltage board in epoxy resin and pump more directly into it.", "This board is in the part of the taser gun that generates electrical pulses when the gun is in stun mode.", "Once cured, the epoxy encapsulates this unit to insulate the components.", "The technician inserts the high-voltage board in the gun casing.", "Along with the controller board-- the brains of the taser-- he also installs an information display board and makes the necessary connections.", "He plugs the assembly into a power source and tests the laser and l.e.d. lights.", "He snaps on the trigger and confirms that it makes contact with the plunger on the control board.", "He joins the other half of the taser casing to the one with all the working parts.", "Then, an ultrasonic welder fuses the casing parts at the tongue and groove seams.", "Protecting the outer casing with a sheet of plastic, the technician welds a safety switch to the trigger.", "This critical part will prevent accidental deployment.", "In a test chamber now, they activate the taser without the air cartridge.", "Without the cartridge and its projectile darts, the taser works as a handheld stun gun to zap the target directly.", "Once it meets the tester's approval, this taser is ready for the police beat.", "A consumer model is also approved for use in some jurisdictions.", "Like the police version, it should deliver a shocking performance.", "Soup is a liquid food that is as old as cooking itself.", "Its appeal is quite literally biblical because in the old testament, a son trades his inheritance for a pot of lentil soup.", "Of course, today, one doesn't have to sacrifice it all for soup because it's usually readily available in cans.", "With the invention of canning in the early 19th century, soup soon became available on demand.", "On the home front, this caused quite a stir.", "No need for a long simmer.", "Just open the can, reheat, and soup's on.", "To manufacture lentil soup, they make a hearty soup base.", "They load measured amounts into a heated mixer, beginning with purée garlic.", "The mixer's walls are steam-jacketed so the mix will cook evenly with no scorching on the bottom.", "The next ingredient is olive oil.", "They activate the steam heat, and the garlic begins to sizzle.", "They add chopped onion.", "The mixing blades gently toss the ingredients as they sauté.", "They blend in diced celery and cook until translucent.", "The next round of ingredients takes the flavor up a notch.", "They include chopped carrots, sea salt, and fragrant spices.", "Balsamic vinegar adds a sweet tartness to this lentil-soup base.", "They're now ready to liquify the ingredients.", "They open the tap, and filtered water spills in.", "As the soup begins to simmer, they add crushed and diced tomatoes.", "The final ingredient for this robust lentil-soup base is spinach.", "Mixing it makes for a colorful swirl, and, as the ingredients cook, they become increasingly aromatic.", "Meanwhile, raw, peeled potatoes ride a steep and slatted conveyor upward.", "The slats keep the potatoes from rolling back as they make the climb up to a hopper.", "From the hopper, the potatoes slide down a chute and into a revolving drum with cross-cutting blades.", "The blades cut the spuds into small cubes and spit them out.", "After a trip past a metal detector, the potato cubes land in a bin.", "In small-cube form, they'll cook faster later.", "Next, lentils, hard and dried, surge in a steady stream onto a revolving round table.", "The table has openings that lead to little chutes with doors.", "They open to funnel the lentils into cans moving on a conveyor below.", "This ensures that a specific amount is fed into the cans.", "Partially cooked green beans and the raw potato cubes now flow onto a second revolving table.", "The cans with the lentils have now moved into position below.", "The veggies fall through the holes and into the cans.", "The cans, with mostly uncooked ingredients, now head towards the piston filler.", "It pipes the steaming hot vegetable-soup base directly from the kettle mixer into the cans, filling them to the brim.", "Immersed in the hot liquid, the lentils, potatoes, and green beans at the base of the can cook a little and soften up.", "Sensors detect the approach of the cans and cue the lids.", "The lids drop one by one onto the cans below.", "A device then interlocks the rims of the cans and the lids for a hermetic seal.", "The cans move into another lane and travel past an x-ray machine.", "It scans the soup inside for metal contaminants like stray bolts or screws.", "If the images are clear, the cans of soup move on to a giant pressure cooker.", "Here, the contents cook under pressure for about a half hour.", "Pressure-cooking simulates the effect of a long simmer in a fraction of the time.", "The soup then cools for 10 minutes.", "It is now thoroughly cooked and preserved.", "Now on their sides with glue applied, the cans of lentil soup roll over labels, and the labels adhere.", "They produce more than 15,000 cans of lentil soup an hour at this factory.", "That's 105,000 cans in one shift.", "It's enough to feed a small city.", "The jaw harp and the mouth bow are among the earliest musical instruments.", "A chinese drawing from the 4th century b.c. is believed to be the first record of a musician playing a jaw harp, and cave paintings in southern france from 15,000 b.c. depict someone playing a mouth bow.", "The mouth bow is a stick of wood with a single string the musician plucks or strums, while altering the vibration-generated sound by mouth.", "The jaw harp is a metal instrument.", "The musician plucks its flexible tongue to produce a twanging sound, which he then modulates with mouth positions and breathing.", "This craftsman makes the jaw harp's frame out of 1/10 of an inch thick square steel rod.", "He measures and marks the required length and bend points.", "He cuts the length with a standard hacksaw...", "Clamps the rod in a vice...", "Then slips metal pipes over the ends to prevent them from twisting as he bends them to form the arms of the frame.", "He aligns the arms, leaving just enough space between them to allow the tongue to vibrate without obstruction.", "For the instrument to produce quality sound, the arms must be perfectly parallel to each other-- their edges in mirror image.", "He marks the tongue's position in between the arms and files down the metal within the markings.", "This creates a notch in which the tongue will sit.", "The tongue is made of spring steel-- a type of steel, which when bent, resumes its original shape.", "Before attaching it, he saws a tiny undercut in each side of the notch.", "Then he inserts the tongue and hammers the undercut sides to compress them over the tongue and lock it into position.", "He heats the tip of the tongue with a propane torch.", "Once the metal softens enough to bend, he angles the tip to form what's called the trigger.", "Then he heats the end of the trigger and bends it into a loop.", "This is what the musician's finger strikes to make the tongue vibrate.", "Finally, he files the tongue's edges sharp-- a last detail to improve the instrument's sound quality.", "To make a mouth bow, his first step is to find a stick that's between roughly 1 1/2 to 6 1/2 feet long, not too heavy, and ideally with a \"t\" shape at the end.", "In his workshop, he clamps it in a vice, trims it to the required length, and, using a rasp, files the knots flat.", "He files the top end until it's about 2/10 of an inch thick.", "This forms the mouthpiece, which you hold gently to your lips while plucking the string.", "The string vibrates the mouthpiece, producing sounds that you alter by changing the shape of your mouth.", "He drills a hole toward the base of the mouthpiece for the string, then, just below that, files a notch for the bridge that supports the string.", "Just below the notch, he hammers in a steel nail called the pin.", "He drills a 2/10 of an inch hole at the \"t\"-shaped end of the stick.", "This is where he'll insert the tuning peg, which he constructs out of a wood knob and dow.", "He makes the string from a length of piano wire.", "He forms a loop at one end by twisting it with pliers around an awl.", "He feeds this end through the hole at the base of the mouthpiece...", "And hooks the loop onto the pin.", "Then he threads the other end of the string through a hole in the shaft at the tuning peg at the bottom of the stick.", "He turns the peg to tighten the string.", "Just as on a violin or a guitar, the tauter the string, the higher the note it produces.", "the final step is to position the bridge-- a hardwood dow-- in its notch, under the tense string.", "By elevating the top of the string, the bridge prevents it from cutting into the stick.", "The mouth bow and the jaw harp are played alone or alongside other instruments in the folk music of numerous cultures around the world.", "The earliest known reference to a diving board appears in a hieroglyphic from 480 b.c. it depicts a man plunging headfirst into a pool of water from a platform.", "Today, diving boards are standard equipment at neighborhood and backyard swimming pools.", "One end of the diving board is fixed to give the other end the bounce required for a big-splash cannonball or a graceful swan dive.", "To make the diving-board shell, workers load a sheet of acrylic into a clamping machine that transports it into an oven.", "The oven heats the sheet for about 30 seconds to soften it.", "Then, a forming machine applies suction to draw the softened acrylic tightly over a mold in the shape of two diving boards.", "Fans blow cool air, hardening the acrylic to this shape within seconds.", "They extract the molded acrylic, then saw it in half to separate the two diving-board shells.", "They coat the shell surface in a resin and fiberglass mixture.", "This tool is called a chopper gun because it chops and shreds the fiberglass string, then shoots it out drenched in resin.", "They roll it to compress the fibers and push out air pockets.", "Any trapped air would create a weak spot in the diving board.", "After letting the resin dry and harden for 30 minutes, they begin filling the shell cavity with 2/10 of an inch thick fiberglass mat.", "They drench the mat in resin, rolling it over to ensure every fraction of an inch gets well-saturated.", "Then they lay down another fiberglass mat, this one a bit thinner and saturated with the existing resin.", "The diving board's core is made of laminated wood, which is several thin layers of wood glued together.", "Laminated wood is actually stronger than a solid piece of wood.", "After rounding the top edge, they lay two wood-laminate cores over the resin-saturated fiberglass mats.", "They position clamps to hold the cores in place.", "But before tightening, they insert metal spacers to ensure the cores are correctly positioned within the shell.", "Once the positioning is perfect, they tighten the clamps, then let the resin cure at room temperature for a half hour or so.", "Then the clamps come off, and workers cover the cores with an even thicker fiberglass mat impregnated with resin.", "This is the bottom of the diving board.", "They make sure the mat is centered...", "Then manually form it to the shape of the board, pushing out the air pockets as they go.", "They spray on some decorative paint, then put the board in an oven for 24 hours to cure.", "When it comes out, they use a diamond blade to saw off the excess fiberglass around the edge.", "Then they do a final trimming to make the edge neat and smooth.", "They mask the sides with tape, leaving only the top exposed.", "This is where they'll now apply a rough texture-- a safe, non-slip surface.", "First, they roll on a thin coat of resin.", "Onto that, they sprinkle a layer of silica sand, making sure to cover the surface thoroughly and evenly.", "The sand sticks to the resin, which sets and cures in about 15 minutes.", "After sweeping off the excess sand that didn't adhere, they roll on a coat of laminating resin, which bonds to the sand, giving the surface a clean, finished look.", "They pull off the tape and apply the manufacture's decal to the side.", "The diving board is now all set to be installed on a stand at the edge of the deep end to await anyone ready to take the plunge." ]

{ "things": [ "Riding Mowers", "Popcorn", "Adjustable Beds", "Cultured Diamonds" ] }

[ "When it comes to sitting down on the job, the riding mower is just the vehicle.", "Animals powered the first ones in england in the 19th century.", "When motorized mowers came along in the 20th century, they improved on the concept, and we were on our way to greener pastures.", "Step behind the controls of a riding mower, and you can tame that unruly lawn without even breaking a sweat.", "The job can be done speedily because a riding mower moves at quite a clip.", "To make one, a robot delivers a sheet of steel to a die.", "The die closes with 1,000 tons of force to make a big impression.", "It shapes it into the part that holds the mowing blades-- what's called the mower deck.", "They transfer the mower decks to a series of presses.", "They punch holes for the blade attachments and trim the edges.", "Workers stack the decks for washing.", "After a treatment with a chemical rust inhibitor, it's time to plunge them into a primer solution.", "The overhead rack delivers a negative charge to the decks, while the primer has a positive charge, which draws it onto the decks in an even coat.", "This is called electrostatic painting.", "They assemble three spindles to mowing blades and hoist the mower deck over the blade assemblies.", "They bolt the head of each blade subassembly to the mower deck.", "Then they thread rubber belts around pulleys to drive the blades.", "Assembly continues with gauge wheels, a protective belt casing, and a chute for the cut grass.", "Next, they clamp a set of steel rails along with some attachments to a welding table.", "The welding table swings around to an awaiting crew of robots.", "The robots move in and weld the attachments to the rails.", "These rails will serve as the framework for the riding mower.", "The attachments are for the front wheels.", "Once the rails have been primed, an overhead conveyor takes them into a paint booth.", "Nozzles spray a powder paint onto the parts for an enamel-like finish.", "The powder that doesn't stick is recycled.", "They lower the engine subassembly into position to build the vehicle framework around it, then bolt the welded and freshly glossed side rails to tubing at the front and back.", "They attach the footrest to the frame, then install the platform for the seat.", "They assemble those nifty steering levers, which can be moved into 15 positions.", "Then they install metal yokes on the front wheels.", "They slot the yoke's shaft into the frame rail, securing it with a metal snap ring.", "Now comes the front grill, that's vented to protect the engine from overheating.", "The rear wheels go on next.", "They're more substantial than the front ones because this is a rear-wheel-drive machine.", "It's time to mount the mower deck and blades onto the vehicle.", "They position it in front and roll the vehicle over it.", "The workers activate a lift that elevates the worktable to a height that makes it easier for them to secure the mower deck to the framework.", "They attach the belts on the mower deck to the engine.", "Monitoring equipment will help them see if this mower's got what it takes to mow down the competition.", "They put it in gear and check the wheels to confirm that they turn at the correct speed.", "They adjust the transmission if they're not.", "They also check the electrical components, and if all systems are go, they complete the assembly.", "They bolt a side panel in place, followed by the instrument panel.", "And last comes the seat, complete with armrests.", "It takes 72 minutes to assemble one of these riding mowers, and it should be good for at least a decade of mowing.", "Good thing, because it's workload is constantly growing.", "We don't know exactly when popcorn first exploded onto the snack scene, but it was likely thousands of years ago.", "Popcorn grains dating back nearly 5,600 years have been discovered in caves in new mexico.", "And down through the ages, this unique grain just keeps popping up.", "Nothing says it's showtime like a big bowl of popcorn.", "This grain has certainly made it big in the entertainment biz.", "This success story has its roots on the farm, of course.", "Popcorn is one of six types of corn, and it's the only kind that pops.", "They even breed the popcorn plant to enhance traits like color, taste, and popability.", "By fall, the crop is ready to harvest.", "Peeling back the husks reveals kernels that are smaller and harder than those of other corn.", "At harvesting, popcorn has moisture content of 16% to 20%.", "That's a bit too high.", "So to bring it down to 14%, they condition the crop in these giant bins, pumping warm air up through it to accelerate the drying.", "It's a critical step.", "Popcorn that's too dry may not pop.", "And if it's too wet, it could spoil when stored.", "In the factory, a series of oscillating screens sift chunks of cob and broken kernels out of the popcorn.", "Vacuum pipes pull the finer impurities to a dust collector and suck the larger impurities into a chute.", "They end up in a waste bin to be discarded or used in animal feed.", "At this junction, the system funnels the filtered popcorn in one direction and the impurities in another.", "It's the perfect opportunity to see the difference between the two streams.", "The purification process continues at the gravity table.", "Its vibrating action, along with powerful fans, cause the popcorn to rise and float on air.", "In the process, kernels that are too heavy or too light gravitate away from the center and are shunted aside.", "The grains in the middle of the mass are the optimal size, but leaving nothing to chance, they go through one more screening.", "The kernels now head into a very different kind of sorter.", "Inside, the kernels fly by an electric eye.", "It detects remaining debris or defective grains.", "The machine sends a blast of air to get rid of them.", "It's time to test a sample of the production run.", "He pours in a half pound of kernels along with some oil.", "As the pot reaches 446 degrees fahrenheit, the water in the kernel starts to steam.", "As the pressure builds, those kernels explode and turn inside out.", "This reveals the starchy part of the kernel and creates a white, fluffy puff.", "To pass this test, the popcorn has to expand 44.5 times the original volume.", "The tester loads the popped puffs into a tube with measurements on it, and this bach of popcorn is right on the mark.", "As you can see, a little bit of popcorn can really go a long way, from a pea-sized kernel to a puffy, white treat in a matter of minutes.", "And although popcorn kernels come in a range of colors, that starchy part that's exposed by popping is always white.", "Now it's all in the packaging.", "Maintaining the correct amount of moisture in each kernel is critical.", "Heat-sealing the bag locks in the grains to keep them from drying out on a store shelf.", "This paper bag destined for the concession market, like movie theaters, is multilayered.", "It includes a vapor barrier to control moisture loss.", "It's taken six months to grow this popcorn and a couple of weeks more to process it.", "But it will all be worth it at snack time, because when these grains explode into a mountain of munchies, there should be enough for the whole gang.", "Some people enjoy the health benefits that adjustable beds may give.", "Others like the built-in massage system that gently rocks them to sleep each night.", "Whatever a person's fancy, adjustable beds can be custom-made to suit their lifestyle and total comfort and class.", "An adjustable bed helps you sleep with a push of the button.", "This convenient hand control easily adjusts the head and foot positions to the contours of your body.", "It all starts with a quilting machine.", "It sews foam padding, fire retardant material, and two layers of backing together.", "Hundreds of thousands of stitches produce a quilted top panel with comfort and style in mind.", "A machine cuts the panel to a specific bed size.", "The four layers that make up the quilted top panel add luxury and security to the mattress.", "Meanwhile, another worker prepares the coil spring.", "He covers it with protective netting.", "This high-density foam pad comes next.", "He staples the pad and netting to the coil spring.", "He puts a bottom cover on the mattress and tucks the foam and coil spring inside.", "He turns the mattress over, covers it with netting, then staples it.", "He puts another high-density foam pad on this side and staples it.", "Then he lays down the quilted top panel.", "He holds on to the backing layer and staples the top panel onto the spring.", "He fills the corners with packing, which gives them a nice, firm edge.", "Then he sews the mattress together with the tape-edge machine that uses binding tape and fire-retardant thread.", "The tape-edge machine makes a perfect seam all the way around and finishes the mattress.", "Next, a length of steel rod goes into a thread-roll machine.", "Its threaded rollers use hydraulic pressure to transform the rod into a worm screw.", "They put the worm screw and gear assembly inside a casing.", "The worm and nylon gears will turn a steel shaft, which raises and lowers the bed.", "A worker closes the motor casing.", "Another worker assembles the bed's foundation.", "He puts flexible nylon hinges between platform boards and staples them in place.", "He turns the platform over and staples them again.", "He protects the platform with a polyester dust cover.", "A worker now bolts a steel frame to the platform.", "He fastens a head motor to one of the metal tubes.", "To another metal tube, he bolts a foot motor.", "Finally, he attaches a massage motor.", "Then a worker covers a support fixture with a cotton bed cover.", "He puts down four-inch high density foam, then places the fully assembled frame on top.", "He pulls up the bed cover and upholsters it to the base.", "The bed is ready for its adjustable bed sheets, but not before a final testing for quality control.", "Every part must pass a flex test the operator controls.", "The paper-protected foundation, the steel frame, and all three motors must allow the bed to rise and descend with gentle, uninterrupted precision-- exactly as it would in the comfort of your own home.", "All you need now is a bowl of popcorn, a movie, and perhaps a soothing massage, and then it's lights-out.", "Diamonds are a flash of brilliance for mother nature.", "Formed in the earth's crust by intense heat and pressure, they're prized for their crystalline beauty.", "But now mother nature has some serious competition, because gem-quality diamonds are actually being grown in laboratories.", "Diamonds grown in labs are dazzling even the skeptics.", "While lower-grade diamonds have long been grown for industrial use, they were more grit than glitter.", "But these diamonds have that gem-quality sparkle.", "They start with a robotic laser.", "It slices slivers from a chunk of real diamond to produce tiny wafers.", "They're five millimeters wide and a quarter millimeter thick.", "That's about as thin as a human hair.", "The laser blackens the diamond, so they place it on a steel block for polishing.", "They rim the wafer with epoxy to keep it from sliding around.", "This epoxy requires an activator, so they brush it on next.", "The chemical reaction causes the epoxy to solidify in seconds to firmly secure the sliver on the block.", "They screw the block to a threaded rod that's attached to a metal arm.", "They lower the block and its diamond wafer onto a wheel that's swirling with diamond grit.", "They apply weights to press the diamond wafer into the grit.", "And as the wheel spins, it creates the necessary friction to polish away the grime.", "A level confirms the wafer is correctly positioned.", "Diamonds are the hardest of minerals, and only other diamonds can effectively polish one.", "The difference is impressive.", "The diamond wafer has gone from sooty to crystal clear, and now it's ready to grow.", "A technician places several wafers on a special metal pedestal using a suction tool.", "He arranges them in a uniform pattern, giving them room to expand, because these slivers of diamond are destined for bigger things.", "He lowers a metal chamber over them.", "Pumps inject hydrogen and methane gas, and the machine heats them to thousands of degrees at just the right pressure.", "The gasses form a plasma, which rains onto the diamond wafers and causes them to grow.", "After just two weeks, the diamond slivers have grown into stones at least 10 times the original size.", "It's quite a transformation.", "But these diamonds in the rough need a lot more work to really sparkle.", "That dab epoxy onto the tip of a pointed steel rod called a dop and center the lab-grown diamond on the epoxy-coated tip.", "Then it's into the laser booth, where the dop is gripped by a robotic arm.", "It turns it so a laser can trim the lab-grown diamond from all sides.", "The process exposes the crystal clarity of the gem.", "A technician checks the quality of the lab-grown diamond with a jeweler's magnifying glass.", "Then she lowers it into another polishing wheel.", "It's similar to the one that was used to clean it when it was just a sliver.", "But this wheel actually contours the grown stone to give it that classic diamond shape.", "The process brings out all of its glittering facets.", "It's taken just a couple of weeks to grow this diamond.", "The process puts geology on fast-forward, because it takes tens of millions of years for real forces to push real diamonds to the earth's surface.", "Only very sophisticated testing can separate the lab-grown diamonds from the mined ones.", "But since they cost 15% less, you'll notice the difference in your pocketbook." ]

{ "things": [ "Traffic Signal Poles", "Coffee Filters", "Chainsaw Mining Machines" ] }

[ "Traffic-signal poles must be strong enough to bear the weight of road signs, street lights, and, of course, traffic signals.", "The poles are also built to withstand extreme weather conditions, such as high winds and heavy snow accumulation.", "Traffic signal poles are made of high-strength steel.", "Years of weather exposure can cause corrosion, so the poles are galvanized on both sides for protection.", "Each pole has a welded plate to connect it to a perpendicular pole.", "The poles are made out of these steel sheets.", "The steel arrives at the factory in one large roll.", "They use a decoiler to unwind the sheet and flatten it out.", "Then a shear cuts it to the correct length.", "A computer-guided plasma cutter marks short lines on both ends of the sheet.", "These lines indicate where to bend the flat sheet to form a round pole.", "The machine cuts the sheet into a rectangular shape, or a trapezoid shape if the pole will taper at the top.", "Workers number the machine lines with chalk, giving lines directly opposite of each other the same number.", "Then they transfer the sheet to a bending machine called a press brake.", "The press brake bends the sheet along the marked line to a preprogrammed angle.", "Workers use a digital measuring device to make sure the first bend is accurate.", "If it is, they continue bending along the remainder of the lines, transforming the flat sheet into a multisided round pole.", "Now the pole moves to a welding station, where hydraulic rollers apply pressure from both sides.", "This forces the edges of the sheet together so that a welding head can fuse the seam with molten steel.", "At the same time, the head deposits a granular powder called flux, which prevents air from penetrating the weld and weakening it.", "Workers place the pole in a hydraulic press so it doesn't warp as the seam weld cools and shrinks.", "Next, a computer-guided plasma machine cuts a connection plate out of thick steel.", "The machine also drills holes for the high-strength bolts needed to attach the plate to the traffic-signal pole.", "Workers center the connection plate on support plates they've already welded to the pole.", "Then they weld everything in place.", "Next, workers weld a baseplate to the bottom of the pole.", "It has holes for the anchor bolts, which are used for securing the traffic signal to the street.", "Workers inspect the welds with a testing device.", "It uses an electric current to magnetically draw colored powder into any defective area.", "The factory ships the finished poles to a galvanizing plant, where they're dipped in a series of wash tanks.", "The plant's tanks are deep enough to fully submerge the poles so they can treat both the inner and outer surface at the same time.", "Now the poles go into a vat of sulfuric acid.", "This bath dissolves the more stubborn contaminants that washing can't remove.", "The next tank contains a chemical that weakens the surface of the poles.", "This allows the galvanizing metal to penetrate the steel, rather than sit on the surface.", "The final tank contains molten zinc.", "As the poles bathe in the 842-degree zinc, workers in fire-protection suits skim the surface to remove iron oxide and ash that floats to the top.", "This keeps the freshly galvanized surface clean as the poles are hoisted out of the tank and set aside to cool.", "Because they're galvanized rather than painted, these poles are able to support traffic lights, signs, and street lamps for 40 years or more.", "In 1908, a german housewife came up with a solution to get rid of bitter-tasting sediment in her coffee.", "She punched nail holes in a pot and covered them with blotting paper.", "Then she placed ground coffee on the paper and filled the pot with hot water.", "It worked so well that she started selling her coffee filters worldwide.", "These coffee filters are made of 100% cellulose fiber harvested from slow-growing pine and spruce trees in the forests of southern scandinavia.", "The raw material produces paper that lets about 3 ounces of water pass through it in approximately 40 seconds.", "That's the optimal saturation rate for producing good coffee.", "30% of the paper's cellulose content is left over from earlier production.", "The other 70% is raw cellulose fiber.", "The materials go into a machine called a pulper, which works like a giant food processor.", "It blends the raw materials with hot water, making a fiber soup called pulp.", "A paper-making machine spreads a one-inch layer of pulp across a wire-mesh belt.", "Water jets cut a straight edge on both sides.", "As moisture drains down through the belt, the pulp forms a soggy sheet of paper.", "It has a water content of 80%.", "All this happens at an astounding pace.", "The machine lays down 1,300 feet of pulp a minute.", "At the next station, heavy compression rollers squeeze almost half the water out of the paper.", "A tool applies a crepe texture.", "This increases the surface area of the paper and improves filtration speed.", "Next, they use 38 steam-heated rollers to dry the paper completely.", "The rollers' surface temperatures are around 250 degrees.", "As the finished paper exits the machine, a camera registers the location of holes, dirt, or other defects that have to be cut out.", "It takes the machine 45 minutes to produce an 11-mile-long sheet of coffee-filter paper.", "The roll is transferred to a cutting machine.", "The paper is sliced into two-foot rolls so it can fit in the filter-making machine.", "Sensors in the filter-making machine make sure the paper is aligned correctly.", "At the machine's first station, tiny needles pierce holes in the paper to enhance the quality of filtration.", "At the next station, a stamp imprints the company logo in the paper.", "A knife slices the paper in half, creating two side-by-side production lines from this point forward.", "Each line enters a folding station, where guides fold the flat sheet in half.", "A roller embosses a seam connecting the two layers of paper along the bottom and side.", "Then a second roller cuts the conical shape of the filter.", "The machine produces 4,000 filters per minute.", "The next station cuts the filters apart and collects the leftover paper, which will be recycled into pulp.", "The filters are sent to an automatic counting machine that divides them into stacks of 80.", "The machine feeds the stacks to the packaging line.", "An automated packaging machine aligns each stack with a flattened box.", "Then it opens the box with a vacuum and inserts the filters.", "If the machine's sensor detects a problem, like filters in the wrong position or missing filters, it ejects that box from the line.", "This factory produces a few different types of filters.", "How the cellulose is processed in the pulper determines how the filter will perform.", "For example, the factory processes cellulose finely to make filters designed to brew strong coffee.", "Fine cellulose produces paper that drains slowly, keeping the water and coffee beans together longer, resulting in a stronger flavor.", "Chainsaw mining machines are among the largest and heaviest chainsaws in the world.", "They're used in rock quarries to cut and extract some of the toughest materials on earth.", "The machine's massive blade can make both vertical and horizontal cuts, slicing through hard stone as if it were butter.", "Hundreds of feet underground, this monster chainsaw is carving through geological deposits of marble.", "The chainsaw arm can rotate to make both horizontal and vertical cuts as needed.", "It cuts uniform blocks of marble.", "Then a loader extracts the blocks from the rock face.", "They're the exact size the customer requested, thanks to the precision and power of the chainsaw mining machine.", "It takes several steel tubes of various dimensions to make a chainsaw mining machine.", "They use an automated saw to cut the tubes to the correct length.", "This one will be used for the chassis.", "They assemble the tubes in the correct configuration.", "Then a worker joins them with welds.", "They lower the completed chassis onto the chainsaw machine tracks.", "The chassis is bolted to the fifth-wheel coupling.", "This allows the machine to rotate 360 degrees.", "They bring in the framework that will house the motors, oil tank, and electrical components.", "They bolt the framework to the chassis.", "The next part is a rail system for raising and lowering the chainsaw blade.", "A worker attaches the rail system to the chassis using a thick pin.", "This pin acts as a hinge, allowing the vertical structure to be folded down when needed.", "After verifying that the machine's basic framework fits together well, they take it apart for painting.", "They also paint the gear motors.", "This one will power the carriage that moves the blade back and forth.", "Once all the parts have been painted, they reassemble the framework.", "Next, they mount the carriage to the front of the machine.", "It rotates within the vertical rail to position the blade for cutting.", "Workers then install the gear motor that powers the horizontal movement of the chainsaw blade.", "They secure it with several bolts.", "Two more gear motors will drive the cutting chain and rotate the blade.", "The team mounts them to the front of the carriage, to the right of the other gear motor.", "At the back of the carriage, a worker assembles a gear known as a pinion.", "The pinion engages with a track called the rack.", "This rack-and-pinion system allows the carriage to slide back and forth.", "A worker folds hydraulic hoses in a long metal cage and bolts the cage to the front of the machine.", "Then he connects the cutting-chain hoses to the motor, protecting the connections with metal half-flanges.", "They make all the electrical connections...", "Then screw fireproof and waterproof covers onto the electronics boxes.", "They program the chainsaw machine's operator screen.", "Stay tuned, because the big chainsaw blade is next.", "Few things are as fierce as the blade of a stonecutting chainsaw machine.", "It's 10 feet long, weighs over 1,300 pounds, and has big teeth that make cutting through solid rock look easy.", "It's no surprise that making one of these giant blades is a huge job.", "A computer-driven plasma flame cuts a large blade from a sheet of high-carbon steel.", "Using a crane with a powerful magnet, they transfer the chainsaw blade to a milling station.", "Here, computerized tools smooth out the steel.", "They also bring the blade to the correct width and carve channels for lubrication tubes.", "They drill holes for metal plates that will align the cutting chain.", "The team paints the saw and adds an attachment bar, then mounts it to the front of the chainsaw machine.", "They slide the bar into the blade support on the front.", "It's a critical connection because it bears the weight of the heavy blade as it saws through stone.", "They secure it to the blade support with a thick pin and a nut.", "Next, they make the cutting-chain sprocket.", "A computer-guided tool carves toothlike projections around the rim of a steel disk.", "These teeth are designed to grab the links of the cutting chain.", "The sprocket is ready to be mounted to the chainsaw machine.", "An employee slides the sprocket onto a shaft protruding from the cutting-chain gear motor.", "He bolts the disk to the surrounding hub.", "Next, they assemble the cutting chain.", "A two-part fastener system holds the links together.", "It starts with this hollow pin.", "A worker drives the hollow pin into a hole in the links using a hydraulic press.", "He inserts an l-shaped pin into the hollow pin.", "The tongue of the l-shaped pin fits into a groove adjacent to the hollow pin.", "The press forces the l-shaped pin into the groove.", "He alternates outer links and inner ones to build a 30-foot chain that will fit to the saw body.", "Then another worker loops it around the saw blade and sprocket.", "The chain fits perfectly to the saw.", "He joins the ends of the chain with a hollow pin and an l-shaped pin to complete the loop.", "He flattens them with a hammer instead of a press because it's easier to use a hammer at this angle.", "The chain is in place, but it doesn't have the teeth it needs to cut stone yet.", "These parts, a carrier and a tungsten carbide cutting bit, give the blade its cutting edge.", "He places a set on each of the chain's outer links...", "Then screws them in.", "Studded with tough, sharp teeth, this mega chainsaw is now ready for rock-cutting action.", "It cuts through stone cleanly and efficiently.", "Its size and power make it a force to be reckoned with underground.", "Despite its bulky frame, this chainsaw mining machine has a wide range of motion.", "Here, the front carriage rotates the blade to demonstrate how it can be repositioned between cuts.", "No matter how you slice it...", "That's pretty impressive." ]

{ "things": [ "Flight Simulators", "Bookbinding", "Greenhouse Tomatoes", "Hurricane" ] }

[ "Most hands-on pilot training occurs not in the air, but on the ground.", "The classroom in which this instruction takes place is a flight simulator-- a high-tech replica of the aircraft cockpit.", "Through the magic of sophisticated computer software, the simulator mimics the process and feel of flying the aircraft.", "The flight simulator can produce darkness or daylight, clear or stormy weather, or an emergency such as engine failure or a runway tire blowout.", "Simulators are modeled after specific aircraft, such as a boeing 737.", "The simulator manufacturer buys the technical data from the aircraft manufacturer so it can build a cockpit which is an exact replica in both look and feel.", "After assembling a steel frame and building the instructor's station behind the cockpit, they mount a sound system beneath the cockpit.", "This enables crew communication and produces realistic aircraft and weather sounds.", "A computer-driven image generator produces the cockpit view on a large, spherical mirror made of a thin polyester film.", "A vacuum pump sucks it flat and wrinkle-free.", "The image reflecting on the mirror creates the illusion of the infinite view pilots have in a real aircraft.", "The image generator doesn't send the visuals directly to the spherical mirror facing the pilots.", "A projector first shoots the image onto a flat, rectangular mirror that reflects the image onto a front projection screen-- that round part at the top.", "The image on the projection screen then reflects in the spherical mirror in front of the pilots.", "This diagram illustrates how the image travels.", "Technicians prepare the cockpit throttles, adjusting the lever tension to be identical to that of the real aircraft.", "Inside each throttle, they check the thrust reverser that pilots activate upon touchdown to reverse air flow and stop the plane.", "Next come the control panels, with all the buttons and switches to operate everything from the engines to the air-conditioning to the lights.", "Next, the motion actuators-- giant legs which move the cockpit.", "They attach to a concrete slab with jumbo bolts.", "Technicians attach conduits through which electrical cables and air hoses run to the actuators.", "The motion is electropneumatic, meaning that air assists the electric motor that moves the legs.", "To attach the actuators, technicians activate the brake inside each one.", "This enables the leg to stretch far enough to reach the base.", "After checking the alignment with this tool...", "They insert a pin.", "Then they test the movement of the entire apparatus.", "The test pilot runs the finished flight simulator through different maneuvers to ensure it performs perfectly.", "The image generator is run by highly sophisticated software.", "It knows the design of every airport in the world, enabling the instructor to conjure up any scenario imaginable...", "Takeoffs, landings, and taxiing at a specific airport, any weather conditions or runway hazards, or any unforeseen events, such as a blackout that plunges the entire airport into darkness.", "Faking it doesn't get any more real than this.", "Today's books are mass-produced by automated equipment, but before the industry was mechanized, book pages were hand-bound, their covers meticulously hand-crafted one at a time by talented book binders.", "This skilled trade still exists, but is now a specialty service.", "Book binders are part artist, part restorer, because they craft new bindings, yet also repair originals.", "Before rebinding a book, the book binder has to unbind it.", "She uses a surgical scalpel to cut the strands of old binding thread.", "This separates the covers and the sections of assembled paged, called signatures.", "Using a paper cutter, she trims the components just enough to make their edges neat and smooth.", "Then she positions the signatures in a vice, sandwiched between cardboard for support.", "She draws lines across what will be the spine of the book.", "Then she carefully saws a groove in each line.", "The groove is just big enough to fit a piece of hemp binding cord.", "One at a time, she reconnects the signatures on a sewing frame.", "The frame has binding cords that correspond to the grooves she sawed into the signatures.", "She sews a linen thread horizontally, looping it around the cords.", "A chain stitch on each end links each signature to the neighboring one.", "When she's done, she coats the sewn area with glue.", "She then lays a thin cloth backing over the glue, then closes the vice tightly to round the back and form joints into which the book's covers will fit.", "She perfects the joints using a hammer.", "Next, she weaves the binding's headband by wrapping threads around support sticks in a specific pattern.", "She does this on both the top and bottom of what will be the book's spine.", "Next, by folding and gluing pieces of paper, she constructs a tube the exact width and length of the spine.", "She glues the tube to the spine.", "Now for the book's front cover.", "She layers pieces of cardboard to create a design, then glues it onto a rectangular piece of leather.", "She presses the leather against the cardboard with a plastic tool called a bone folder.", "Next, she cuts a strip of thick paper the width of the book spine and glues small bands across it.", "Then she glues this onto the leather, right next to the cardboard.", "Using the bone folder again, she presses the leather down.", "After adding a second cardboard for the back cover, she glues and folds over the edges.", "Then she makes two swift incisions to remove a triangle of leather.", "This produces perfect corners every time.", "Next step-- to embellish the cover and spine with gold-embossed decorations and lettering.", "She lays down a sheet of genuine gold foil and hot-stamps the design onto the surface.", "After attaching the bound pages with leather hinges that match the cover, the book binder applies the finishing touch-- decorative paper on the inside covers.", "From such traditional styles to ultramodern fish-skin bindings, it's hard not to judge these books by their covers.", "Some of the finest tomatoes come not from the field, but from the greenhouse.", "When cultivating tomatoes indoors, producers can strictly control the growing conditions, so greenhouse tomatoes are more uniform in size, shape, and color than field-grown tomatoes.", "Some would argue that they taste better, too.", "This company grows large cluster type and smaller cocktail-size tomatoes.", "It also produces a kit containing tomatoes, a pouch of italian spices, and a bruschetta recipe.", "In this hydroponic greenhouse, the tomato plants grow in a substrate rather than soil.", "The substrate is a block of coconut-shell fibers that retains and drains water very well.", "Greenhouse workers mix fertilizer primarily out of powdered iron and calcium nitrate.", "They dissolve these and additional chemicals in water, which they then dilute and store in tanks.", "Computerized fertilizer injectors shoot controlled amounts of the solution directly into the irrigation-system water supply.", "A new tomato plant takes 30 to 55 days to blossom, then another 8 weeks to produce fully ripened fruit.", "Each plant receives up to one gallon of fertilized water per day via an irrigation dripper.", "The irrigation system collects whatever the plant doesn't absorb, mixes it with fresh water, adjusts the fertilization, then re-feeds it to the plants.", "The task of pollination is left to a resident colony of bumblebees.", "The plants grow at an astounding rate of 8 to 12 inches per week.", "To train them upright so they won't get tangled with neighboring plants, workers twist each one around a nylon cord every week.", "Tomato plants grow to a height of more than 36 feet.", "That's taller than the greenhouse, which is why, once a week, workers lower the plants by 8 inches.", "The lowering process also lines them up at the same height, which makes harvesting much easier.", "The greenhouse temperature is 70 to 77 degrees fahrenheit during the day and 54 to 61 degrees at night.", "Artificial lighting simulates 18-hour stretches of sunshine.", "Thanks to these controlled growing conditions, greenhouse tomato plants, unlike field plants, are in continuous bloom.", "Every week, a new cluster appears at the top of each plant, while a cluster at the bottom is ready for picking.", "In its one-year lifetime, a tomato plant yields some 200 large tomatoes or 500 cocktail tomatoes.", "As conveyor belts move the tomatoes through the packaging area, workers separate the green ones from the ripe ones.", "Each shipping box must contain 11 pounds.", "Workers place the box on a tray scale and clusters of tomatoes on digital scales above it.", "A computer calculates which combination of clusters would total the target weight, then illuminates the light under those clusters to tell the packer which ones to put in the box.", "Once filled, the box is passed through an automated labeling machine.", "A camera takes a photo of the configuration, then guides an applicator to slap a code sticker on every tomato.", "Besides selling bulk tomatoes in the bruschetta kit, this company packages cocktail tomatoes in two formats-- loose and still on the vine...", "Giving greenhouse-tomato lovers a few tasty options.", "Hurricane-proof shutters prevent violent winds and flying debris from shattering windows.", "Not only can breaking glass cause injury and let winds enter and wreak destruction inside, but the difference between indoor and outdoor air pressure can cause the roof and walls to collapse.", "Roll-down shutters move vertically...", "Whereas accordion shutters consist of two sections that move sideways.", "To make the accordion style, they cut stacks of blades to the height of the customer's window.", "Blades are interlocking aluminum strips manufactured for the shutter factory by a supplier.", "Workers assemble enough to build two shutter sections that cover the width of the window.", "These two sections are called vertical stacks.", "They punch holes in the last blade of each stack for a locking mechanism.", "These two blades are called center mates because they overlap at the center of the window and lock together.", "They slide each center mate into its respective vertical stack.", "The next step is attaching nylon bushings and wheels, which ride in horizontal tracks installed at the top and bottom of the window opening.", "Each center mate has vertical locking pins.", "Activated by a thumbscrew, these pins slide through a hole in the track to lock the shutter open or closed.", "The horizontal slats of a roll-down shutter are made of the same material as the accordion shutter's vertical blades.", "After cutting the slats to the width of the customer's window, workers assemble enough to cover the window's height.", "These slats have a different type of interlock than the accordion shutter blades, but they connect the same way.", "The tongue edge of one blade slides into the groove edge of the next.", "Nylon locks prevent the slats from disconnecting.", "After hammering the locks into place, they crimp the edge of each slat.", "The connected slats will later be coiled around a motorized tube inside the shutter's aluminum housing.", "A technician installs a ball-bearing assembly in one side of that housing...", "Then a safety plate to prevent the slat roll from shifting sideways.", "On the other side, they install a plate with protruding screws to which they mount the motor.", "Next, they install a safety plate to prevent the slats from catching on the motor's power cord.", "On each end of the motor, they fit spacers...", "Then, over the motor, a roller tube.", "They insert a connecting shaft, which attaches the tube to the ball-bearing assembly on the other side.", "All these steps assemble a motorized axle around which the roll of slats will wrap.", "Once a quality-control check ensures it operates flawlessly...", "They close off the back of the housing with an aluminum cover.", "Working from the front of the housing, they rivet plastic rings along the length of the tube.", "These help muffle the noise the slats make as they roll and unroll.", "Workers rivet slat hangers to the roller tube.", "They slide the first slat onto these hangers.", "Then they slide the slat roll onto that first slat.", "The slat edges run in vertical side rails, which installers mount in the window opening.", "Now for a last round of quality-control testing.", "Workers lift and lower the shutter in manual mode, as well as by remote control.", "When everything works perfectly, the shutters are subjected to one final test to ensure they can handle everything that a hurricane can muster." ]

{ "things": [ "Barber Chairs", "Sewage Pumps", "Bimini Boat Tops", "Diesel Filters" ] }

[ "The reclining barber chair was invented in america in 1878.", "At the time, it was a grooming breakthrough.", "With a chair that leaned back and moved forward, the barber could shave the customer with greater precision, and when wielding a straight-edged razor, precision is definitely a good thing.", "The barber chair is the original easy chair.", "Just sit back and enjoy the recline.", "The client doesn't need to position himself for a shave.", "The chair does all the moving.", "It even lifts and swivels.", "Production starts with the base of the chair.", "An employee places a flat, round piece of steel in a two-part die.", "The die comes together and applies pressure to take the steel from flat to domed.", "The domed chair base then spins as an abrasive wheel etches a brushed finish onto the surface.", "Next, the worker tucks the end of a strip of steel between rollers and turns them to curl the steel into a sleeve for the hydraulic chair lift.", "He slides a piece of plastic into grooves on the ends to close the steel sleeve.", "Then he slides it onto the chair lift pump.", "He places a large trim ring on the end of the pump and sets the domed chair base on top.", "Screws secure the base and chair-lift assembly.", "With the assembly now right-side-up, he attaches a u-shaped foot pedal to the pump.", "Production then moves to the construction of the actual seat.", "The worker glues several sheets of russian birch and staples them together.", "She continues to layer until the birch is nearly an inch thick.", "The last layer is thick plywood.", "It's been cut to accommodate a steel frame.", "She glues and staples the plywood to the layered birch.", "Then it's into a press for the chair's seat, back, and arms.", "It bends the parts to a gentle curvature that will make the chair more comfortable to sit in.", "With a hot stamp, the worker brands the company name and logo into vinyl upholstery.", "He places the wood chair back into a bed of cushy foam.", "He pulls the edges of the foam tightly to the wood and staples it.", "He trims the excess.", "He covers the chair back with the pre-sewn vinyl upholstery, and it's a snug fit.", "Next, he gets a hand from a pneumatic device.", "It holds the chair part in place as he staples the upholstery to it.", "He trims the vinyl for a clean edge.", "He checks the fit, and, once satisfied, he moves on to the chair arms.", "He locks an arm in a clamp and installs the chrome end piece.", "The chrome resists wear better than vinyl does-- important on this gripping part.", "The crew attaches the steel chair frame to the underside of the upholstered seat.", "They screw the arms onto the frame.", "They install the pneumatic mechanism that makes the chair recline.", "They screw the upholstered chair back to the steel frame and link the recliner mechanism to it.", "They test the recline and incline functions.", "The footrest is next.", "They then pump up the lift shaft and transfer the upholstered chair to it.", "They close the back of the chair with an upholstered panel, and finally, they give the customer a place to rest his head.", "With the headrest installed, this barber chair is ready for customers.", "Time spent reclining in it will no doubt leave the client looking and feeling refreshed.", "A sewage pump is part of an underground operation to dispose of human waste.", "It is essential equipment when sewage must be pumped to a septic system or sewer line at a higher underground location.", "Working below the surface, sewage pumps take care of unpleasant business.", "When it comes to sewage, people understandably prefer to flush and forget.", "The sewage pump helps make that possible.", "It is the number-one way to move waste.", "When the sewage reaches a certain level upon discharge, the pump's floating sensor activates a switch to start pumping.", "Then it's on its way to a septic system or sewer line, ensuring that sewage receives the necessary treatment.", "They make the sewage-pump housing from a rugged cast iron.", "A chain conveyor takes the housing parts for a rinse and an application of a chemical that slightly etches the surface in preparation for finishing.", "The journey continues through a big dryer that removes residual moisture.", "The parts now head into the spray booth for a finish that will protect the surface.", "The conveyor delivers a negative charge to the parts, causing the positively charged powder finish to gravitate to them.", "It completely coats the parts, and they travel through an oven to bake on the powder finish.", "Next, workers move the pump-housing units across to a spinning, abrasive disk.", "This grinds the edges flat to allow for a tight seal to other parts.", "Here's the housing before grinding, and here it is after.", "He places a gauge under the part in several places to ensure that it's completely even.", "Next, a tool machines the part of the housing that holds the stator, the stationary part of the motor.", "It carves the opening so that the stator will fit to it and also align next to the motor housing.", "Using a drill press, a worker cuts a thread into another part of the pump.", "This will allow it to connect to a discharge pipe.", "The parts are now ready for assembly.", "A worker presses the carbon half of a seal for the rotor shaft into place.", "He lubricates the rotor shaft and inserts it into the pump housing.", "A blast of compressed air removes any contaminants.", "And he installs the ceramic half of the rotor-shaft seal.", "Next, he screws the impeller to the rotor shaft.", "The impeller will move sewage from the pumping chamber to the discharge pipe.", "He installs an o-ring around the opening to the motor.", "He inserts the stator...", "And screws it into place.", "He connects lead wires to terminals in the motor housing and sets it in place.", "He runs the power cord through the motor housing and tightens a seal around the cord.", "He attaches a metal guard to give the pump float adequate clearance, then seals the motor housing and wires the pump switch.", "He screws the switch case to the housing.", "A worker plugs in the pump to test for any shorts in the electrical components.", "The pump passes all the tests.", "It's ready for the float that actuates the pump switch.", "A piece has been cut out of this pump to give us an inside look at the sewage pump and its operation.", "As waste water rises, so does the float, and it activates the switch to turn on the pump.", "When the sewage subsides, the float lowers and switches off the pump.", "Next, the pump takes the plunge in a test tank to ensure that it can handle the pressure and that it meets all the performance standards.", "Once the computer gives the sewage pump the green light, it's on its way to a septic system near you.", "Built for a life of effluence, this sewage pump is now ready to go with the flow.", "There are unofficial claims that bimini boat tops were named for the sun-drenched bimini islands of the bahamas.", "The open-sided canvas tops are usually retractable, and beginning in the early '60s, were developed to offer boaters protection from the sun.", "Out on the open water, bimini boat tops provide shelter from the rain and shade in the sun.", "Their durable and versatile materials withstand rugged sea breezes and intense u.v. rays while providing ample headroom for boaters.", "A worker measures a piece of anodized aluminum tubing for the exact leg height needed for each custom-made bimini boat top.", "Then he cuts the tubing to the dimension needed for each boat.", "They use aluminum and stainless steel because they don't rust.", "The worker begins bending the frame of the boat top.", "The eventual roof support is on the floor while he holds the leg height in his hand.", "He must be careful to not overbend.", "The final angle is about 88 degrees.", "The worker crowns the tubing, a process that puts a rise in the center of the roof and pulls the legs inward.", "Each bimini boat top is made of three bows of different heights.", "The front is shorter than the back, while the center is usually about 40% of the back leg height.", "Workers now assemble the bows.", "They attach eye ends and jaw slides to form rudimentary hinges.", "They now unfold the assembled tubing using the precise measurements of a customer's boat.", "They simulate the final shape of the boat top by using tape to spread the bows to exact widths.", "Once the bows have been spread and the distance is measured, they can see the shape of the final boat top.", "All that's left is installing the roof itself.", "The roof is made of acrylic canvas that is both water- and fade-resistant.", "And there are plenty of colors to choose from.", "The patterning process begins.", "Once the roof is cut, a worker stitches the roof panels.", "Workers spread the cut panels over the bow setup to finalize the roof dimensions.", "The canvas fabric is clamped to the bow setup as a worker marks the edges on the outside of the fabric.", "The roof is made in panels.", "It usually takes two or more panels to complete a roof, depending on the size of the boat.", "Once excess material has been trimmed off, the worker begins stitching.", "She turns the outer edge of the roof and uses a straight stitch.", "She works on the sides of the canvas roof before the ends.", "The worker now patterns the listing, which is a pocket through which the bow will be inserted.", "Here's what the listing's raw pattern looks like once measured and cut.", "She places the finished listing on top of the panel and stitches it to the end of the roof panel.", "The stitching process is key to the durability of the boat top.", "She turns the roof over so the listing is backwards.", "It's actually sewn on inside-out and then turned over.", "She stitches the entire length of the listing closed...", "Then the company's identification tag.", "Workers now insert the pieces of tubing into the listings of the canvas roof.", "First, they push the rear bow all the way through.", "Once the rear bow is in place, they prepare to insert the center and front bow of the boat top.", "They unfurl the remainder of the roof and position the center bow on the center listing.", "Gradually, they slide the tubing all the way through the center listing.", "With the front bow inserted, the bimini boat top is almost complete.", "An employee inspects the boat top for any defects.", "Once installed, the bimini boat top can either be tucked away in its boot or opened up and held in place by front straps.", "For the life of your boat, a well-maintained bimini boat top has it covered.", "Running an engine on diesel fuel is efficient, but it emits smelly, black exhaust, soot, leftover carbon that didn't burn off in the combustion process.", "To prevent exhaust emissions from polluting the air, diesel engines and diesel-powered generators need powerful filters.", "This self-cleaning diesel filter traps engine-exhaust soot and burns it off by heating the filter elements.", "This effectively completes the combustion process.", "At the core of those filter elements are heating strips made of steel fiber, which is like dense steel wool.", "But the steel is a special mix of alloys resistant to high temperatures and corrosion.", "Each heating strip goes into a machine which repeatedly folds it up then down, pleating it like an accordion.", "The thick steel fibers are what trap the soot particles as the engine exhaust flows through.", "An electrical current heats these conductive fibers, burning off the soot regardless of engine-exhaust temperatures.", "Using nickel crimps, workers connect-- depending on the filter size-- up to seven pleated strips per filter element.", "They press the crimps securely into the steel fiber with a press.", "They attach a different type of crimp at the far ends.", "This type has a tab with three holes for the electrical connections.", "Next, they bend the assembled strips into a circle and place them inside a perforated steel housing.", "A temporary cardboard spacer creates a gap between strips and housing to insulate against short circuits.", "The electrical-connection tabs on the ends fit through slots at the front.", "An insulating block made of mica, a non-conductive mineral, goes behind the tabs, followed by steel-fiber spacers.", "All this sets up a clear and strong conductive path from the power source to the strips.", "They fasten the insulating block to the housing.", "Then, using tweezers, they place a mica spacer in between each pleat.", "This prevents the pleats from touching each other and causing a short circuit as the electrical current passes through the strips.", "They place a spacing stick inside each pleat.", "This is just temporary, to size the pleat's width uniformly until they're cemented permanently in position.", "To do that, workers pour ceramic cement into a circular bottom plate made of perforated steel.", "The perforations ensure better bonding.", "They spread the cement evenly across the plate...", "Then position a stainless-steel tube in the center to connect this plate to an identical plate on top.", "They carefully place the strips into the cement and position the top plate...", "Then add a weight to hold it down while it goes into an oven at 85 degrees to cure the cement.", "45 minutes later, they take it out of the oven and remove the top plate.", "They also remove the spacing sticks and cardboard spacer, which are no longer required because the spacing is now permanently set in cement.", "They repeat the cementing process with the top plate.", "After a final four hours in the curing oven, the electrically heated filter element, this diesel filter's key component, is completed, and the main assembly can begin.", "The larger the filter, the more filter elements it contains in its stainless-steel housing.", "For this mid-sized model, technicians stack four sets of six elements then connect electrical cables to the tab holes of each one.", "Next, technicians install a flow-control valve for each stack.", "When activated, the valve reduces exhaust flow to that stack, enabling the system to automatically clean elements by electrically heating the strip.", "An internal computer manages the cleaning cycles.", "It uses sensors that detect soot accumulation in the elements, isolating and cleaning one or multiple elements at a time.", "On the front, techs mount the inlet flange through which the dirty diesel exhaust enters the filter...", "On top, the outlet flange through which that exhaust exits soot-free." ]

{ "things": [ "Escalator Handrails", "Highlighters", "Guitar Strings", "Wigs" ] }

[ "Today on \"how it's made\"...", "Escalator handrails...", "Highlighter pens...", "Guitar strings...", "And wigs.", "The escalator was invented over 100 years ago as an amusement park ride.", "The moving staircase was soon equipped with a moving handrail for safety reasons, but those early handrails were driven by oily chains, leaving passengers with greasy hands.", "We get a cleaner ride on today's escalators, and if we want thrills, we try a roller coaster.", "An escalator's handrail moves at the same speed as the stairs.", "This makes the trip up safer because you have something to hold on to the entire way.", "To make an escalator handrail, a machine called an extruder pulls synthetic rubber up into it.", "A turning screw inside the extruder forces the rubber through a die the way a pasta maker squeezes out spaghetti.", "4- to 6-inch-wide rubber strips roll out into a tank of water to cool because the heat from the extruder could alter their molecular structure.", "Now the rubber strips move over rollers that are part of a mechanical measuring system.", "There's a little indicator on the roller that gauges the width and thickness of the rubber as it moves across.", "Over at the splitter machine, small round knives slice rubberized cotton the same width as the rubber strips.", "Then a mechanical puller unrolls material from four different spools.", "There are two streams of rubberized fabric-- one stream of the synthetic rubber which came out of the extruder earlier and one of rubberized cable wiring.", "They merge and stick together as they travel over a big steel roller.", "An unwinder peels away a plastic liner from the now four-plied strip.", "Next, a worker places a piece of rubberized fabric and one of synthetic rubber on either side of the four-plied strip.", "He presses everything except the strip of rubber around a u-shaped aluminum former.", "With a piece of steel, he bears down on the shape so the layers stick together.", "Then he brushes tack cement on the outside and pulls that piece of synthetic rubber at the bottom up around it.", "He folds the rim down, and, using a hand roller, he seals its edges.", "Now the handrail has taken shape, but it's not strong enough, so a worker places it in a molding press.", "He positions a steel form inside the handrail so that it holds its shape.", "The top part of the mold lowers, and the handrail bakes under high pressure at 350 degrees fahrenheit.", "10 to 15 minutes later, the mold lifts, and a chemical reaction called vulcanization has occurred.", "The layers have been laminated, and the handrail is now strong enough.", "The last step is to trim away the flash or excess material.", "Here's the latest way to make an escalator handrail.", "A puller unwinds brass-coated steel wires from spools, drawing them, along with thermoplastic urethane and polyester fabric, through the dies of an extruder.", "What comes out is a strip of plastic-encased wires and sliders.", "The handrail shape passes through measuring devices that check its dimensions.", "Now they splice the ends of two plastic handrails together to form an endless loop.", "Using a roller, a worker presses the wires and plastic sliders of the inner carcass together.", "As he rolls, he blasts hot air into the splice with a heat gun.", "This softens the plastic so that it melds together.", "He covers it with a piece of thermoplastic urethane and, again, uses a heat gun to join the pieces.", "He wipes it clean with alcohol.", "Then he heats it up in a mold for a minute or two.", "The spliced section melts together, and then cool water hardens it.", "There's no seam line where the handrail could break.", "It's just one long, continuous piece.", "And that's the inside story on the escalator handrail-- something to think about when you're on your way up.", "The highlighter pen was invented in the 1960s simply to get your attention.", "When text is shaded with transparent, vivid inks in hot pinks or warm yellows, our eye goes directly to it.", "Marketers have always known that color has impact, and it's a principle highlighted by these pens.", "Highlighters come in lots of shades and colors-- even neon.", "This is how a highlighter pen gets its start.", "A vacuum siphons plastic pellets into this container.", "The red ones will tint the whole mix as it melts inside a heating tube.", "A mechanized steel screw pushes the melted plastic into pen molds.", "The force applied is equal to the weight of 350 elephants.", "Cooled by water, the newly-molded pen barrels spill into a container below.", "Now some clear-colored pen barrels drop onto a conveyor track, and ink reservoirs that look like pieces of chalk but are made of polyester drop down a shaft, and a robotic arm thrusts them into the plastic barrels.", "The back-end plug goes in the same way.", "The plugs fall to a robotic arm, and it pushes them into the back of the pen.", "Now a chemist drops a concentrate of dye into a beaker of water.", "Just over 1/3 of an ounce or 10 drops is enough to turn it fire-engine red.", "A humectant, already in the water, will keep the ink from drying out when it's in the pen.", "Next he measures the ink's thickness.", "He lowers a steel probe into it, and the probe turns.", "A gauge measures the speed.", "If the probe turns too fast, it means the ink is too thin.", "If it revolves too slowly, then the mix is too thick.", "At four revolutions per minute, the ink is just the right consistency.", "A vacuum pump sucks the ink into six-inch steel needles, and a robotic arm pushes the needles into the polyester reservoirs, injecting them with ink.", "Now we arrive at the next part of assembly.", "A combination of mechanical vibrations and compressed air drive a conveyor belt carrying the pen nibs.", "The nibs fall into the clutch of a mechanical claw which drops them to a circular pusher.", "It shoves the nibs onto the pens, and they interlock.", "The impact floods the reservoir inside the pen with ink.", "Now it's time to top it all off.", "A conveyor transports caps to a mechanical gripper.", "The gripper slides them over the nibs.", "Over on another assembly line, they're making a three-in-one marker.", "A conveyor bowl funnels smaller ink reservoirs into a shaft, and they drop to a robotic arm.", "The arm stuffs the reservoirs into the small barrels, and then a needle injects them with ink, quickly saturating the reservoirs with vibrant color.", "The next robotic arm shoves a receptacle onto the barrel, and then another robot presses a polyester nib onto it.", "A robot now slips a hood-like cap over the nib.", "Another mechanical arm suctions up the fuchsia-colored mini markers and transfers them to a triangular case.", "Down the line, another suctioning arm picks up a red mini marker and deposits it in the triangle.", "A steel probe presses it in.", "Finally, a yellow-colored marker completes the triangle.", "Now a robot uses an electrical charge to pick up metallic confetti.", "When the charge is turned off, the confetti drops into the triangle, adding some glitter.", "Next a suctioning robot drops the top part of the triangle onto the lower case, and a metal cylinder presses it shut.", "Another suctioning arm carries the three-in-one marker to a conveyor belt which unloads it into a box.", "This three-in-one highlighter makes it easier to color-code text-- a different color for each theme.", "Now an electrical conveyor moves the highlighters to a mechanical arm.", "The arm flips it around, positioning it for the next step.", "A squeegee silk-screens a logo onto it.", "I wonder how they came up with that one.", "Now the highlighters enter an ultraviolet-light chamber.", "The light bonds the ink to the case.", "And finally, the ultimate test-- plastic grippers guide markers as they make circles.", "700 to 1,000 circles means this particular production line will definitely stand out.", "Playing the guitar is all about vibrations.", "The guitar uses vibrating strings to generate the tones that the audience hears.", "Strings under tension vibrate at a specific frequency or pitch, so if the song that you're hearing is in tune, it's because those guitar strings are vibrating correctly.", "a good set of strings is behind many a soulful tune.", "They're an important part of a guitar's sound.", "To make a guitar string, they start with a steel core wire that they examine under a zoom stereomicroscope.", "They magnify it 100 times, looking for flaws in the hexagonal wire.", "Next, they measure the core wire's diameter with a digital micrometer.", "It has to be just the right size.", "Now they coil the wrap wire made of nickel-plated steel around posts on the instron testing machine.", "This machine stretches the wire until it breaks.", "It's a test of its ability to perform under tension.", "A computer measures the distance and the amount of load the wire was under before it broke to determine how much tension this string can take.", "Now the core wire undergoes a twist test.", "They loop the wire onto a hook in a machine called a torsion tester.", "It spins rapidly, twisting the core wire until it breaks.", "This is a test of the wire's strength and elasticity.", "These plastic hoppers are full of ball ends.", "This machine is called a ball-end sorter.", "Hollow pistons move up and down, selecting one ball end at a time.", "This ensures that only those of the proper size will get through.", "The ball ends shoot out of the pistons into a bucket underneath.", "From here they'll go to the core-string machine.", "A mechanism places the ball ends on a pin as they drop from a hopper.", "Rollers feed the core wire into a clamping guide which aligns it with the ball end.", "Then the pin spins, twisting the wire into a neat loop around the ball end.", "This is the twisting action in slow motion.", "The core strings with the ball ends now attached drop into a repository.", "Then a worker hooks a ball end with its core wire onto the string winder, and he loops bronze wrap wire around the core wire.", "A string-winding carriage guides the bronze wire down the length of the core wire as it wraps around.", "The electrically powered winder spins the core wire, and it's that action that grabs the wrap wire as the carriage ensures that it gets wrapped neatly.", "Computerized sensors monitor the speed that the string is wound at, as well as the tension.", "The winder applies a critical amount of tension as it wraps the bronze wiring around the core.", "They're bundled up like straw, 144 wires to the bunch.", "Guitar strings are also made from nylon.", "They hook the nylon core material onto a winder, pulling it down from a big spool.", "Next, they loop silver-plated copper wrap wire onto the nylon.", "The hook spins, and this coils the wrap wire around the nylon string binding it.", "Again, a carriage system, run by an electric motor, ensures that everything falls into place.", "A worker removes the strings and hangs them on a rack.", "Gravity causes the strings to slide into a station where workers coil them and then place them on a conveyor belt.", "Further down the line, another worker puts them in a bag that has a gas-neutralizing barrier built into the plastic to prevent corrosion.", "And now these strings are ready for some playing.", "Throughout history, wigs were status symbols-- hence the term \"bigwig\".", "One early wig-making technique was to use goatskin to simulate a scalp and then hook hair into it with an embroidery needle.", "Today, animal skin is no longer used.", "These days, wigs can look so real that no one would notice.", "To make a custom wig, a wig master measures the client's head from all angles, because heads come in many shapes and sizes.", "He wraps her head in cellophane, twisting it just under the earlobes.", "Next, he sticks filament tape all over the cellophane wrap.", "He layers it four times to make a cast.", "He lifts the tape and cellophane cast from her head and places it on a wig block, a head shape made of canvas or wood.", "Using a grease pencil, he traces around the cast, making a pattern of the client's hairline on the wig block.", "The wig master then cuts pieces of plain blue paper.", "He pins it on the wig block within the pattern lines.", "The paper will prevent light from reflecting into his eyes as he works.", "Now he places a large-sized polyester-and-cotton lace on the block and cuts it to pencilled outline.", "He pins a finer lace from front to back, pleating the edges with pins.", "He pulls open a drawer full of real and fake hair, and it's hard to tell the difference between them.", "He chooses a tail of synthetic hair labelled \"venetian blond\".", "Pieces of pink and orange synthetic hair will be blended into the venetian blond tresses to create dramatic highlights.", "This is the tool for the job.", "It's a giant comb with rows of sharp steel teeth.", "It's called a hackle.", "The wig master places the venetian blond synthetic hair between the teeth of the hackle and sets the bright pink and orange locks on top.", "Now he repeatedly drags the hair through the hackle.", "He loses some strands in the comb, but those are usually the weaker ones.", "This is called hackling, and the action gets progressively more vigorous.", "He twists and twirls the tail as he pulls it through the hackle.", "This is actually dangerous work.", "One wrong move and he could pierce his hand on the barbed comb.", "Once the hair is blended, he cuts it in two.", "Then he presses the hair into little metal pins on a leather holding card.", "The pins on a top card interlock with the bottom one.", "He pulls hair out of the holding cards a few strands at a time.", "With a small needle that looks like a fishing hook, he knots the strands into the lace beginning at the nape.", "This is called ventilating.", "It's very similar to rug hooking.", "In fact, it may be why toupees are often referred to as rugs.", "Ventilating is labor-intensive.", "He spends a minimum of 50 hours knotting the thousands of strands that it takes to make a wig.", "Partway into the job, he combs out any tangles and flounces the hair to make sure it moves naturally.", "Wigs for film and tv are usually made by hand rather than machine because the result is more authentic-looking.", "Because the camera tells all, the wigs need to look as real as possible.", "He weaves the front of the wig one strand at a time, because the front hairline always gets the most scrutiny.", "Now it's time for the fitting and the transformation.", "The wig needs a little styling...", "And he trims the ends.", "He cuts away the extra lace, and voilà.", "She's ready to let her synthetic hair down and get into her new role." ]

{ "things": [ "Racing Leathers", "Evaporative Cooling Towers", "Wood Rocking Chairs", "Wire Wheels" ] }

[ "With no car frame around them, motorcycle racers look to their clothes for protection.", "One-piece suits called racing leathers provide it.", "They're made of padded leather, and the design is form-fitting and aerodynamic.", "Motorcycle racing leathers are a kind of body armor.", "Equipped with padding and airbags, the suit is a protective shell.", "It must fit the rider like a second skin.", "To achieve this, racing leathers are usually custom made by a team of specialists.", "They take over 40 measurements as the racer assumes different poses.", "The pattern maker types the measurements into a computer.", "Special software creates a pattern for the suit.", "She assembles the pattern parts on the screen to ensure they match up and then sends the drawings to a printer.", "It prints the life-sized patterns onto large sheets of thin tracing paper.", "A member of the team then sprays the backs of the paper patterns with adhesive.", "She presses the patterns onto sheets of cardboard.", "She cuts out the cardboard following the designs on the paper.", "The cardboard backing gives the patterns a more substantial structure.", "Before cutting the leather, they clamp a sample in an automated tool that moves it repeatedly across a piece of sandpaper.", "This confirms that the leather is strong enough to withstand significant abrasion.", "They apply graphics to the patterns to estimate the placement, and then they're ready to cut.", "The cutter carves into the white leather with a thin blade.", "He follows the lines of the pattern and leaves a generous margin.", "The parts will be cut more precisely later.", "He transfers the leather panels to a large sheet of paper stretched across the bed of a printing machine.", "Light glue applied to the paper keeps the leather pieces in place during printing.", "The printer's jets spray designs onto the parts.", "It uses inks that have been specially formulated for leather.", "The inks start to dry immediately, but they leave the printed leather to set overnight for a full cure.", "Next, using a hinged scissor frame, they stretch and expand an elastic fabric.", "A member of the team sprays adhesive onto the back of a leather panel.", "She presses a piece of kevlar onto the leather, and this reinforces it.", "She then places the kevlar and leather panel on the fabric that's still pulled tight in the scissor frame.", "She stitches the leather and kevlar part to the stretched material, creating a ribbed pattern.", "She now cuts the panel to its final dimensions.", "The elastic fabric contracts, causing the leather to pucker into accordion-like folds.", "A seamstress stitches the ribbed panel to the back of the motorcycle racing suit.", "It takes over 200 parts to achieve the desired shape and fit.", "Some of them, like these shoulder protectors, are made of molded plastic and foam.", "They're designed to dissipate the force of an impact.", "Meanwhile, at a test station, they slam weights into a molded knee pad and measure the energy that penetrates.", "Now a member of the team inserts a pair of pads into suit leg pockets and secures them with velcro.", "The suit is ready for airbags.", "She installs them over the shoulders.", "She tucks the microprocessor and gas inflation canisters in the hump.", "This is an aerodynamic part at the back of the suit.", "She connects the sensors and powers up the airbags.", "L.e.d. lights on the sleeve illuminate, indicating that they're operational.", "With the leather suit complete, they sew a microfiber liner.", "The liner wicks sweat away from the body, making the suit cooler to wear.", "The racer suits up and tests the fit, and they make any final alterations.", "These racing leathers are now ready for the thrills and spills of the sport.", "Evaporative cooling towers keep large buildings and industrial machines cool.", "Circulating liquid carries the excess heat to the cooling tower, typically installed on the roof.", "The tower uses cold water to cool that fluid, then transfers the heat to the atmosphere through an evaporation process.", "Pumps move the fluid carrying the excess heat through the cooling tower's closed-circuit coil.", "Nozzles spray the coil with cold water.", "The spray water absorbs the heat, and the cooled fluid returns to the building.", "Fans blow air onto the now warm spray water to evaporate just enough to release the heat.", "Then the cooled water loops back to the spray system, and the cycle repeats.", "Depending on the size, the coil is made up of as many as 56 circuits.", "A circuit is a zigzagged tube one inch in diameter.", "The mill forms a continuous straight tube from a strip of carbon steel.", "The rollers progressively curve the edges upward until they join at the top.", "The last station on the mill welds the joined edges together to form a continuous seam.", "Next, workers transfer the straight tube to a semi-automated tube bender, which forms it into a circuit.", "Depending on the size of the circuit, there can be as few as 6 bends or as many as 18.", "To make a circuit with 18 bends can require a straight tube that's over 300 feet long.", "Once all the circuits are ready, workers stack them on a frame, then weld the tube ends to the corresponding holes of a steel plate.", "They close up the plate with a cover called a header.", "After clamping the header in position, they weld it in place, forming a pressure-tight seal.", "The coil is now fully constructed and ready for testing.", "Technicians submerge it in water, then pump air through at high pressure and look for bubbles, which would indicate a leak in a circuit.", "If they do find a leak, they either repair or replace the circuit.", "Meanwhile, work is under way on the cooling tower's mechanical section.", "A computer-guided laser cutter prepares the steel panels that make up the section's rugged structure.", "Workers then bend the panels where required with a machine called a press brake.", "Then, they assemble the panels to build the structure.", "Meanwhile, another team has assembled the mechanical section's ceiling, which houses the fans.", "Workers lower this onto the structure.", "Inside the mechanical section, they install the belt that links the motor's pulley to each fan pulley.", "After tightening the belt screw with an impact wrench, they test the fans.", "Meanwhile, the coil has been dipped in molten zinc to make it corrosion-resistant.", "Workers mount it next to the cooling tower's mechanical section.", "They cover it with a steel housing and install the water-spray system on top of it.", "The sprayed cold water absorbs the heat from the fluid circulating through the coil.", "The fans then cool the water by evaporation as it flows downward through a bundle of pvc sheets.", "The machine first heats the pvc to soften it, then stamps it with the mold plate.", "This imprints a proprietary pattern of peaks and valleys.", "This pattern is the secret to the evaporative cooling process because it moves the air and spreads the water in a way that maximizes efficiency.", "Workers stack the sheets on pole supports to construct a bundle of 300 sheets.", "After placing the bundle in a housing, they install it over a basin.", "This basin collects the cooled water before it's pumped back up to the sprayers to repeat the cycle.", "This completes the cooling tower's lower module.", "They now mate it with the upper module, containing the fans, coil, and spray system.", "This evaporative cooling tower has more than 300 times the capacity of a typical residential air-conditioning system.", "Now, that'spretty cool.", "The rocking chair was invented back in the 18th century, when when people first thought of putting skates, or rockers, on the bottom of chairs.", "The tilting movement it produces reminds us of a cradle or a rocking horse, which might be what makes rocking chairs so comforting.", "These stained jumbo rockers are caned in a herringbone pattern with indonesian rattan vine.", "22 pieces of solid appalachian red oak form the frame and the base of these rocking chairs.", "To start, the carpenter connects the tenon joints of the stretchers to the mortises of the back frame and hammers them in place with a rubber mallet.", "A caner drains a coil of binder cane, which is soaked overnight to make it more pliable while weaving the back and seat of the rocking chair.", "She uncoils the rattan vine threads and starts wrapping the back frame from bottom to top.", "The wrapping and weaving process for each chair lasts about eight hours and requires about 2,000 feet of rattan vine threads.", "When the caner reaches the end of a rattan vine, she fastens a new coil to the first one.", "She staples the threads together and closes them tight with a pair of needle-nose pliers.", "She continues wrapping the back frame.", "She tightens the wrapping around the frame, leaving no gap between the cane strands.", "She then tucks the final strand underneath one of the rails.", "She now starts the weaving process moving from left to right, using the wrapping as a base grid for the pattern.", "Each thread passes over three, then goes under three.", "She turns the frame over to weave the back of the frame in the same fashion.", "The challenge is to keep the weaving straight and sleek to give it the classic herringbone finish.", "A carpenter attaches side stretchers to the front posts, which are already assembled to the front rounds.", "He hammers the pieces in with a rubber mallet and assembles the seat frame with the back posts.", "There's no need for glue.", "The seat caning will solidify the rocker's structure.", "A caner uses the same rattan vine that was used on the back to wrap the seat frame.", "He makes sure there are no gaps between the strands of cane before he starts weaving the herringbone pattern.", "He weaves the over-under pattern in the center of the seat, where there's more slack in the wrapping.", "Then he pushes the threads up with a wooden wedge to tighten the caning as much as possible.", "Straps reinforce the structure of the chair before the seat frame is caned.", "To ensure authenticity, a carpenter brands the left armrest of each chair with the original branding iron used by the company since 1875.", "He hammers the armrest into the back post.", "Then he aligns the spokes of the front post with the hole in the armrest.", "A clamp keeps the back and front post aligned while he inserts the armrest.", "A wooden wedge in the spoke prevents the armrest from disconnecting from the front post over time.", "The carpenter hammers it in with a steel hammer.", "The wedge replaces the need for glue and ensures a snug fit between the armrest and the front post.", "The carpenter secures the armrest to the chair by drilling a solid brass carriage bolt through the back post.", "With a belt sander, he levels the wedge and front post with the armrest and makes it smooth to the touch.", "Before the runners, or rockers, are assembled to the base, the carpenter stains the chair.", "The oil-based stain protects the wood and brings out the natural grain of the solid oak frame.", "The stain is then sealed with two coats of clear varnish that will endure high humidity levels, sun, and climate changes.", "The carpenter assembles the runner to the base and measures the distance to the front post.", "This ensures an even rocking movement on every chair.", "He fastens them with brass carriage bolts.", "The finished chairs will endure the test of time and provide comfortable seating options for both indoors and outdoors.", "Wheels with wire spokes ruled the highways until the 1970s, when they were replaced by cast alloy ones.", "But factories still make wire wheels for the classic car market and for drivers who want to use them to customize their ride.", "Wire wheels suspend the weight of a car with flexible metal spokes arranged in a specific geometric pattern.", "They start with an aluminum alloy disc.", "A factory worker clamps the disc in a metal spinning machine.", "This machine shapes metal as if it were a piece of clay.", "It spins the disc at a high speed, while a series of tools press it to a round form.", "It takes 20 minutes to transform the flat disc into a wheel rim, complete with a bead for the tire.", "The process also causes the metal to undergo molecular transformation, and it becomes stronger.", "After polishing, a worker moves the rim under a tool that punches dimples in it.", "The dimples will accommodate nuts that will be used to secure the spokes.", "He drills into the dimples to create holes for attaching the spokes.", "He angles the holes slightly so that the spokes sit correctly.", "He stamps the wheel's design number and other identifying information into the outer edge of the wheel rim.", "By now, the wheel's steel centerpiece has also taken shape.", "An employee turns it for even spacing, as a tool repeatedly punctures it.", "This creates rows of small holes in both the inner ring and outer flange.", "He then drills those holes larger to prepare for the spokes to be assembled to the part.", "At the next station, a worker inserts spokes into a press that bends its ends with hooks.", "The angle of the hook varies depending on the part of the wheel the spoke is to be assembled to.", "He adjusts the settings on the press to achieve the different bends.", "Then it's over to an automatic blade that cuts the spokes to length.", "This also varies.", "They cut outer spokes longer and inner ones shorter.", "He now places the ends of the spokes in a device that rolls them against a cutting block.", "It carves threads in the metal in mere seconds.", "With the spokes now hooked, cut, and threaded, the wire wheel is ready for assembly.", "The employee hooks the appropriate spokes into the holes in the centerpiece.", "He places the aluminum rim around the centerpiece.", "He attaches the threaded ends of the spokes to the rim using steel nuts that fit into the tapered holes.", "He screws them loosely into place.", "He configures the spokes in a criss-cross geometric pattern, specified by the engineers.", "This pattern is designed for strength and flexibility, but it also gives the wheel a visual appeal.", "Once he's laced all the spokes from the centerpiece to the rim, he tightens the fittings.", "This secures the assembly, but it's not the final torque.", "They now transfer the loosely assembled wire wheel to a shaft and turn a crank to lower the centerpiece within the rim.", "This brings the spokes into the correct position, and a worker tightens them substantially.", "All 72 of them.", "He does the final tweaking by hand.", "Seven hours in the making, this wire wheel is now ready to roll.", "With the rubber tire attached, he secures the wheel to the car using a single large nut.", "It's called a knockoff nut because you simply knock it off to change the tire.", "It's just one of the things that makes the wire wheel a classic choice." ]

{ "things": [ "Halogen Bulbs", "Cellulose Insulation", "Aluminum Ladders", "Bamboo Fly Rods" ] }

[ "Today, on \"how it's made\"...", "Halogen bulbs...", "Cellulose insulation...", "Aluminum ladders...", "And bamboo fly rods.", "Halogen headlights are an example of technological progress.", "The halogen bulbs throw cool, white light that mimics daylight, illuminating the road ahead.", "And because they're energy-efficient, they don't burn out too often.", "That's a plus when you're trying to keep your eyes on the road.", "To make a halogen headlight, mechanical jaws load three lead wires into a machine.", "A gripper moves in and bends the wires at the bottom.", "Meanwhile, a conveyer system feeds little glass rods to a burner.", "The softened glass is now pressed under either side of the lead wires, encasing them.", "Next, a welding head fuses tungsten coils to the lead-wire assembly.", "The coil is the filament, the part of the bulb that emits light.", "Over at another station, a mechanical arm loads a glass tube into a machine head.", "A burner aims a flame at the center to soften it up.", "Then mechanical heads pull the glass at both ends as the burner continues to fire heat at the middle.", "This creates a neck in the tube.", "Now mechanical arms position the coil-and-lead-wire assembly under the newly shaped glass tubes.", "Grippers lower the glass tube over them so they sit under the neck.", "Burners move in and encircle the glass at the bottom, softening it.", "Then a press seals the glass around the lead wires, which protrude from the bottom.", "Next, a test-- an electrode sparks the lead wires.", "When the capsule illuminates, it means there's ambient air inside that would interfere with the bulb's function.", "Vacuums at the top of the bulb suck out all the air and contaminants.", "Then nozzles spray liquid nitrogen onto the bulb.", "This freezes it inside and out, creating a pressure difference.", "That change in pressure pulls halogen gas into the bulb from a chamber above.", "Allowing no time for the gas to escape, burners heat-seal the bulb at the neck.", "The bulbs then cool as they move on a transfer chain.", "Grippers now load the bulbs into another machine.", "A pusher moves up and snaps a steel retainer around the bottom of each bulb.", "Meanwhile, another machine builds the base for the bulb.", "It pushes electrical contacts into the plastic receptacle.", "This is the view from the bottom.", "These prongs will eventually connect the headlight to the vehicle.", "Next, jaws flip the bases.", "They load them onto a tray on tracks.", "The tray delivers the plastic bases to a mechanical arm that installs metal retainers on each one.", "The bases slide forward, and the machine inserts the glass bulbs into them.", "But it's a loose fit.", "This machine aligns each bulb to its base.", "Jaws tilt and slide it into place, then a laser welds it together.", "This alignment is critical.", "Coils for the low-beam and high-beam mechanisms must be precisely positioned for the headlight to project the right light.", "Next, a series of claws pick up the bulbs.", "They dip them in an opaque coating.", "It's called blacktop because it only covers the tops of the bulbs.", "This will direct light out of the sides of the bulb.", "Now it's time to take these headlights for a test-drive, so to speak.", "A bracket holds them down while probes underneath energize them to make sure they work.", "A plunger places a gasket around the base.", "This will seal the headlight capsule to the automobile.", "And now they're ready to guide you on your nighttime drives.", "Insulation keeps your home warmer in the winter and cooler in the summer.", "One type of insulation material is cellulose fiber made from recycled paper.", "It's derived from a natural source, wood fiber, so it's nonpolluting.", "It contains no asbestos, no fiberglass, and there's no formaldehyde in it, so it doesn't emit any gases.", "Like other insulation materials, cellulose fiber has to meet strict government safety standards.", "One firesafety test assesses what's called smolder resistance.", "The company lab weighs a sample from the production line, then inserts a lit cigarette in it.", "Once the cigarette burns out, which takes an hour or two, the lab weighs the sample again.", "The weight loss must be less than 15%.", "How they make cellulose insulation isn't very complicated.", "It all begins with recycled paper delivered in bulk.", "Workers load it onto a conveyor belt, and from that point on, the entire process is automated.", "The paper first goes into a machine called the primary mixer.", "It separates the bunched-up pieces, preparing them for shredding.", "The machine's powerful magnet removes staples, paper clips, and any other pieces of metal.", "From there, the paper goes into a shredder, which rips it into pieces about 2 inches long.", "The factory mixes the shredded paper with boric acid, a natural compound that acts as a fire retardant.", "It also makes the insulation pest-resistant, and it helps fend off mold, wood decay, and corrosion.", "Now a machine called a fiberizer shreds the paper into tiny pieces only about 1/8 of an inch long, and it mixes them with more boric acid.", "From the time the recycled paper arrives by truck to the time it comes off the line as cellulose-fiber insulation, only about five minutes have passed.", "But the insulation doesn't leave the factory before undergoing thorough safety testing.", "This test assesses what's called open flammability.", "They heat the insulation to 122 degrees fahrenheit to represent the temperature of a roof in the hot sun.", "Then they ignite it.", "The flame travels but then dies out, thanks to the boric acid.", "If that happens within a certain distance, the insulation is safe.", "Outside research firms also test the product for safety to independently corroborate the results of the company's tests.", "The automated packaging equipment blows 25 pounds of insulation into a bag, at the same time compressing the fiber into a block.", "Some types of thermal insulation come as thick rectangular blankets known as batts.", "You install them by hand, fitting them snugly between the wall studs.", "Cellulose fiber doesn't come in batts.", "It's known as loose-fill insulation.", "A professional installer has to inject it in between the walls.", "By spraying it under pressure, it fills all the spaces without any gaps, something that's hard to do with pre-shaped batts.", "Insulating performance is referred to as r-value.", "The higher the r-value, the more effective the insulation.", "Cellulose-fiber insulation has a higher r-value than loose-fill mineral-fiber insulation and, depending on which statistics you're looking at, has either the same r-value as loose-fill fiberglass or a higher r-value than fiberglass.", "Cellulose fiber is denser than other materials, so it better resists air movement, making it less likely to move out of place after installation.", "The aluminum ladder is very convenient.", "Lightweight and sturdy, it makes any ascent easier.", "Back in the 1930s, wooden ladders were the standard but were extremely heavy and difficult to position.", "The use of aluminum took things to a whole new level.", "For a ladder to really hold up, the aluminum needs to be strengthened with these ingredients-- silicon, magnesium, manganese, and copper.", "It all goes into an enormous furnace.", "It takes a crane to transport a hopper full of aluminum over to the furnace.", "The hopper opens at the bottom to unload.", "A worker opens a door at the front of the furnace.", "He wears a face shield to protect him from the blistering 1,300 degrees fahrenheit.", "He adds the other ingredients, and the heat turns it all into a liquid mass.", "The liquid flows out of the furnace into troughs.", "It seeps through holes in the troughs to molds in the ground.", "The liquid cools and hardens in the molds.", "This makes log shapes that are almost 23 feet in length.", "A hydraulic lift extracts them from the molds and slowly takes them to the next station.", "You wouldn't want to rush this job.", "Each log weighs about 1,100 pounds, and dropping one could do serious damage.", "A saw cuts them into pellets.", "The size depends on the type of ladder being made.", "A mechanical lift delivers a heated pellet to an extruder, and a ram pushes it into the opening.", "They move the die plate into position.", "The ram forces the hot pellet through the holes in the die plate.", "This makes a rail shape about 130 feet long.", "A puller drags the rail onto a table and leaves it to cool and harden.", "Then a circular saw slices it into manageable lengths-- 19 1/2 feet.", "Operators feed each end of the ladder rail to jaw systems which pull it to make it completely straight.", "The straightened rails now move on to the next station, where they rivet plastic feet onto the ends to keep the ladder from slipping.", "They stick safety information onto the rails.", "And now they assemble the ladder one step at a time.", "Workers fit each step in the rims of the ladder rails.", "They rivet them into place.", "This will be the front of a light-duty stepladder.", "They install a diagonal brace...", "And turn the ladder over to rivet the steps from the other side.", "It's a little more reinforcement.", "Then they build the backside of the stepladder.", "They rivet the sturdy blue plastic top onto the front and back pieces, joining the two.", "They install a spreader, securing it with rivets, as well.", "And now this stepladder is ready to provide a little elevation.", "For a lot of elevation, they make extension ladders.", "They use round rungs for greater strength.", "They feed each rung to a coining machine, which tapers the ends.", "Another machine presses aluminum ferrules on rings onto each end.", "This allows the rungs to fit snugly into slots in the extension ladder's side rails.", "Hydraulic arms reach from above and below to press-fit the rungs into the side rails.", "Finally, workers rivet rubber pads onto the ends of the rails.", "This provides a firm footing for the ladder.", "These ladders are now complete.", "And if you're on your way up in the world, they'll come in handy.", "The bamboo fly rod is a classic.", "The split-bamboo rod has been around since the early 19th century, and for many years, it was the only kind of rod available.", "These days, synthetic rods abound, but bamboo still holds a traditional appeal to those that like to fish the old-fashioned way.", "Going fishing?", "A bamboo rod is considered a work of art in fly-fishing circles.", "To make one, a craftsman toasts a bamboo pole on an open flame.", "He holds it close to the fire, but not too close-- one false move, and he could scorch it.", "The goal is to turn the bamboo a golden brown.", "He pounds a wedge into the toasted bamboo and drives it down the length of the pole.", "He pulls the pole apart, splitting it in two.", "Then he continues to split the bamboo, making strips that are less than a half-inch in width.", "He grinds down the bumps on the exterior of each bamboo strip using a belt sander.", "Next, it's over to the milling machine.", "It tapers the underside of the bamboo strip, beveling it to a 60-degree angle from end to end.", "The tapering is a critical step that will affect the rod's casting performance.", "Each strip has to be perfect.", "The rod maker inspects them for flaws...", "And then fits six together in a hexagonal configuration.", "He wraps them with cotton twine to hold them together very loosely at one end.", "Then he dips the bamboo strips in a tank of thermosetting glue.", "He feeds them to a twining machine which binds the strips tightly together.", "It's a temporary wrap-- a kind of clamp to hold the pieces together while the glue dries.", "The pieces are now laminated into one, but the result is never perfectly straight, so the rod maker heats it over an open flame.", "The heat softens the bamboo so he can smooth out the kinks.", "Next, he glues ferrules made from nickel silver onto the laminated bamboo pieces.", "This tubing will be used to connect the tip and butt pieces of the rod.", "The butt section now turns on a lathe while a blade cuts into it.", "It's slimming down sections to accommodate the handle and reel seat.", "He slips on the walnut reel seat and then slides cork rings onto the rod to make the handle.", "He glues each ring.", "It takes 12 to 14 to make a handle for the typical bamboo rod.", "It will allow for a soft, nonslip grip.", "Once the glue hardens, he shapes the cork on a lathe.", "He sands it to give an even finish.", "Next, he heats glue over a flame.", "He applies the hot glue to the stainless-steel tip and sticks it on the narrow end of the rod.", "With black india ink, he inscribes the model and serial number onto the rod.", "Now they coat it with varnish, using a turkey baster.", "He hangs the rods to dry.", "It will take three coats to give them a nice gloss.", "After that, they wind silk thread to attach the steel guides to the rod.", "They're the loops that the fishing line will go through.", "They brush three coats of varnish onto the string.", "This solidifies the wrap...", "And fuses it to the rod.", "They slide a ring onto the reel seat.", "It provides a little separation from the cork grip.", "They fit the butt and tip pieces of the bamboo rod together and do a final inspection.", "It has taken 40 hours to make this bamboo fly rod.", "But it shouldn't take you that long to catch the big one." ]

{ "things": [ "Ski Goggles", "Tower Cranes", "Porcelain Figurines", "Diesel Engines" ] }

[ "Fog and blinding snow can obscure the view from the top of a ski mountain, but a good pair of ski goggles can add some clarity to the situation.", "They shield the eyes from the elements, and certain lenses add contrast in low light to allow the skier to see the bumps and dips ahead.", "Goggle lenses come in different tints to adjust for specific weather scenarios.", "They start with this injection molding machine.", "The operator sprays a nonstick substance into the mold and closes the door.", "The machine sucks up urethane pellets, then melts them into a thick liquid to mold into goggle frames.", "It takes just seconds for the shape to harden.", "A worker clips away unwanted bits, and then he's ready to give these goggles a more graphic look.", "He immerses the cellophane-like material, printed side down, in a mix of water and solvent.", "A chemical reaction lifts the graphic design off the film and suspends it in the liquid.", "He sprays solvent on the other side to both activate a bonding agent and dissolve the film.", "He then immerses a rack of goggle frames in the floating graphic.", "The surface tension of the water causes the graphic pattern to wrap around the frames, and the bonding agent makes it stick.", "This technique is called hydrographics, and it's a good way to transfer a pattern onto a three-dimensional surface.", "He washes away any paint or dirt from the surface of the frames.", "A clear lacquer is the finishing touch.", "For an understated look, there's always monochromatic white.", "A worker applies glue around the vents of a pair, then presses foam onto them.", "The foam will keep snow out of the goggles but allow air to be vented to prevent fogging.", "She applies thicker foam around the perimeter for a weather-tight fit on the skier's face.", "Once the straps are installed, the goggles are ready for the latest innovation, a microelectronic fan.", "It will pull warm, humid air out of the goggles to further of the goggles to further prevent fogging.", "Prevent fogging.", "He screws the mini fan to the frames and listens to it spin to confirm its operating correctly.", "Next, a machine cuts shapes out of polycarbonate to make lenses.", "Then, this special press applies heat to bend the lens.", "This shape will make it easier to secure the lens to the frame, and it also reduces optical and it also reduces optical distortion.", "Distortion.", "Production now moves to this liner-backed foam with precut lens patterns.", "The worker peels off a strip to expose a goggle-shaped strip of foam.", "She then presses a colored lens onto the strip.", "High-strength adhesive on the foam bonds to the lens.", "She pulls away the rest of the material, leaving that narrow ribbon of foam.", "It will serve as spacer between the outer-colored lens and an inner clear one.", "The space between the two lenses is a buffer zone to prevent condensation buildup and fogging.", "Now they shoot a steel pellet at a randomly-selected pair of goggles.", "It doesn't shatter, which means it will effectively shield the skier's eyes from sharp objects like tree branches and ski poles.", "It's time to snap the dual-layer lens to the frame's molded groove.", "A u.v. mirror coating has also been applied to protect the eyes from the sun's rays and reduce glare.", "These goggles have everything covered, leaving the skier free to focus on the thrill of the to focus on the thrill of the ride.", "Ride.", "A tower crane moves building materials up to construction crews working above the ground.", "The operator's cabin is near the top.", "Just above that is the jib, which hoists the load and trolleys it back and forth.", "The jib and cabin rotate on a turntable called a slueing platform.", "A crane's tower is modular, meaning the more tower sections installation crews add, the taller the crane.", "At the crane factory, workers construct the slueing platform by welding together huge steel plates and square tubes.", "Welders also fuse sections of ladder to sections of safety cage.", "Then they weld each ladder and cage unit to a tower section.", "Throughout the assembly process, robots perform the simpler welds.", "Once all the crane's structural components are welded, they go to the paint shop for an anticorrosion primer, then a top coat of paint.", "After each application, the part dries in an oven for about an hour at 175 degrees.", "The slueing platform sits on a turning mechanism that consists of two concentric rings with ball bearings in between.", "Computer-guided machines grind teeth on the outside and grooves on the inside in which the bearings will ride.", "After lubricating the grooves, workers install the outer ring around the inner one.", "Then they fill the groove with steel balls and high-strength plastic spacers.", "This allows the outer rim to revolve smoothly around the stationary inner ring.", "The operator cabin is made of steel panels.", "It's integrated into the slueing platform.", "The cabin's large windows enable the operator to view how the jib is maneuvering the load.", "The crane's controls are built right into the cabin seat.", "The seat itself is designed to be as comfortable as possible because you can't step out of because you can't step out of the cab to stretch your legs.", "The cab to stretch your legs.", "A motorized gear rotates the slueing ring which rotates the slueing platform, supporting the crane's cabin and jib.", "The factory's computer-guided machining equipment makes all the parts for this gear as well as for the gears which enable the jib to hoist and trolley the load.", "Workers assemble the slueing gear and mount the motor that drives it.", "Then they connect the slueing gear to the slueing ring and mount the ring on the slueing platform into which they've platform into which they've installed the cabin.", "Installed the cabin.", "An automatic greasing system keeps the ring's teeth lubricated as it rotates the platform.", "After an extensive test, they install the tower head on top of the cabin.", "Now this entire slueing unit goes off to the construction site.", "After anchoring the crane's base, the installers use a mobile crane to mount the slueing unit on the tower and the jib onto the slueing unit.", "Then they add tower sections to build the crane to the required height.", "An elevating device lifts the slueing unit, clearing enough space underneath to insert an additional tower section.", "They connect the tower sections with giant high-strength bolts.", "Then, repeat this procedure until the crane is as high as it needs to be.", "Once the crane is fully erected, the operator climbs the tower ladder up to the cabin.", "As he works, he observes what he's doing through the windows.", "He also watches a computer monitor which displays how the jib is hoisting, trolleying, and depositing the load.", "He can communicate with the ground via phone or walkie-talkie so things are walkie-talkie so things are never left up in the air.", "Never left up in the air.", "Europe is renowned for producing magnificent porcelain figurines even though it was the chinese who first invented the art.", "In 1718, the first european factories began making ornate porcelain objects, which quickly became a status symbol among the nobility.", "This viennese palace is home to europe's second oldest manufacturer of handmade porcelain.", "Following photos of a subject, a modeler sculpts a three-dimensional figure out of clay.", "Not only must he include all the intricate details, he also has to make the model 14% larger than the final size because porcelain shrinks during the firing process.", "He uses the model to cast a master mold out of plaster.", "From the master mold, he casts a plastic mold and from that, plaster production molds with which to cast the figurines.", "In its raw form, porcelain is a paste which contains water, the minerals feldspar and quartz, and white kaolin, a type of clay.", "They water down the paste into a liquid called slip, then pour it into the plaster production molds.", "The plaster immediately begins drawing out the water, causing a firm layer of slip to form against the mold cavity.", "They pour out the remaining liquid.", "When the slip layer is finally thick enough, they open the mold and carefully extract what is by now a figurine with fine details.", "More complex figurines are cast in parts, each in its own mold.", "The modeler carefully touches up each casting, scraping off seams and fine-tuning the details.", "Then, he assembles the parts, using a slip to stick them using a slip to stick them together.", "Together.", "It's critical to keep the figurine hydrated because if it dries out even slightly, it will crack during firing.", "The figurine goes through two main firings.", "The first time at over 1,700 degrees-- hot enough to harden the porcelain but also keep the surface porous so the glaze will adhere.", "They inspect and dust the fired figurine then stamp it with coat of arms in cobalt-blue enamel.", "The mark as described this brand of austrian porcelain since 1744.", "Then they dip the figurine in glaze-- a mixture of water and several materials, including quartz, feldspar, kaolin and ground-up porcelain.", "Then, into the kiln again, this time over 2,500 degrees.", "This bakes the glaze to a glassy finish and further hardens the porcelain.", "The figurine exits this firing about 14% smaller as the remaining moisture has evaporated.", "Once it cools, they begin decorating the figurine.", "Using a variety of fine-tipped pens and brushes, an artist paints enamel onto the glazed paints enamel onto the glazed surface.", "Surface.", "Between paint applications, depending on the number of colors and intricacy of color blending, the figurine undergoes as many as six minor firings at 1,500 degrees.", "This melts the vitreous ingredient in the enamel fusing it with the glaze.", "The end result is rich, permanent color that never fades.", "Despite its delicate appearance, porcelain is nearly as strong as steel when under compression, but it's not nearly as resistant to impacts, so when handling these magnificent works of ceramic art, a good grip is ceramic art, a good grip is highly recommended.", "Highly recommended.", "Drivers looking for greener cars, but with more powerful acceleration than hybrids deliver, can opt for a vehicle that runs on diesel.", "Today's diesel fuel burns as cleanly as gasoline, yet diesel-powered cars are 30% more fuel efficient than gas-powered cars, meaning they consume less fuel and, therefore, pollute less.", "The secret behind this car's powerful diesel engine is a turbocharger.", "It compresses the air entering the engine's combustion chambers filling them with a greater quantity of air.", "The more air, the better the fuel burns, generating extra power.", "The engine assembly begins with a v-shaped block with two sets of three cylindrical holes called cylinders.", "Robots first mount a retaining frame to support the crankshaft.", "Each cylinder will contain a piston that moves up and down with the combustion cycle.", "This piston motion will turn the crankshaft which, in turn, will move the whole vehicle.", "But first, a laser-beam device hones the cylinders.", "The laser's heat melts the surface of the inner walls, smoothing them.", "This ensures the pistons will move with minimal friction.", "Meanwhile, a robot oils up the crankshaft's main bearings.", "Then, once the cylinder honing is done, workers install the crankshaft at the bottom of the engine block, locking it in position with a retaining frame.", "Now they flip the engine block right side up to install the pistons, which are already attached to connecting rods.", "Once all six pistons are in, they turn the engine block upside down again and fasten each connecting rod around the crankshaft.", "Next, they connect the chain drive to one end of the crankshaft.", "The chain drive operates camshafts that open and close the valves on top of the cylinders.", "Those valves are located in these cylinder heads, four valves per cylinder-- two through which air enters the combustion chamber and two through which exhaust exits following each combustion cycle.", "Workers flip the heads upside down and insert long bolts.", "Then they position the heads over the cylinders, aligning the bolts with holes in the engine block.", "Robots drive in the bolts to a specific tightness.", "This caps each cylinder, closing its combustion chamber.", "Next, workers install a fuel injector into special shafts in each cylinder head.", "Injectors shoot a specific amount of fuel into the combustion chambers at precisely the right time.", "These cutting-edge piezo injectors do that multiple times per cycle rather than just once, making the combustion process much smoother.", "The engine, therefore, is quieter and pollutes less.", "The next component is the air-intake manifold.", "It goes on top of the engine.", "Air enters on the left and, as this animation shows, runs to the intake valves on top of the cylinders.", "It's time to install this engine's secret weapon, the turbocharger.", "It contains two turbine wheels that spin at nearly 200,000 rpm.", "One turbine compresses air entering the air-intake manifold.", "The other draws out the hot exhaust and sends it out the car's exhaust pipe.", "The turbocharger sits at the rear of the engine block in the \"v\" between the cylinders.", "Over at the testing department, technicians analyze the engine's performance, in particular, its torque, which determines how much power the engine can produce.", "Next, the engine goes into a test vehicle which runs through specific driving cycles that simulate both highway and city conditions, all the while collecting the emissions exiting out the exhaust pipe.", "This test insures that the engine meets or exceeds all the engine meets or exceeds all the emission standards.", "Emission standards.", "Not only does the turbocharger give the car better acceleration, it also solves a common problem in high-altitude regions, where decreased atmospheric pressure slows down nonturbo engines.", "Because turbocharging compresses the air going into the engine, even at high altitudes, the car even at high altitudes, the car drives at full power.", "Drives at full power." ]

{ "things": [ "Commercial Drones", "Aquarium Fish", "Runway Cleaners", "Shuttlecocks" ] }

[ "A commercial drone is a small, unmanned aircraft with an onboard camera it can capture a bird's-eye view of the ground, collecting up-to-the-minute data useful for many types of applications.", "They're used to plan infrastructure projects, overseeing natural resources, or manage farmland.", "Spanning about five feet and a half in diameter, this commercial drone is known as an octocopter it has eight rotors, which enable it to maneuver in the air like a helicopter.", "The drone's components are made of carbon fiber, a highly stiff, strong, and durable material carbon fiber is also lightweight, a critical factor in aviation.", "Computer-guided milling machine cuts the parts.", "A technician manually sands their edges smooth.", "This component is half of one of the drone's legs.", "The mill also cuts out the top and bottom frames for the drone's body.", "Technicians then assemble the two halves of each leg.", "Some of the drone's components are produced by a 3-d printer, the printer builds each part layer by layer out of a thin stream of plastic.", "This is one of the drone's eight arm receptacles.", "A technician bores the hole where the arm will be fitted.", "The hole must be precise to ensure a secure fit.", "After verifying its diameter with digital calipers, the technician installs the back part of the receptacle and the lever that clamps the inserted arm firmly in place.", "He attaches an electronic speed controller to one end.", "Then, he screws the receptacle to the bottom frame of the drone's body.", "The wires coming out the other end of the controller connect to an electrical power harness and to the autopilot.", "The autopilot is the onboard computer that runs the drone.", "He installs the seven remaining receptacles, then the power harness.", "It has eight connectors, one for each electronic speed controller.", "Next, he attaches the top frame, then the payload mount that holds the camera and hard drive.", "He links the payload mount to this servomotor, which is guided by the autopilot.", "The drone's body is protected by a cover.", "Workers mount a sheet of plastic on a vacuum former machine.", "They start up the machine's heating element and position the plastic just beneath it.", "This gradually heats the plastic to a malleable state.", "Once the plastic is soft, they position a wooden mold on the machine, activate the suction, then drop the sheet onto the mold.", "The vacuum draws the plastic tightly against it.", "They let the vacuum-formed plastic to cool and harden, then carefully trim off the excess they cut out a rough opening for the payload mount through that opening, they secure the cover to the computer-guided milling machine, which finalizes the shape to precise specifications.", "Once the cover is finished, they install it on the top frame.", "They attach the four legs to the bottom frame.", "Then, they install the camera on to the payload mount.", "The mount pivots to angle the camera at the ground.", "They insert and clamp the arms into the receptacles.", "Each arm is a carbon fiber tube with a plastic rotor that's driven by a small motor underneath.", "Upon inserting an arm, its motor makes contact with its electronic speed controller.", "They also install the autopilot, the autopilot executes the programmed flight path and operates the camera, the servomotor that moves the payload, and the electronic speed controllers.", "The drone operator can communicate wirelessly with the autopilot using a remote control.", "But it's more common to program the gps coordinates of the drone's route prior to takeoff.", "Aquariums have been around for hundreds of years.", "Even now, having a body of water in a glass box seems like magic.", "The most common aquarium fish is the goldfish, domesticated in china more than 1,000 years ago.", "Goldfish are a type of carp native to asia.", "They tend to be silver or gray in color.", "But ancient chinese breeders took advantage of orange and yellow mutations to breed a gold-colored fish.", "Like all fish, aquarium goldfish start life as eggs.", "To start the breeding process, a worker separates the males from the females.", "Telling the girls from the boys can be difficult.", "But if she finds eggs, there's no question.", "It must be female.", "The eggs fall to the bottom.", "This facility harvests around 1,000 eggs a day.", "Adding oxygen helps the eggs mature.", "A week later, the eggs hatch.", "The hatchlings are called fry.", "By the second week, they're little fish.", "Not all of them are the typical orange color even after centuries of breeding, many of them are still silver and gray.", "As the fry increase in size, workers must transfer them from buckets to larger holding tanks.", "This facility sells fish at different stages of growth.", "Here, a worker selects a particular size to sell.", "Once the selection process is complete, she transfers the selected fish to a bag for transportation.", "She adds air so the fish will have enough oxygen during transport.", "A worker tosses dry food into a series of ponds.", "Each pond is roughly 100 square feet and holds about 500 fish.", "The food provides the nutrients needed for growth.", "A worker checks the fish tanks for signs of illness, such as parasites or fungus.", "He carefully portions out and adds a liquid known as methylene blue.", "It's an anti-fungal treatment.", "These 1-year-old fish are a different type of carp known as koi.", "Koi were first bred in japan for their color and pattern variations.", "A worker isolates a quantity of koi with a specially designed shallow net.", "This allows her to select the right-sized fish to bag for sale.", "The bagged fish await transport to the market.", "It's time to prepare the bags of goldfish for shipping.", "A worker empties a batch of them into a netting suspended in water.", "A team of workers sort through the goldfish.", "They select the fish that meet the size criteria and use spoons to transfer them to a bucket.", "To prepare fish for shipment, workers dip them in a green solution.", "They then rinse them in clear water before bagging them again.", "The green solution contains a specially calibrated medication that helps reduce stress during transport.", "Next, a worker adds air to the bag, ensuring the fish have plenty of oxygen while en route.", "The fish have been double bagged for protection.", "A second worker squeezes out some of the oxygen so the bag won't take up too much room, then seals the top of both layers.", "A packer carefully loads four bags into a styrofoam box.", "The box provides a rigid casing to protect the fish while insulating them against temperature fluctuations during transport.", "This facility also sells whole aquariums already populated with fish.", "A worker inspects a row of aquariums, assessing the size and quality of the fish while checking for any signs of disease.", "The facility sells 50,000 fish a week, or to two million every year.", "When a plane lands, the tires burn rubber that melts into the pavement.", "This can make the runway slick when wet.", "Special cleaning machines ensure that the runway is always clean and clear for takeoff and landing.", "They blast off the rubber streaks, then suction the rubber bits into tanks.", "A runway-cleaning machine is a serious power washer.", "It pressurizes hot water to at least 20 times the force of the average power washer.", "The spray heads are designed specifically for blasting away aircraft tire rubber that's melted into airstrip pavement.", "They ensure airports are a safe place to land.", "Making one starts with the hydraulic motors that spin the sprayers.", "A technician inserts a shaft that will hold the spray bar into a motor unit.", "He installs sealing cylinders to prevent hydraulic oils from leaking.", "He tops the assembly with a metal plate.", "The plate serves as a base for thrust bearings, which he installs next.", "Ceiling caps complete the thrust bearing assembly.", "A computerized test system now measures the motor's torque and the flow of hydraulic fluids.", "The system also simulates the force of the highly pressurized water to confirm that the thrust bearings will keep the motor stable.", "A powerful water-jet tool carves through steel to produce the components for the arm that holds the runway cleaner's spray heads.", "A worker then fits the steel plates together.", "He welds the seams to create permanent bonds.", "And this completes the stray arm's structure.", "After the arm has been sandblasted and painted, they hoist it to the front of the runway-cleaning truck.", "They attach it with large, zinc-coated steel bolts.", "A worker then mounts hydraulic motors to a long, wheeled bracket.", "He removed the sealing caps before this installation to make it easier.", "Once the motors have been secured to the bracket, he replaces the caps.", "He attaches the wheeled bracket to the spray arm and installs metal shrouds for the sprayers.", "They have fringes of nylon bristles to contain the spray.", "He fastens rotating sealers to the hole in the center of each shroud to keep out dirt and water.", "He screws the spray bars to the shafts that extend from the motors.", "The nozzles are made of sapphire, a tough mineral that can withstand the force of the pressurized spray.", "The next worker runs vacuum hoses to the shrouds and connects them using cam and groove couplings.", "The sprayer assemblies are now complete.", "The team lowers a large gearbox between the frame rails of the truck.", "They bolt it to the rails.", "This gearbox will transfer power from the truck engine to a high-pressure pump and the vacuum.", "The pump and vacuum systems have been assembled into one big module.", "A technician tests the belt and pulley that will connect to the gearbox.", "It's in good, working order, so they cover the system with steel casing for safety reasons.", "This module is ready to be assembled to the runway cleaner truck.", "It weighs 2 1/2 tons, so a crane does the heavy lifting.", "Workers then build a tank that's as tall as they are.", "This tank will contain the rubber bits vacuumed off the runway, along with the water used in the cleaning process.", "Once it's been painted, they assemble it to the chassis next to the clean water tanks.", "Moving inside the truck cab, a worker installs controls for the runway cleaner's operation.", "One console has a joystick for manipulating the position of the spray heads.", "Other switches are for the operation of the water pump and vacuum.", "Runway cleaners can also be used to erase painted lines when landing strips need to be reconfigured.", "Just adjust the nozzle size and forward speed, and, like the rubber streaks, the lines disappear.", "People have been playing games with shuttlecocks for millennia.", "In the mid-19th century, the british created the game badminton, in which players hit a shuttlecock back and forth over a net.", "Made of feathers and cork, the shuttlecock predates badminton by thousands of years.", "Many people are familiar with the plastic shuttlecocks used for badminton games in backyards everywhere.", "But serious players use the original feathered shuttlecock.", "This facility uses duck feathers to build their shuttlecocks.", "Workers start by aligning them with the feather side up and storing them in cups in preparation for the next phase of production.", "Having the feathers aligned makes it easier for a worker to feed them, one by one, into a specialized sorting machine.", "This device has 26 different sensors that measure each feather.", "The feathers must be a specific size and have a precise angle.", "The machine sorts feathers of the same size and angle into different bins.", "Sometimes, the sensors are unable to measure certain feathers, those feathers fall into a separate bin.", "A worker uses a special chart to measure them by hand.", "The tips of these shuttlecocks are made of cork and synthetic foam covered with white leather.", "It's time to start assembling the shuttlecocks.", "Each shuttlecock has 16 feathers, which must all be precisely the same length.", "The punching machine begins the assembly process.", "It starts by punching 16 holes in the perimeter of the shuttlecock tip.", "The worker feeding the feathers into the device must keep pace with the machine.", "A worker uses flat-nose pliers to adjust the angle of each feather.", "She then places the shuttlecocks inside a miniature wind tunnel to see if they're properly balanced.", "On some shuttlecocks, each feather might have a slightly different angle to maximize balance.", "Once the angle of the feathers has been adjusted, they're transferred to a machine that applies a bead of glue around the interior perimeter of the shuttlecock tip.", "This secures the feathers in place.", "To further stabilize the feathers, workers place them in a specialized sewing machine that binds them securely together with two rows of thread.", "The threads stitch each feather to the next.", "This process strengthens the shuttlecocks, helping them maintain their shape even when they're getting slammed back and forth over a net.", "When the machine has finished stitching a shuttlecock, a worker ties off the thread to keep it from unraveling and cuts off the excess.", "Finally, she evens out the thread rows.", "With the threads in place, the shuttlecocks must undergo a final tuning.", "A worker once again adjusts the feathers to ensure proper balance.", "A machine applies glue to the threads on the shuttlecock, locking them in place to give them the necessary rigidity.", "The thread is made to quickly absorb glue.", "A worker applies a green strip, which indicates a slow-speed shuttlecock.", "Medium-speed shuttlecocks get a blue strip.", "Fast ones are red.", "It's time for quality-control testing.", "A machine equipped with a racket-like arm fires the shuttlecocks to a waiting worker.", "Shuttlecocks can travel at speeds as high as 300 feet a second.", "That's twice as fast as a pitcher can throw a baseball.", "Once the shuttlecocks have passed the quality-control test, a worker inserts 12 at a time into long cardboard tubes similar to those used to hold tennis balls.", "With its 16 feathers, it's no wonder the shuttlecock is also known as a birdie.", "These high-quality products are ready to fly." ]

{ "things": [ "Stuffed Olives", "Astrolabes", "Western Saddles" ] }

[ "Several millennia before it ever adorned a martini, the olive and its oil were central to many ancient economies.", "Today, olives remain as popular as ever.", "Not only are they tasty, they're also healthy, low in calories and cholesterol and high in dietary fiber and iron.", "Olives are inedible unless they're pickled.", "These gourmet olives are stuffed by hand with all kinds of fillings, from almonds to garlic cloves, even blue cheese.", "Straight from the field, they go into barrels of brine.", "For nine months, they ferment.", "Their hard and bitter flesh becoming softer and sweeter.", "Then it's on to a conveyor that takes them to the cleaning area, where workers remove leaves and other debris.", "Next, they drop on to a belted conveyor.", "The openings between the belts gradually widen.", "As an olive reaches an opening exceeding its width, it falls through into a barrel below.", "By the time the olives reach the end of the conveyor, they're all sorted by size, from small to extra large.", "The next stop is the pitting room.", "The first phase of the pitting operation is a spinning drum with olive-sized pockets lining its perimeter.", "As the drum rotates, an olive settles into each pocket.", "This lines them up so that they exit the drum in a line onto the conveyor that transports them to the pitting machine.", "The machine pits 900 olives per minute.", "Let's slow it down to show you what happens.", "A coring knife enters one end of the olive, pushing the pit out the other end.", "As the pit exits, it creates a hole that's just the perfect size for the stuffing.", "Next, a quality inspection.", "Workers weed out any olives that aren't perfect.", "Then it's off to the stuffing department.", "These beauties are being stuffed with pickled garlic gloves.", "The stuffer cuts the gloves into hole-sized pieces, then inserts one piece into each olive.", "It's the same procedure with other stuffings, such as jalapeño peppers, sun-dried tomatoes, habanero peppers, onions, almonds, and more.", "Workers empty the baskets of stuffed olives onto a table of empty jars, spreading them around until every jar is full.", "On their way to the capping machine, the open jars pass under nozzles that fill them with fresh brine.", "An air jet blows off just a bit to help the cap go on easily.", "From there, it's into the capping machine, which twists a lid on each jar, heat-sealing it for an airtight fit...", "Then stamping on a lot number for tracking purposes.", "Finally, the jars head into a machine that rolls on an adhesive label.", "The brine serves as a natural preservative, giving these delectable gourmet olives a two-year shelf life.", "In the middle ages, navigators looked to the stars and planets to find their way, and for that, they relied on a scientific instrument called the astrolabe.", "Using this instrument, they could measure the angular distances between celestial objects to calculate latitude.", "It was the medieval equivalent of gps.", "Today, craftsmen still make astrolabes to celebrate their place in history.", "Without it, columbus may not have discovered the americas in 1492.", "Back then, astrolabes were hand-forged and hand-engraved.", "Today, these instruments take shape in two-part rubber molds and closed in a metal drum.", "The operator ladles molten pewter into the mold through an opening in the drum's lid.", "Inside, the mold spins, forcing pewter into every part of this astrolabe plate, complete with geometric engravings on both sides.", "He molds the dial and pointers the same way.", "He slices off excess pewter.", "It will be remelted and reused.", "He then sands the ragged edges of the plate for a smoother circumference.", "Next, he pours an acidic liquid onto the astrolabe plate, which blackens the pewter.", "He swishing the blackening agent around to ensure it covers every surface completely.", "He places the blackened plate in a barrel full of gritty, plastic cones, soap, and water.", "As it revolves, everything tosses about inside to scrub the surface of the astrolabe plate, believe the engraved designs black.", "This process adds definition to the markings.", "In columbus's time, they would have used a pumice stone and a lot of elbow grease to achieve this effect.", "Next, the astrolabe plate goes for a tumble with bits of ceramic to buff the pewter to a glossy shine.", "Against the shiny pewter backdrop, the geometric markings now stand out.", "Clearly visible on the front is a map of the sky and the zodiac calendar.", "And on the back, the mathematical scales are now clearly defined.", "The elaborate dial undergoes the same processing to enhance its celestial engravings.", "He now inserts a brash bushing in the center hole of the astrolabe plate and twists it into position.", "This bushing will act as a pivot for the dial and pointers.", "Once the dial is in position, he installs a pointer on each side of the plate.", "These pointers can be turned like the hands of a clock, and the user measures the angle of the stars and planets in relation to the horizon to calculate his location.", "He caps the bushing with a screw on one side and a nut on the other.", "He secures the assembly with a specific amount of torque to allow the dial and pointers to move freely.", "He slips a metal ring through the top hole of the astrolabe so this instrument can be linked to a chain if the owner wishes.", "He spins the dial and pointers to confirm that they don't snag on the outer lip of the instrument.", "Centuries after its heyday, this incredible instrument still fascinates.", "The amount of information that can be gleamed from holding it to the sky is astounding.", "More than latitude, the astrolabe can be used to tell time, determine seasons, and predict the future with horoscopes.", "Of course, it takes a basic understanding of geometry and astronomy to use it.", "To the trained eye, this astrolabe now reads 1:00 p.m., proving that this instrument from another era can still provide up-to-the-moment information.", "In the american wild west, cowboys spent long days in the saddle, which could leave them too sore to ride off into the sunset.", "And that led to the development of the western saddle.", "Large and sturdy, this saddle was modeled on the type used by spanish conquistadors, and it made chasing cows a less painful experience.", "Today, riders still saddle up western-style, which is more relaxed than english-stile, with the reins held in one hand instead of two.", "The contours of the saddle seat are more pronounced for added comfort.", "A western saddle also has a horn for looping rope, called the lariat in cowboy lingo.", "It starts with the saddletree, made from laminated wood covered in sections of rawhide.", "An artisan cuts out the saddle skirt and other components using a hydraulic press.", "He cuts the saddle seat by hand with this tool, called a head knife.", "The seat gets special attention because it's being custom-made for a particular horse.", "He shaves the edges of each cut out so it can be tucked neatly onto the saddletree.", "The technique is called skiving.", "He brushes glue on the leather section that fits around the stem of the saddle horn.", "Then he works it into position, creating a lip around the horn's top.", "He presses the horn cap onto the leather-rimmed top, then crimps the edges together.", "He collects tacks with a magnetic tip of a hammer, then pounds them through the leather cap, securing it to the wood.", "A thick leather cutout hides the nail heads.", "He carves a groove around the top of the horn and punches holes through the leather.", "This will make it easier to sew the layers together.", "He uses two needles to interlock the stitches.", "This secures the cap and gives the saddle horn a tailored look.", "To complete the horn, the saddlemaker trims away excess leather with a special forked blade.", "Now the artisan builds up sections of the saddletree with strategically placed strips of leather.", "He skives away some leather to improve the form.", "Then he places a leather-backed piece of tin over the built-up areas and nails it down.", "This part will add strength to the seat.", "He continues shaping the seat, then shaves the edges to blend it to the saddletree.", "The seat area gets one last leather buildup and some intensive skiving and sanding.", "Next, he glues the nail's leather around the base of the horn-- an area called the swells.", "He then applies leather to the back of the seat, called the cantle.", "After cutting away surplus leather, the artisan uses this edging tool to trim the skirt.", "This makes it smooth so it won't chafe the horse or the rider.", "Another worker immerses the saddle seat in warm water.", "This makes the leather soft and pliable, allowing it to be shaped.", "He drapes the seat around the built-up saddletree and straps it down.", "As it dries, it hardens into the shape of the tree.", "He shapes the back section of the seat separately and pins the wet leather to dry to the form.", "Then he glues the whole seat to the saddletree.", "But there is much more to be done before it's ready for ranch duty, so stay tuned.", "A western saddle serves an important function, but it also sports elaborate artwork engraved in the leather.", "This custom goes back to the wild west, when a saddle was a status symbol and ornate art and decorative silver signified that a cowboy was riding high.", "The saddlemaker now shapes the seat right up to the back of the cantle.", "He crimps the edge to build up a part called the cheyenne roll.", "He maps out its precise dimensions with a compass...", "Then trims the part following his scratch line.", "With a wooden dowel, he again presses the leather seat to the saddle's contours for a final shaping.", "He sews through four layers of leather to finish off the cheyenne roll.", "The thread is an artificial sinew-- a superstrong nylon that makes the seam virtually indestructible.", "The focus now moves to the leather saddle skirts, as an artist engraves a floral design.", "The artist uses a wide range of tools with expertise, like this one, called a back rounder, which he uses to carve recesses around the design.", "A spray of water softens the leather, making it easier to engrave.", "Next, he installs metal plates on either side of each skirt.", "They're part of the saddle rigging, which will be used to secure the saddle to the horse, so it's crucial that these plates be firmly entrenched in the leather.", "He secures each plate to the skirt with several rivets, then rounds them off, getting rid of any sharp edges that would irritate the horse.", "The saddlemaker then brushes glue on the back of the skirt to attach a leather part with a rear cinch ring riveted to it.", "Here, he glues and rivets the top part to this skirt to the main section.", "He arranges a piece of sheepskin facedown...", "Then glues the back of the saddle skirt to it so the woolly side will rest against the horse.", "This part is all about the horse's creature comfort.", "The saddlemaker sews the skirt onto the sheepskin using a machine with a heavy-duty needle.", "He then trims the excess sheepskin following the line of the leather skirt.", "To remove some of the bulk, he shears the wool, tapering it around the edges.", "Next, he braids leather lace into a tight weave called latigo lace.", "It ties both halves of the skirt together and will later be used to fasten the skirt to the saddle.", "He pulls the lace under the weave to secure it.", "Next, he applies a generous amount of glue to a leather stirrup cover.", "The stirrup is meat of oak, steamed into a \"u\" shape and then reinforced with galvanized tin.", "He presses leather into the crook of the stirrup.", "Then he bolts a metal spacer into the top.", "Now it's time to attach the saddle skirts to the tree.", "He threads cinch strings through the cinch keeper and nails it to the saddle.", "Another worker now rubs special oil into this western saddle to add color to the leather and preserve it.", "The oiling also exposes the grain of the leather and highlights the engraved designs.", "From start to finish, this western saddle has taken 40 hours to make, but the modern cowboy should get plenty of mileage out of it." ]

{ "things": [ "Rice Cookers", "Concealment Furniture", "Promotional Origami", "Hedge Shears" ] }

[ "Preparing rice in an electric cooker is easier than cooking rice on the stove.", "You throw in the rice and water, press a button, and walk away until it's ready.", "This machine is designed to steam rice to perfection.", "Rice cookers use indirect heat to circulate steam around rice and water, from the outer pot to an inner pot.", "This process cooks the rice evenly in half an hour.", "To cast the outer cooking pot, aluminum ingots are melted in a furnace.", "A robotic arm scoops up the required amount of molten aluminum with a ladle...", "Then pours it into the top of the mold.", "It takes the metal four minutes to cool and solidify.", "Then technicians extract the pot from the mold.", "To refine its form, the pot is mounted on a computer-guided lathe.", "As it spins, several machines contour the pot's outside surface to its final shape.", "Next, the pot is loaded onto an automated drilling machine.", "The machine punctures 18 holes through the bottom.", "The rice cooker's heating components and its painted steel shell are attached to the outer pot through these holes.", "Then the pot is returned to the computer-guided lathe.", "A tool polishes the interior until the aluminum is smooth and bright.", "A disk of stainless steel is placed in a press.", "The press molds the steel into the inner cooking pot.", "The next press trims off any excess metal around the top, leaving a clean and even edge.", "Another machine curls that edge to form a rounded lip.", "The lip strengthens the pot and provides a place to grip when the inner pot is placed into the outer pot.", "Once polished, the pot is placed in another press.", "This press stamps water-level lines on the side and a trench on the bottom.", "The trench helps the water evaporate quickly.", "Next, an automated booth paints the rice cooker's steel shells.", "The shells are baked in an oven for 15 minutes at 390 degrees fahrenheit so that the paint can set.", "With a pad printer, the company logo is applied to the shell.", "Technicians install part of the switch mechanism to the shell.", "Another technician places the heating element in a slot on the bottom of the outer pot, securing it with three clips.", "They install two connection plates used to attach the steel shell-- a porcelain plate and a magnetic core.", "The core controls the on/off switch based on the temperature inside the cooker.", "The technician connects the power cord and attaches the thermal-insulation sheet, which allows the cooked rice to maintain a temperature of 158 degrees fahrenheit.", "This part of the switch mechanism hovers over the magnetic core.", "When the cooking temperature hits 158 degrees fahrenheit, the core activates the switch to turn off the heating element and start up the thermal-insulation sheet.", "After more switch wiring, technicians install the fuse, which prevents the cooker from overheating.", "One end is connected to the heating element, the other end to the power cord by the porcelain plate.", "The painted steel shell is attached to the base of the outer pot.", "Once attached, each connection plate is secured with screws, then handles are installed.", "Finally, every rice cooker undergoes a temperature test.", "After starting the machine, the cooking temperature is measured with a thermometer.", "Once approved, the cooker is packaged with a cover and perforated insert for steaming other foods.", "To use the cooker, you put rice and water in the inner pot and water in the outer pot.", "In under an hour, the heating element turns off, and the insulation sheet kicks in to keep your rice warm.", "One way to keep personal valuables secure and safely out of sight is by storing them in concealment furniture.", "This custom-designed home decor allows you or your family an understated place to store and lock a number of items.", "This seemingly ordinary bookcase has a few surprises.", "Behind it's decorative medallion is a hidden release for side pullout compartments.", "And inside the lower section is a wireless keypad which unlocks a drawer.", "This company handcrafts various items, from dressers to mirrors to wall art.", "Each piece of furniture is customized based on the customer's wood, finish, and storage configuration.", "To create a valance at the top of a bookcase, a planer levels a piece of wood to its required thickness.", "A computer-guided router carves designs into the wood and cuts out the shape of the medallion.", "Next, the medallion is attached to the valance and release device through three slots at the center of the valance.", "This is one of the side pullouts after assembly is complete.", "Like the valance components, the router carved the design on the front panel.", "A craftsman uses an electric sander on the pullout's side panel which has no carving.", "All the decorative details are sanded by hand.", "The craftsman assembles the second side pullout.", "A laser engraves the company's name and logo on the inside of the side panel.", "The craftsman measures and marks where the pullout's bottom and top panels will be placed.", "Glue is applied into a groove running the length of the fluted front panel.", "Then the side panel is inserted into the groove and the parts are clamped together.", "The bottom and top panels are glued at the pre-marked points and secured.", "All the wooden components of the bookcase are glued to each other.", "Three temporary boards in between the top and bottom panels keep the structure square while the glue dries.", "Next, a craftsman assembles the top of the bookcase, attaching the base and sides, back, top, the valance, and crown molding.", "The customer selects the color of the finish.", "Painted on by hand, the stain takes up to an hour to dry.", "A craftsman sprays on a coat of vinyl sealer.", "Once the sealer dries, the surfaces are sanded and two coats of fast-drying lacquer are applied.", "The craftsman sands the wood between applications.", "Next, the hardware is installed.", "A technician attaches the drawer slides for each side pullout...", "Bolts in the lock for the hidden release device, and secures a triangular latch to the pullout.", "Then a long rod is inserted.", "This connects the locks to the release so when you slide the center medallion right or left, it pushes the rod against the pullout lock, popping the latch.", "The corresponding drawer slides are attached to the pullout.", "The triangular latch, which releases the pullout, goes in the top front corner so that it aligns with the lock.", "Once the pullouts are installed, they form the sides of the upper section of the bookcase.", "These sections are now useable, sturdy storage compartments.", "The next step is to connect the rod to the center medallion.", "The craftsman bolts a rectangular piece of metal to the medallion through the valance's top slot, connecting the medallion to the valance through the other two slots.", "A large opening on the top of the bookcase provides access to the device should it ever need repair.", "Once joined with the lower section, the bookcase, like this china cabinet, is ready for double duty.", "Often associated with japanese culture, traditional origami is best known as the art of paper folding.", "It dates back to at least the 17th century.", "Today, marketing companies are engineering origami for promotional use, creating materials with more impact than your standard brochure.", "Open this invitation, and an interesting scene unfolds.", "Based on strategic marketing research, nontraditional invitations and three-dimensional paper structures can attract more interest.", "A specialist known as a paper engineer replicates an ultrasound machine in origami.", "The paper engineer breaks down the design into flat parts to be printed and folded into modular pieces.", "Guided by a digital design, a machine cuts and scores a thick sheet of paper in the shape of the engineered origami parts.", "Later, the scored shapes will be punched out and assessed.", "The design will need tweaking before the pieces of paper ultrasound are ready for mass production.", "Next, the designer folds the cutouts and glues them together, creating the base of the ultrasound.", "This particular module is a test build to confirm that it folds correctly and will fit to the other parts of the mini paper replica.", "The designer makes more prototypes and adjusts some of the parameters.", "He builds the undercarriage and wheels out of chipboard.", "These elements support the paper modular structure.", "Each part is labeled accordingly.", "The designer constructs the final prototype, checking that the seams are tight and that all the parts are in perfect alignment.", "Once structurally sound, the designer starts building the graphic details.", "He refers to photos of the prototype and compares them to the flat screen image.", "When complete, the artwork is printed, producing a proof.", "The proof is a test copy of the artwork.", "The areas to be glued or cut out are printed in green.", "This is done to indicate that no ink or coatings are needed during the final printing.", "The technician does an initial check to confirm the quality of the print and that all the art has been properly placed.", "Then, the designer and the production supervisor evaluate the proof.", "They confirm that the lines correspond with those of the cutting die by comparing folded modules to the flat proof.", "This step ensures that when the artwork is printed for mass production, the cutouts will fit.", "Adjustments are made to any problematic areas of the proof.", "Once the artwork is complete, the revised artwork is printed and scored by a digital cutter.", "This computerized cutter is only used for test purposes.", "A cutting die will be used for mass production of the origami parts.", "Technicians insert the cutouts in the corresponding parts of the die.", "This step confirms that the lines are correct and are ready to go to print.", "Machines may mass produce thousands of printed and die-cut sheets, but it's up to the assemblers to fold and glue the modules together.", "The assembler starts with a base, followed by the articulating arm for the ultrasound screen.", "The arm fits into a slot in the base, which can be lifted and lowered.", "The assembler attaches the control panel to the lower part of the arm.", "He installs the folded ultrasound screen on the top and inspects his work.", "Weeks of design and planning have gone into this moment.", "Now assembled, this piece of promotional origami can be packaged and mailed to targeted recipients.", "Hedge shears have long steel blades that hold a sharp edge.", "They're essentially a serious pair of scissors.", "Used by a skilled gardener, they can cut a large area of vegetation with one stroke.", "Needless to say, hedge shears can truly change the landscape.", "Taming an unruly hedge or garden often calls for sheer strength.", "That's why, for many gardeners, hedge shears are a go-to tool.", "To make hedge shears, technicians cut out the blades from carbon steel using a die cutter.", "The steel uncoils and travels over a roller conveyor, sending it to the cutter.", "The die cutter stamps out multiple blade blanks.", "Once the steel advances, the die cuts the next batch of blanks, cutting a hole in the center for the assembly of the shear blades.", "A technician arranges the blade blanks on a conveyor heading to the oven.", "The blanks bake at 1,470 degrees fahrenheit.", "This heat treatment is the first stage of the hardening process.", "Another technician exposes the cutting edge to the heat.", "This makes the edge a little stronger than the rest of the blade.", "The technician submerges the blade in oil to bring down the temperature, which completes the hardening process.", "A grinding stone removes the dull, gray layer on both sides of the blade.", "This gets rid of scorch marks, and it brightens the finish.", "Then the grinder cleans and sharpens the blades.", "Before the grinding, the hedge-shear blade looked lackluster, and its performance would have been dull.", "The grinding has given the blade a sheen and a cutting edge.", "Next, technicians install a rubber bumper device on the blade's stem.", "The rubber will cushion the force of the impact created as the shear blades come together.", "Another technician joins the blades with a pivot bolt and nut.", "This connection allows the shears to swing toward each other.", "A team examines the blades to confirm they're engaged properly and operate smoothly.", "If needed, they adjust the interface by bending back the blades.", "This tweaking can be critical to the functioning of the hedge shears.", "Then the shears are placed in a fixture, and the device press-fits telescoping handles onto the tangs.", "An inspector tests the telescoping action to confirm that the handles extend and retract effectively.", "Other technicians slide plastic gripper sleeves onto the ends of the handles.", "It's an initial installation.", "The gripper sleeves will need to be pushed further up the handles.", "A mechanical pusher shoves the grippers into their final position.", "It's a press fit-- no glue or screws required.", "The tips of the hedge shears are dipped in an anti-rust solution and placed on a rack to dry.", "Then a worker rubs the solution residue into the steel.", "The shears undergo another inspection, which checks the interface of the blades one last time.", "The technician tweaks the angle of the blades and tightens the pivot bolt.", "A label is pressed on the shears, providing product information and safety precautions.", "The hedge shears undergo a final inspection.", "Once cleared, they are packed for shipping.", "These hedge shears should hold up to years of trimming, cutting, and pruning.", "Without them, gardens might look a lot wilder." ]

{ "things": [ "Audio Vacuum Tubes", "Light Bars", "Wood Model Aircraft", "Metal Snare Drums" ] }

[ "When it comes to sound quality, audiophiles swear by amplifiers which contain vacuum tubes to boost and modify the electrical signal.", "They were the norm until transistors came along in the 1950s.", "Many audio enthusiasts still prefer tube sound, which they find warmer, richer, and more natural.", "once standard in radios, phonographs, and televisions, today you see vacuum tubes only in very high-end audio equipment.", "They come in an array of models designed to perform specific sound-enhancing tasks.", "Technicians at this czech factory first wind wire a precise number of revolutions with a very specific degree of tension.", "Then they clean the surface and weld it to a support structure.", "This completes the grid, one of the tube's main components.", "Next, technicians take the second main component, the cathode, and insert it into the grid.", "When the sound signal enters the tube, the cathode produces a flow of electrons.", "The grid controls that flow as it travels to the third main component, the anode.", "The anode's top secret black coating increases the effect of the electrons hitting it, causing the anode and cathode to have two different voltages, both of which are greater than that of the original signal.", "This makes the signal larger and more powerful, meaning it amplifies the sound.", "With those three components now assembled into one unit, the inside structure of the tube is complete.", "Now for the bulb, which will encase the unit.", "A glass blower skillfully crafts it out of hard, laboratory-grade glass.", "Using a high-temperature torch and glass-making tools, he melts the open end and seals it off.", "Then he blows in a bit of air to shape the end into an evenly rounded dome.", "Now he mounts the bulb on a lathe to complete the shaping.", "Keeping the glass evenly heated, he blows in just enough air pressure to keep the bulb from collapsing inward.", "When the glass reaches just the right temperature, a die presses against it, setting the final shape.", "Next, they mount a glass collar over copper wires clamped into a motorized vice, then insert a glass straw called an evacuation port.", "As the vise rotates, they heat the collar uniformly with stationary torches.", "Using a handheld torch, they remove any stretches or runs in the softening glass.", "When the time is right, they activate a die to press the glass into the final shape.", "This completes the stem on which the tube's inside structure sits.", "The wires protruding from the top of the stem connect to the structure's terminals.", "Now they put this assembled unit on a turntable and center the bulb over it.", "As the turntable revolves, they heat the bottom of the bulb.", "As the glass melts, they press it inward, fusing it to the stem.", "They remove the excess glass and continue heating to ensure the bottom is fully sealed.", "Next, they prepare to suction out the air.", "This step is critical to the tube's performance, because air molecules hinder the flow of electrons.", "Technicians fuse the tube's evacuation port to the glass evacuation line of a vacuum pump.", "The pump then extracts the air through the port.", "At the same time, they heat the tube in a pull-down oven.", "This increases pressure inside the tube, creating a stronger vacuum.", "Next, they run an inductive heater over the tube.", "This dislodges damaging impurities, enabling the vacuum pump to draw them out.", "They target the stem area with a second inductive heater to draw particles called ions onto the glass permanently so that they can't later damage the tube.", "Finally, they connect the protruding wires to a plastic plug-in base.", "There are subtle technical differences between tubes of the same model.", "So the factory tests each tube, then matches pairs with similar performance features.", "This ensures they'll amplify sound evenly.", "A light bar is that strip of flashing lights on top of a police car or emergency vehicle.", "The lights are high-output l.e.d.s, far more efficient and durable than incandescent or quartz halogen bulbs or strobe tubes.", "The mounting system is designed to withstand emergency high-speed driving.", "the l.e.d.s are grouped by color within a module.", "Modules can be arranged in any configuration on the light-bar base.", "The base mounts to the vehicle's roof via straps made of high-strength stainless steel.", "Those straps begin as flat pieces, laser cut to a starting shape.", "A 50-ton forming press bends them to the final shape, which fits the exact contour of the vehicle's doorjamb.", "The light bar's white light modules fasten onto the base with the aluminum brackets this worker is assembling.", "These brackets also help draw out the heat the lights generate.", "This is critical, because if l.e.d.s overheat, they burn out.", "The base is made of extruded aluminum.", "This computer-controlled laser, working on six bases at a time, cuts out holes for venting and cables.", "The light bar has two cables-- one running power from the vehicle's battery to the light bar and another connecting control switches on the dashboard to the light bar's electronic control board.", "An automatic machine measures and cuts the required length of each cable, then strips off a specific amount of the pvc outer jacket at both ends.", "This exposes three wires, two of which are insulated and inside a foil wrap.", "After stripping off the foil, an automatic stripping machine removes some insulation, bearing the tin-coated copper wire within.", "Workers put contacts onto two of those wires-- the ground and the power-- then press the contacts on securely with a crimping device.", "Next, they connect a terminal to the third wire, the shield drain.", "This wire reduces electronic interference from sources like the police radio.", "Now for the l.e.d. light modules, the main component of which is a reflector.", "They put the reflector's plastic body into the sealed chamber of a metalizing machine.", "The machine then releases argon gas while applying hundreds of volts of electricity to a solid piece of aluminum.", "This vaporizes the metal into tiny particles, which a vacuum draws onto the plastic body in an ultra-thin reflective coating.", "To broaden the horizontal range of the reflection, workers install a device called a collimator.", "Then they take an l.e.d. light, put an electric insulator on the back of it...", "And mount it inside a housing that's specifically designed to remove heat from the l.e.d.s.", "Then they install these assembled light components in the reflector...", "Install the connector that plugs into the wire harness that leads to the control board...", "And test the finished module.", "To assemble the light bar, they slide the control board onto the base, plug in the control cable that connects the board to the dashboard switches, install the power cable that runs from the vehicle's battery to the light bar, and the wiring connecting the lights to the board.", "After mounting the white light modules on the brackets and securing them to the base, workers take the colored l.e.d. modules and slide them onto the tracks on the base.", "They make the internal connections to the control board, then plug each module into the control board harnesses.", "After testing to make sure everything works properly, it's just a matter of encasing the modules, starting with an aluminum top, then slide on transparent plastic lenses with divider gaskets in between to prevent rain from penetrating and shorting out the light.", "A cap closes up each end.", "After a final round of testing, the light bar is ready to hit the roof and the road.", "Flying a wood model aircraft is a way to experience the adventure of flight on a small scale.", "But there's a lot to do before takeoff.", "These miniature planes usually come in kits that can take dozens of hours to piece together.", "But, of course, that's just part of the fun.", "Wood model planes are part of aviation history.", "The first real flying machines were made of wood, and soon after their invention, people began building miniature wood replicas in kit form.", "Today modern manufacturing techniques take the concept to a whole new level.", "Production begins with blocks of wood that circle on a system of conveyors.", "Each time around, a long blade slices away a thin piece.", "They transfer the sheets of wood to a table that moves in a computer-choreographed sequence while lasers overhead make cuts.", "This computerized system produces parts that will fit together perfectly, no matter how intricate the design.", "To assemble the kit at home, the modeler extracts the precut parts.", "He then builds the fuselage right on top of the plans in order to follow them to the letter.", "After the fuselage has been assembled, he focuses on the wings.", "He braces the main spar with numerous ribs to create a cross-sectional air foil that will generate lift.", "He then glues the wings' leading edge to the framework.", "The framework is very similar to that of full-sized wooden wings built in the early days of flight.", "It's made mainly of tropical balsa, a wood that's both lightweight and exceptionally strong.", "The modeler joins the two wings.", "The tongue of one fits into the laser-cut slot of another.", "This joint will later be glued to reinforce it.", "He demonstrates the next step using the wing of another model.", "He drapes plastic film over the wing's skeleton.", "He tacks the plastic to it and smoothes out ripples and bubbles.", "He then heat-shrinks the plastic to give the model aircraft its tight skin.", "Of course, there's no need for a paint job because the plastic is tinted.", "Finally, he confirms that it's drum tight.", "Back on the production line, they're now winding wire to produce a spring.", "This spring is a shock absorber for the plane's front landing gear.", "With that complete, they now position a sheet of preheated plastic above six molds of wheel covers.", "He activates a vacuum that pulls the plastic over the molds.", "In seconds, it cools and solidifies into the shape of the wheel covers, called pants.", "With the wheel pants assembled to the craft, the modeler now installs the two-stroked alcohol-burning engine in the front compartment.", "He attaches the muffler to the engine's crank case.", "He then secures the spinner's back plate and propeller onto the engine's driveshaft with a washer and bolt.", "This assembly will have to withstand the force of the spinning propeller, so he tightens it to the max.", "And this model plane is now ready for flight.", "Incredibly, it started out as a bunch of parts in a box, but they all come together in the hands of a skillful modeler.", "Of course, a good set of instructions is essential.", "Assembling each model can take up to 50 hours.", "We've just shown the highlights.", "The payoff comes when the operator manipulates the transmitter joystick and the parts of the plane move right on cue.", "From fighter planes and biplanes to civilian aircraft and extreme aerobatic machines, when it comes to these historical replicas, the sky really is the limit.", "The sound of a snare drum is unmistakable-- a sharp rattle with a somewhat tinny resonance.", "What produces this distinctive sound?", "It's a vibrating set of wires called the snare wire stretched across the bottom of the drum.", "The snare drum is the center of the drum kit.", "the circular frame of a snare drum, called the shell, can be made of either wood or metal.", "Metal shells produce a sharp, loud, and more brilliant sound.", "The metal this german drum company uses is known as bell bronze, which is approximately 78% copper and 22% tin.", "Workers first glue together a three-part mold.", "It's made of a sand and chemical mixture because sand can withstand the temperature of the hot molten metal.", "The glue sets in about half an hour, and the mold is ready.", "They steady it with heavy steel plates, then scoop a bucket full of bell bronze from the furnace and pour it in.", "It took four hours at 2,300 degrees fahrenheit to melt the metal, but just a few seconds for it to solidify inside the mold cavity.", "They let the casting cool for a couple of hours, then break the sand mold to extract it.", "They clean off the loose sand with a wire brush, then ship the shell to the drum factory, where its first stop is onto an automated lathe.", "As the lathe spins, a cutter skims off a thin layer of metal, making the shell's exterior surface clean and smooth.", "Next, a computer-guided drilling machine bores 47 holes for various components, including fittings that hold and adjust the drum heads and a vent hole that increases the drum's volume.", "Then the machine changes the drilling tool for a milling tool and makes two recessed areas called snare beds in the shell's bottom edge.", "The drill left rough edges, so they clean and smooth the holes with a small grinding tool.", "Then they manually sand the snare beds.", "Next, they sand the shell's outside surface, first with a rough abrasive belt, then with a fine one.", "This leaves the metal shiny and silky smooth.", "Now they sand the inside surface by hand.", "Then they spray it with bronze-colored lacquer to give the metal an even color and prevent tarnishing.", "They taped over the holes to keep the colored lacquer from hitting the outside surface.", "Now they remove the tape and spray the outside with transparent lacquer, which allows the natural color of the metal to show through.", "25 minutes in an oven hardens the lacquer into a super durable finish.", "Then final assembly begins, starting with the tension lugs, the fittings that hold and adjust the tension of the drum heads.", "Next comes the action strainer, the mechanism the drummer flips up or down to activate and deactivate the snare sound.", "The top drum head is made of a strong polyester material.", "A chrome-plated metal hoop will hold the head to the shell.", "To tune the drum to a higher or lower pitch, the drummer tightens or loosens the screws to increase or decrease tension.", "Drumhead tension determines pitch.", "The bottom drumhead is made of clear polyester film.", "It's much thinner than the top drumhead to enable the snare wire to respond faster.", "That snare wire is made of multiple strands of stainless steel, brass, or copper wire.", "They stretch it across the bottom head, laying each end on a snare bed.", "They attach the ends with nylon cords to the action strainer on one side and to a part called the butt end on the other.", "To play the drum with the snare sound, the drummer simply pulls up on the action strainer's handle.", "Every drum undergoes a final inspection, then tuning, and a thorough performance test.", "talk about ending with a bang." ]

{ "things": [ "Hot Rods", "Decorative Eggs", "Fire Hose Nozzles", "Baseballs" ] }

[ "A hot rod is a normal car that's been radically modified to look snazzier and drive faster.", "Some amateur mechanics tinker away at building one in their garage, while other car buffs custom-order one from a specialty auto shop.", "Either way, hot-rod lovers are driven by their passion for these mean machines.", "Hot rods are customized inside and out.", "The classic cars they start out as are pretty scarce these days, so specialty shops now design and build hot-rod bodies from scratch, using state-of-the-art technologies.", "It all starts with curved steel rails 15 feet long that form the basis of the chassis.", "Every 12 inches, workers weld the rails to the car's frame.", "Next they position cross members to reinforce the frame.", "With utmost concern for quality control, they'll assemble and install by hand the transmission, the suspension, and the shock absorbers and weld those precisely aligned cross members to the curved rails.", "Elsewhere, someone polishes the stainless-steel wings, which have been laser cut.", "These wings make up the hot rod's signature front grill.", "Mounting the disc brakes onto such a high-end machine takes specialists.", "First, they screw the spindles to the suspension arm...", "Then grease the ball-bearing mechanism...", "And finally block the disc brake with a cotter pin to fasten the pieces together.", "The brake system has four calipers, one per wheel.", "Each one holds two brackets called the brake shoes.", "They close down on the brake disc to slow down and stop the wheel's rotation.", "A couple of slide pins lock the caliper into place.", "Brake shoes are prone to wear, so their alignment and oiling must be perfect.", "Time has come to install a hydraulic device that reacts to the steering wheel's movement, directing the tie rods to turn the front wheels accordingly.", "A pneumatic tool is used to affix the pinion of the steering mechanism.", "At every step, workers check and double-check each part.", "Using a jack, they lift the differential housing into position.", "It anchors the rear wheels' propulsion system to the car's frame.", "They attach the suspension arms to the axles at an angle.", "Meanwhile, a painter sprays a coat of resin gel on the plastic molds with which they make the car's fiberglass body parts.", "The gel coating eases extraction and gives the fiberglass a high-gloss finish.", "To mold the parts, a worker spreads resin on fiberglass cloth.", "They call this step \"wetting the fiberglass map\".", "They lay the map on the mold-- in this case, on a door mold-- then with a roller, carefully press out all the air bubbles.", "It takes about 40 minutes for the resin-impregnated map to solidify.", "Extracting the body part is a tricky procedure.", "They hammer wood wedges in between the hardened fiberglass in the mold.", "It's crucial to angle the wedge just right.", "Otherwise, the mold may collapse.", "It typically takes about 25 molded parts to make up a complete hot-rod body.", "After three week's work, final assembly begins.", "After the back panels comes the front, otherwise known as the nose.", "Next come the fenders, then the stylish running board.", "And no hot rod is complete without its signature grill.", "The windshield frame helps support the roof, or \"carson top\" in hot-rod lingo.", "The front hood completes this '37-ford-inspired body.", "It ships out without a paint job.", "That's because customization is everything in the hot-rod biz.", "The buyer decides how to finish the car by choosing, for example, this retro dashboard designed to blend spectacularly with the rest of the car.", "Even car junkies can be forgiven for struggling to keep up to speed with the ever-growing customization options out there.", "From the engine to the rims to the seats to the chrome-- when it comes to customizing your hot rod, you're in the driver's seat.", "Egg decorating is a craft practiced around the world for centuries.", "The ancient persians painted eggs for noruz, their new year celebration, a tradition that continues today.", "Probably the most famous are the exquisitely decorated fabergé eggs, except they aren't eggs at all.", "They're made from precious metals and gemstones.", "Each one of these decorative eggs is a unique piece.", "The artist paints them, collages images and fabric, and creates jewelry and music boxes or hangs them as ornaments.", "She always works with real eggs from birds like the rhea, the emu, geese, or turkeys.", "Here, she selects an ostrich egg and gently clamps it in place on an egg-marker stand.", "On the underside of the stand are a series of guidelines to help divide the egg into two or more equal parts.", "Working with the pencil held in a brace, she divides the egg into four equal parts.", "Then she draws a horizontal line across the egg where she'll cut it in half to create a lid.", "She'll use a hinge to hold the lid in place, so first, she draws the contour...", "Then a loose, wavy line all along the egg circumference, using the pencil guidelines as reference.", "A rotating cutter equipped with a diamond dusted blade makes a cut where the hinge will be.", "The artist now prepares some five-minute epoxy glue.", "She has a neat trick to apply just the right amount.", "She works with a strand of uncooked spaghetti, then sets the hinge in place.", "Once the hinge has set, she cuts all around the egg, then opens and closes it to make sure that hinge works properly.", "It's the first time she sees the egg's interior.", "If it needs cleaning, now's the time.", "Though this artist often chooses to leave ostrich eggs their natural color, here she's decided to give the lid a thin coat of acrylic paint.", "For the lower half, she chooses a dark tone.", "Acrylic paint allows her to work quickly, as it tries in just a few seconds.", "Next, she uses a special glue to collage strips of japanese rice paper onto the egg.", "She layers small pieces to achieve a tortoise-shell finish.", "She's ready to set the egg on its stand, so she coats the rim with epoxy, then sets the egg down, making sure the hinge is level with the stand's rim.", "The artist now turns her attention to the egg's interior.", "She lightly glues perfumed cotton balls to fill out the top and bottom parts.", "Then she applies glue along the inner rims and clips on a piece of ivory satin.", "By the time she makes it around both halves, she can remove the clips.", "The fabric now holds firmly in place.", "Next, she glues a fabric braid to trim the satin's edge.", "Here, the artist lays down a delicate strand of rhinestones.", "She applies more glue to add another braid along the lower rim...", "Then places a final strand to complete the effect.", "She sets in a tiny rhinestone to decorate the metallic filigree that hides the hinges.", "Even the egg's underside gets special attention.", "She glues another filigree to cover the hole through which they emptied the egg, then applies a water-based varnish.", "This strengthens the egg and gives it a glossy finish.", "Here's the finished piece-- a delicate jewelry box that opens with the help of a fine chain to reveal its satin interior.", "There's no end to the creativity that goes into making these decorative eggs.", "This model even has a music box built in.", "Precision tools that perform their tasks with split-second speed and accuracy are key in jobs where time is off the essence.", "Take for example the nozzle at the end of a firefighting hose.", "It allows a firefighter to regular the pressure of the water exiting the hose, no matter how confined or widespread the flames.", "A fire-hose nozzle isn't a simple point-and-shoot device.", "It enables firefighters to tailor their tactics by firing water in a stream or flush.", "Production begins with a long aluminum tube.", "A saw slices off 6-inch pieces called blanks.", "Just one tube makes about 46 blanks.", "A robotic arms swoops down to transport them to a lathe.", "Cutting tools form the valve body, which controls the flow of water.", "Then they rough up the surface, making it easier to grip.", "They make a ball groove on the outside rim for attaching the hose coupling.", "Next, they form the interior.", "Technicians verify the inside shaping with computer-imaging software.", "It's on to the milling process.", "A computer-guided drill bores several holes for the nozzle and grip attachments.", "Coolant washes away the metal chips and keeps the drill bit from overheating.", "The transformation from a blank to valve body is structurally complete.", "A laser now engraves the flow indication.", "Workers install rubber o-rings on a mandrel shaped like the valve-body interior.", "The rings keep water from leaking out the side of the nozzle.", "They position the valve body over the mandrel and blow the rings into place with a blast of air.", "Automated machines now mate the valve body to the nozzle's handle.", "A heated mold melts granulated rubber and casts it into ridges at the top of a rubber cylinder.", "This makes the shaper, the nozzle's adjustable head that switches the water from a wide spray to a narrow stream.", "Workers snip off any excess rubber, then ensure the rubber is solidly molded.", "Next, they apply grease to the inside to lubricate the parts and prevent corrosion.", "Two more o-rings are inserted to keep water from leaking out under the shaper.", "Using a specially designed spoon, they scoop up tiny, plastic ball bearings and drop them into a groove in the shaper.", "These allow the shaper to rotate easily.", "The shaper then goes over a barrel-- a metal tube that helps form the stream of water.", "To attach it, they apply an adhesive to the threads on the shaper's base, then slide the part into place.", "Workers insert a pair of hard plastic balls into the shaper.", "These enable the shaper to glide back and forth on the barrel to shape the water stream.", "Now it's time to build the sub-baffle, the nozzle component that controls water pressure.", "First they insert a pressure-regulation spring into the baffle body, then snap on a knob, which changes between standard water pressure and low pressure.", "The whole device slides directly into the barrel.", "On the other end of the barrel, they screw on the valve body.", "A rotating wheel simplifies this process.", "They now affix a pistol-style grip.", "Finally, the gasket grabber goes in.", "The steel screen keeps out nozzle-clogging debris coming from the hose.", "With the nozzle assembly now complete, it's time for what they call a damp run.", "Workers check everything to ensure the nozzle performs its task at every twist and turn.", "From the old-fashioned nozzle to the modern variety that comes in an assortment of flows, pressures, and sizes, the evolution of the fire-house nozzle is undoubtedly a lifesaver.", "When they make baseballs for the pros, they aren't just playing around.", "They build these balls precisely to league standards.", "And incredibly, those standards date back to 1872.", "Each ball is uniform in circumference and weight so the game is an equal contest.", "Crowds will go wild for these professional baseballs.", "And at the heart of each one is something called the pill.", "The pill is smaller than a golf ball.", "It's about 4 1/2 inches in circumference.", "Inside the pill's rubber casing is a sphere of cork.", "They pour latex adhesive over hundreds of pills loaded into a drum.", "Rollers spin the drum to evenly coat the pills with the adhesive.", "This adhesive never dries out completely, and the pills remain sticky to the touch.", "Next, they loop four-ply wool around the pill.", "This machine spins the pill to wind the yarn around it.", "This winding substantially fattens the pill.", "It's the first time a camera has ever been allowed to record this proprietary machine, so we can't show you all of it.", "They wind a second layer of wool around the pills.", "This yarn is three-ply, and it thickens the ball a little more.", "For a third winding, they use another three-play yard, but it's a bit lighter.", "The various layers of yarn are what give the baseball resilience, so it springs back into shape despite being hit repeatedly.", "For the final winding, they use a much thinner poly/wool blend because its surface is smoother.", "This wound pill is called the center.", "They weigh it and measure its circumference, which should be about nine inches.", "They add adhesive to a spinning drum, then load the centers into it.", "As the centers tumble, they absorb the glue, and the wound fibers adhere to each other.", "The centers air dry for 48 hours but remain sticky.", "Using this hydraulic press, they punch out figure-eight shapes from leather, complete with holes around the periphery, allowing them to be stitched into baseball covers.", "But first, they stamp the date and lot number onto them.", "Then they wrap them in wet towels.", "The moisture will make the leather pliable enough to sew.", "They roll the water-based adhesive onto one side of the cutouts, which sticks to the moist leather.", "They press two cutouts to the center's sticky surface.", "It's an exact fit.", "They clamp the leather ball in a vice, and it's time to sew.", "Working with two needles, the sewer pulls thread through the ball's center and up through the holes in the leather pieces to cross-stitch them together.", "He rubs wax on the thread to stiffen it, because if it slackens, it's more likely to tangle.", "When it comes to cross-stitching, these workers are in a league of their own.", "They make quick work of the 108 stitches in each ball.", "There are 350 sewers in this factory, and they produce 8,000 to 10,000 balls per day.", "That's a lot of home runs.", "The final stitch goes through the center of the baseball and out the other side.", "The sewer then pulls stitches into a \"v\" configuration to give the ball a consistent look and feel.", "The balls now roll into a press that smoothes down the seams.", "Smoother balls are harder to grip, and they make pitching a bit tougher for the pros.", "Finally, a three-headed stamper gives it the trademark, league logo, and the commissioner's signature.", "With drying cycles, it takes a week to make a professional baseball.", "It will be whacked and slammed out of the playing field.", "But that's life in the big leagues." ]

{ "things": [ "Recycled Skateboards", "Braided Pastry", "Construction Trailers", "Metalworking Vises" ] }

[ "Sixty years ago, surfers in california were looking to ride the streets like they surf the waves.", "They came up with an idea to strap roller skate wheels on their surfboards, and the skateboard was born.", "Since then, skateboarding has evolved into a sport, a passion and a lifestyle for people all over the world.", "In a backyard pool, a skater gauges the feel and response of these recycled skateboards.", "Recycled skateboards give new life to unrideable old boards.", "The boards on this rack would normally end up in a landfill.", "First, the designer heats up the old grip tape and peels it off.", "This reveals the board's original graphics.", "He grinds off the graphics, leaving bare wood.", "He applies epoxy on top of a colored veneer coating and stacks the boards on the table of a bottle jack press.", "He glues another board and places it on top of the first one.", "He repeats this stack process with different colored boards.", "The stacking continues until the designer has about 20 boards on the table.", "He puts the bottle jacks in place and cranks them up.", "Each jack applies 10 tons of compression, pressing the boards together while the epoxy cures and the excess glue drips out.", "The designer makes a cross cut in the stack with a bandsaw.", "Each new board he makes comes with a unique color design.", "A worker traces a cutting mark on the board and makes a rough cut along it with a jigsaw.", "He sands down the rough profile of the board using a table-mounted belt sander.", "Before the board goes to silk screening, he uses a custom template to drill holes for the assembly bolts.", "A designer pours water-based ink on top of a screen printing mesh.", "He takes a squeegee and pulls the ink through the membrane to print the company logo onto the board.", "He removes the silk screening frame, and the board continues on to the epoxy phase.", "A worker pours epoxy resin on top of a fiberglass cloth.", "He spreads out the epoxy with a squeegee in a slow, constant motion.", "This keeps air bubbles, runs, or drips from ruining the finish of the board.", "The cloth absorbs the resin.", "The worker cuts off the excess cloth with a razor blade and applies a finish coat of epoxy, completing the board's covering.", "A worker uses a router to smooth out the curve of a different board.", "He finishes the board profile with fine sanding paper.", "A worker sprinkles recycled crushed glass on the epoxy-covered board.", "This will provide grip for the board instead of grip tape.", "Before the resin hardens and cures, he presses the glass into the epoxy with a wheel.", "He sands the bottom of the board with a sanding block.", "He goes through seven different grits of sand paper.", "Then the board is washed and polished before starting the final assembly process.", "A worker assembles the wheels on a truck and bolts them on with hex nuts.", "He tightens the wheels with a wrench until he's reached the desired torque ratio and gives them a test spin.", "He inserts bolts through the board and places a urethane riser pad underneath the skate deck.", "Then he starts assembling the truck.", "He uses a screw gun to secure the wheel trucks in place.", "Each skateboard is equipped with polyurethane wheels mounted on metal trucks.", "These allow the rider to steer and control the board.", "Recycled skateboards are made form a wide variety of shapes, deck sizes, wheels and trucks, suiting each rider's unique tastes and performance needs.", "Many years ago, danish bakers got creative with pastry dough.", "They began braiding it, putting a whole new twist on deserts.", "Braided pastry looks more elaborate than ordinary pastry.", "The flakiness of the dough and the scrumptious fillings make braided pastry taste as good as it looks.", "Factory-made braided pasty can be kept frozen until you're ready to eat it.", "After just a few minutes in the oven, you will have a fresh-baked desert.", "The pastry looks as though it takes many hours to prepare, but of course, it is no trouble at all.", "To produce braided pastry, this factory uses a number of ingredients, including yeast...", "Granulated sugar...", "Pastry flour....", "Dried eggs and water.", "The ingredients go into a large refrigerated mixer.", "The cooling keeps the yeast dormant as beaters work the ingredients into dough.", "After the dough leaves the mixer, it tumbles into a hopper.", "A cutter wheel chops the dough into several pieces.", "The pieces of dough travel between conveyors that squeeze them into ribbons of dough that will be fed to an extruder.", "The extruder shapes the elongated dough pieces into one continuous sheet.", "At the exit of the extruder, an employee dusts the conveyor with flour.", "This prevents the dough from sticking to it.", "A pump at the extruder exit spreads big blocks of soft butter across the newly formed sheet of dough.", "Down the conveyor, plow-like flaps fold the buttered dough over, creating a double layer.", "This folding process, called lamination, will build up multiple layers of buttered dough, resulting in a very flaky pastry.", "Next, the dough travels into a drum with spinning rolling pins.", "These rolling pins flatten the folded dough significantly, compressing the layers into one thin sheet.", "Now, a conveyor takes the compressed sheet through a device that will fold the dough again.", "Next, rolling pins squeeze the stack of dough into a single piece once again.", "Revolving cutters slice the laminated dough as it moves forward.", "The cuts create angled strips for braiding.", "At the next station, a sweet cherry filling with a jam-like consistency is waiting.", "Nozzles deposit precise amounts of cherry filling between the angled cuts.", "Next, workers braid the dough over the center filling, creating an attractive-looking pastry.", "Sensors determine where the blade will slice the braided pastries.", "The braided pastries are transferred to another conveyor with a scale.", "The scale confirms that there is a sufficient amount of filling in each pastry.", "The braided pastries now head into a freezer set a temperature of 29 degrees below zero.", "Inside the freezer, the pastries revolve on carousels for 45 minutes.", "This gradual freezing process preserves the yeast.", "Next, the pastries wind their way toward the packaging station.", "Here, workers place a packet of icing under each braided pastry and send them to an automated packager.", "Machines wrap a plastic sleeve around the pasty.", "To minimize the amount of time the pastry is out of the freezer, things must move quickly.", "The pastries pass over a weigh station to confirm the correct amount has been packaged.", "When baked, the pastry rises significantly, allowing the braided profile to expand.", "The layers of dough separate and become flaky.", "The cherry filling seeps into the pastry.", "Endings don't get much sweeter than this.", "Pass by any construction site, and you'll probably see a trailer.", "Construction trailers provide room for an on-site office or lunch room for the construction workers.", "A trailer can also be used as a decontamination room for workers to remove their protective clothing and shower after handling hazardous materials.", "Construction trailers are typically 10 to 13 feet wide and up to 59 feet long.", "The inside of the trailer can be equipped for whatever function it will serve.", "The structure of the trailer is made of spruce, pine, or fir.", "Workers start with an underfloor made of wood particle board.", "Then they nail floor joists to the boar and frame them.", "The insulate the floor with fiberglass wool and nail a plywood subfloor on top.", "Then they spread tile glue over the subfloor.", "The glue is freeze-proof and mold resistant.", "They complete the floor by laying down commercial-grade vinyl tile or linoleum.", "To build the walls of the trailer.", "They nail pieces of woods called studs every 15 inches along the sole plate.", "The sole plate is the bottom section of the trailer's wall.", "Then they build rough openings for the windows and doors.", "Finally, they nail another horizontal piece along the top of the studs.", "This is called the double top plate.", "The structure of the wall is complete.", "Now, they apply glue to the studs and nail on a sheet of plywood to the lower part of the wall structure.", "They repeat this process with the three other walls of the trailer.", "Then they raise each wall and nail a sole plate to the floor.", "The plywood exterior wall extends below the sole plate, covering the side of the floor frame.", "They glue the plywood to the floor frame and reinforce it with nails.", "Next, the roof of the trailer-- it is constructed in layers.", "First, they lay down the fiber board ceiling, then install a plastic vapor barrier.", "Next, the roof joists-- the joists have sloped edges to drain water off the roof and holes for electric cables.", "Once the joists are installed, workers frame the roof structure with end plates.", "Then they thread in electric cables for the lights, outlets, baseboard heaters, and other electrical components.", "Now, they begin their work inside the trailer.", "First, fiberglass wool insulation is installed between the studs.", "A plastic vapor barrier is added.", "Then they install smooth wood panels.", "The wood panels are laminated with vinyl for a clean finish.", "At the same time, work continues on the outside of the construction trailer.", "Under the floor, workers install one to three axles.", "The amount depends on the trailer's length.", "Each axle can support around two and a half tons.", "After workers install all of the exterior plywood, workers begin the finishing process.", "At the top and bottom of the trailer, they install starter moldings made of painted sheet steel.", "Then they begin installing panels of painted steel.", "Windows and doors are installed before adding the painted steel siding.", "This is so the ends of the steel siding will beneath the door or window moldings, producing a neater finish.", "Trailers longer than 32 feet have both heating and air conditioning via a duct system.", "Workers mount the air ducts to the ceiling with brackets.", "They also install electrical outlets, light fixtures, interior trims, and electric baseboards for additional heating.", "Trailers shorter than 32 feet only have electric baseboard heaters and a window-mounted air conditioner.", "However, there is the option to upgrade to the full duct system.", "To finish the roof, they staple white fiberboard to the roof joists.", "Then a hitch system is installed.", "This enables a truck to haul the trailer to and from the construction site.", "A metalworking vise holds a piece of metal in place so that a computerized cutter can shape it into a part.", "You often see vises on \"how it's made\".", "Now it's time to find out how they are made.", "Metalworking vises have parallel jaws that close tightly around a piece of metal.", "Their firm grip allows a part to be machined with pinpoint accuracy.", "To make a metalworking vise, they start with a steel rod.", "It spins in a lathe as tools carve threads into it.", "The result is a lead screw that will be used to open and close the jaws of the vise.", "Next, cutters transform a piece of aluminum into a thumb screw.", "The thumb screw is used for turning the lead screw.", "The outside of the screw is given a neural texture for better gripping.", "The final tool shaves the roughed-edge rim of the screw to make it smoother to the touch.", "This completes the thumb screw.", "Now, an automated saw cuts the steel bar into smaller pieces.", "Each piece will be used to make the base of a vise.", "Next, a cutter sculpts the outside of a base piece to the desired profile.", "Another tool carves a channel in the center of the base piece.", "The cutting machine also creates components for the vise's shuttle system.", "Then a machine cuts the reverse side of the vise base flat and smooth.", "It also drills holes for mounting the vise to milling equipment.", "A constant flow of coolant is applied to protect the tool from wear.", "Next, a steel block is locked in a vise.", "Yes, they used vises to make new vises.", "The vise holds the piece of steel firmly in place as tools shape it into one of the new vise's jaws.", "After a heat treatment, they spray small particles of sand onto the newly formed jaw.", "The sand blasting removes blemishes.", "A worker now submerges all parts of the vise in a hot chemical solution, leaving them there for eight hours.", "This chemical solution gives the parts a black oxide finish and protects them from rust.", "Here is the vise before and after the oxide treatment.", "Next, a laser etches the brand name, part number, and basic dimensions onto the base of the vise.", "Then a probe gauges the size of the mounting hole.", "It also determines if they've been drilled in the correct location.", "Now, it's time to assemble all the parts of the metalworking vise.", "The worker threads retainer rings onto the lead screw.", "Then he installs the lead screw in the base.", "He places shuttle devices onto each end of the lead screw.", "He inserts spacing blocks in the channel.", "He moves the shuttle devices forward, using the spacing blocks as guides for the correct positioning.", "After removing the spacing blocks, he adjusts the retainer rings.", "He places steel jaws on the shuttle devices and bolts them in place.", "Once the thumb screw has been attached to the lead screw, the assembly is complete.", "Now, it's over to a computerized measuring station.", "The controller positions the vise in the equipment, then a probe moves in.", "The probe compares the coordinates of the vise to a computer model and checks that it measures up to standards.", "Metalworking vises take four weeks to make and will hold up for many years." ]

{ "things": [ "Yacht Wheels", "Braided Rugs", "Automobile Thermostats", "Chisels" ] }

[ "Today on \"how it's made\"...", "Yacht wheels...", "Braided rugs...", "Automobile thermostats...", "And chisels.", "A wheel is a fairly modern way to steer a boat.", "Before the 18th century, captains shifted a stake attached directly to the rudder.", "Today ship wheels connect to the rudder through a mechanical or hydraulic system.", "Found mostly in yachts up to 200 feet long, they're a luxurious way to echo the glory days of the sea.", "This company makes yacht wheels as large as 5 feet in diameter.", "It uses two traditional shipbuilding woods-- american holly and burmese teak, species that are as beautiful as they are durable.", "Workers use a table saw to cut both types of wood into long, thin strips that will become the wheel's rim.", "They measure the strips with digital calipers, then sand them down to a thickness of just 1/8 of an inch.", "Using a disk sander now, a worker angles the ends into what are called scarf joints.", "He'll join the strips by fitting these angles together.", "After coating each strip with epoxy, he attaches it with clamps to a round jig, waxed beforehand to prevent sticking.", "The glue is waterproof because the wheels are often exposed to rough weather up on deck.", "The worker gradually bends each 6 1/2-foot-long strip all the way around the jig.", "And a spring-loaded clamp temporarily holds the end of each strip in place until he aligns the scarf joint with that of the next strip.", "It takes up to eight hours of nonstop work to lay all the strips.", "He alternates between the blond holly and the darker teak for a total of seven layers.", "Then he leaves the rim to set overnight.", "To make each spoke-- the wheel has five of them-- a worker temporarily joins strips of holly and teak with double-sided tape.", "A computer-guided cutting machine then carves an opening through the middle and shapes the outer edge into a triangular shape.", "This reduces the spoke's weight and helps it fit to the rim later on.", "Next he removes the tape and glues the wood strips together, along with others made of carbon fiber.", "They strengthen the spoke while keeping it lightweight.", "He places a waxed jig in the center and clamps in place.", "He leaves the spoke to set overnight.", "The next day, he sands away the dried glue, then uses a router to round the edges.", "Together, the four wood and three carbon-fiber layers are just one inch thick.", "He traces a template on a stack of 14 pre-glued, curved strips of holly and teak.", "He follows his trace lines with a band saw, cutting out what's called a fairing.", "This component will join each spoke to the rim.", "Now he drills a hole in each fairing...", "And inserts a temporary dowel to position a reinforcing strip of carbon fiber at the top.", "It's time to join the spokes to the rim.", "Earlier, he glued strong fiberglass dowels to the rim.", "Now he inserts them into the fairings and into holes in the spokes, also glued beforehand.", "Through the openings, he clamps the spokes to the rim.", "Then he positions an aluminum hub in the center, tapping it into place with a mallet.", "Now, with a jigsaw, he cuts a sliver off the ends of the fairings so they'll curve into the rim.", "He uses a router to round off the vertical edges of the wheel.", "He files the fairings by hand to complete the smooth transition to the rim.", "Just these finishing touches alone can take up to five hours to complete.", "Using a router, it takes him another five hours to gradually round off the horizontal edge.", "Now to protect the wheel from the elements-- particularly sun damage.", "First, a polyester primer.", "Then they sand it and apply two coats of waterproof varnish.", "On the yacht, five stainless-steel bolts attach the wheel to a pedestal that connects to the rest of the steering mechanism.", "To change how fast the rudder moves, you simply turn a knob at the center of the wheel.", "How's that for power steering?", "A relatively high-tech way to navigate the open seas.", "New england settlers in the 1700s were the first to braid strips of used clothing and then sew them into rugs.", "Today high-speed machines create this classic look in a fraction of the time, but with synthetic as well as natural fabric and yarns so the rugs last even longer.", "This company's most popular rugs are oval or rectangular, some small enough for your stairs.", "The rugs begin as yarn.", "They wind the yarn onto bobbins that fit the factory's machines.", "The yarn ranges from pure wool to a blend of wool and polypropylene that makes the rug durable even outdoors.", "This machine braids yarn from 24 bobbins around a core of synthetic fabric.", "The result is a complicated weave called cable lock.", "Other rugs have just three braided segments, in what's called a flat braid.", "Here a worker uses a powerful sewing machine to join flat braids with sturdy nylon thread.", "This makes one enormous piece the length of half a tennis court.", "The piece moves along a conveyer to an automated rotary saw that cuts it to size.", "The saw passes twice to ensure a clean cut through the one-inch thickness.", "Another industrial sewing machine attaches binding tape to seal the edge.", "This prevents rectangular and square rugs from unraveling.", "Oval and round rugs don't need this because their braids aren't cut.", "This machine does what's called serging.", "It sews yarn over the binding tape to cover it, a purely aesthetic gesture.", "To make fabric rugs, a seamstress joins several pieces of different fabric along one edge.", "They're a cotton-and-polyester blend that's durable and easy to wash.", "The more patterns, the more complex the rug will look.", "After they wind the fabric into a roll, a rotary saw cuts the roll to make strips that are one inch wide.", "The fabric strip then unwinds into a machine that folds it over filler.", "This forms the core of the fabric tubes they call spaghetti.", "The machine wraps the fabric around the filler, then sews the edges into a closed tube.", "Rollers guide the spaghetti out of the machine and onto bobbins.", "This machine weaves spaghetti from three bobbins into a flat braid.", "Fabric rugs are made only as flat braids because the material is too thick to weave into a cable lock.", "The braids settle into barrels for storage until they're woven into rugs.", "Sometimes mats are assembled from a variety of braids for a different look.", "To make an oval or round rug, a worker coils one continuous braid around itself.", "At the same time, she sews each braid to the next.", "These rugs can have anywhere from 16 to 320 rows.", "This factory uses tables with holes that blow pressurized air to float rugs like this one as they grow heavier.", "The ovals range in size.", "They can be as small as a doormat and as large as a swimming pool.", "But when the rugs get really big, some extra help may be required.", "It takes her about two hours to sew together one of these huge rugs.", "Lastly, the worker staples a tag to the rug that reveals the style and size before the rug heads off to shipping.", "Perhaps more than any other floor covering, these rugs don't just lie there.", "The variety of styles and shapes means they really tell a story at your feet.", "Only about 2 inches in diameter, a car's thermostat sits between the engine and the radiator.", "Until the engine warms up, it blocks the flow of coolant to the radiator.", "When the engine reaches about 200 degrees fahrenheit, the thermostat opens, letting coolant flow through the radiator and into the engine to prevent overheating.", "The key component inside the thermostat is wax.", "When the engine heats up, the wax melts and the thermostat opens, triggering the cooling system.", "The wax melts quickly because it contains powdered copper, graphite, and/or aluminum.", "As the wax transforms from solid to liquid, it expands.", "The pressure pushes a pin that opens the valve that enables the flow of coolant to the engine.", "After heating and mixing in the powders, workers pour the wax into slab-shaped molds.", "It takes about a half-hour to cool and solidify.", "Then they extract the slabs and grind them up.", "They feed the granulated wax to a pill-making machine, the kind pharmaceutical factories use.", "It compress the granules into cylindrical pellets.", "Meanwhile, workers feed a copper strip into a machine called a high-speed transfer press.", "Its successive stations shape the copper cup that will house the wax pellet.", "The first station stamps out a circle.", "The others progressively stretch and form the circle into a cup.", "The cups go into an automated assembly machine, which drops a pellet into each one.", "A pin then bores a hole down the center of each wax pellet.", "The machine inserts a rubber sleeve into the pellet hole and caps the sleeve with a brass cover.", "Then it crimps the cup over the cover, forming a seal that's leak-resistant.", "Now the machine inserts the stainless-steel pin that opens and closes the coolant valve.", "The pin goes right into the rubber sleeve in the center of the wax pellet.", "How do all these parts work together?", "The melting wax expands within the cup, squeezing the rubber sleeve.", "That forces the pin upward, opening the coolant valve.", "Now they heat the parts to the temperature at which the engine coolant should kick in.", "A calibration machine squeezes the cup until the pin rises enough to open the coolant valve.", "The components now enter a machine which connects that valve.", "The valve is made up of two stainless-steel pieces.", "The machine loads one on top of the other, over the thin end of the cup...", "Then pushes the valve over the end of the cup, attaching it to the wide end.", "On the left is before the valve installation, and here's after.", "Meanwhile, a press forms the top part of the thermostat, called the flange.", "It's made of stainless steel coated with a lubricant.", "As with the cup, a series of dies progressively forms the flange.", "Now for the final assembly.", "First, the thermostat's stainless-steel frame.", "Next, a stainless-steel spring.", "Its job is to close the valve when the engine cools.", "Now the assembled components go inside the spring.", "The flange goes on top.", "A tool called an orbital riveter flattens a tab on either side of the flange.", "This holds the frame onto the flange.", "The assembly machine now crimps two little tabs against the pin, keeping it from falling out of the rubber sleeve.", "And with that, the thermostat is finished.", "This demonstration shows how, as the engine heats up, the melting wax pushes the pin upward, and when the engine cools, the opposite happens so that even though you might boil over in heavy traffic, your engine doesn't have to.", "A chisel is a metal tool with a sharp end for shaping stone, metal, or wood.", "You use your hand, a hammer, or a mallet to drive it in and cut.", "Although chisels date back to ancient asia, today's factories use heat-treated steel and high-tech machines to make them stay sharper longer.", "A wood chisel needs to be very sharp, especially for intricate carving.", "Making chisels starts when they insert a 16 1/2-foot-long bar of high-carbon steel in a mechanical press.", "The carbon lets them heat-treat the steel to give it a long-lasting edge.", "But first the press cuts the bar into 8 1/2-inch-long rods.", "The rods then go through an induction heater.", "In just six seconds, a magnetic field heats them to about 2,300 degrees fahrenheit, a temperature at which the steel can be forged.", "A worker sets each hot rod into a die in a forging press.", "The die slams down, applying 700 tons of pressure.", "This produces what's called a forging, a rough shaping.", "The die can produce as many as 60,000 forgings before it wears out.", "Each one goes into what's called a trimming press.", "Here a die cuts out the precise shape of the chisel, with the blade on one end and the tang on the other.", "The tang later fits into a plastic or wooden handle so you can comfortably grip the tool.", "The factory sends the excess metal out for recycling.", "After the chisels cool off for several hours, workers run them through another induction-heating machine, this one with two coils.", "The first heats them to 1,400 degrees fahrenheit.", "Then warm water cools them down.", "This rapid reduction in temperature is called quenching.", "It's what hardens the chisels enough to be strong and stay sharp.", "The next coil heats them to about 700 degrees fahrenheit.", "This step is called tempering.", "It relieves the stresses that the quenching phase created inside the metal.", "Spring-loaded clamps now release the chisels from the machine, and they drop into a container to cool overnight.", "The next day, workers can start to polish and sharpen the chisels.", "That removes the metal discoloration the heat-treating caused.", "To polish the barrels, the round areas joining the blade and the tang, workers load the chisels into devices called chucks.", "These clamp the chisels securely by the blade as the barrels spin against a rough-grit sanding wheel.", "After about seven seconds of sanding, the blades are ready for polishing.", "A powerful magnet locks them in place on a round table.", "It rotates, running the blades against an abrasive grinding wheel.", "As water cools the metal, it also applies a rust-proofing chemical to the steel.", "This polishing cycle takes about 20 seconds.", "The highly polished finish is a key selling point.", "Now to sharpen the blades.", "A worker loads the chisels into another machine.", "It moves the chisels back and forth against another grinding wheel.", "After about five minutes of this, the blades are razor-sharp.", "Only the last 1/2 inch of the chisel, sloping at a 22-degree angle, is the cutting edge.", "This factory uses preformed extruded-plastic handles for its chisels.", "A hot metal die with raised lettering presses and melts a colored plastic ribbon into each handle.", "This imprints the company logo, the model size, and a reminder to wear safety goggles.", "The next machine puts a steel cap on top and forces the tang inside the hole.", "The cap reinforces the handle against hammer blows.", "The tang stays put because it's actually a bit bigger than the hole it goes into-- in industry lingo, an interference fit.", "The finished tools come off the line.", "Now you can chisel your crafts for years to come." ]

{ "things": [ "Custom Running Shoes", "Axes", "Racing Karts", "Animatronics" ] }

[ "Poorly fitted shoes can ruin a runner's day.", "They can compromise the runner's gait and lead to injuries.", "It's why custom-made running shoes have become popular.", "Tailored for one specific pair of feet, they give the runner the necessary support to go the distance.", "Thanks to the use of synthetic materials, the running shoe is more lightweight and flexible than ever before.", "Customizing these shoes takes the concept one step further.", "They start by taking a precise 3-d laser scan of each foot.", "Then the runner steps onto a device called a pressure plate.", "Rubber tipped pins sprout up around the foot.", "This technique creates an exact outline of the sole, including the arch.", "Next, a high-pressure water jet cuts through synthetic fabric like a knife.", "A computer guides the cuts, following the measurements from the scans.", "The cutouts will be used to make the upper-- that's the part of the shoe that wraps around the top of the foot.", "A seamstress sews together the cutouts, creating the basic shell of the running shoe's upper.", "Uppers come in a variety of colors, and when a shoe is custom ordered, the athlete can choose.", "After holes for the laces have been punched into the upper part of the running shoe, the seamstress stitches on stripes-- a trademark look for the company.", "She sews the tongue and a fabric innersole to the upper, using rounded stitching that will prevent fraying.", "The innersole joins the two sides of the upper, and this custom running shoe is starting to come together.", "But this shoe needs shape and structure before it's ready to pound pavement.", "So, the next worker inserts a plastic replica of the athlete's foot, called a last, into the shoes.", "She glues fabric to the heel of each shoe, and then pounds and presses it to ensure the fabric adheres.", "Left to sit for five hours, the shoes conform to the shape of the custom-made lasts.", "But if the measurements are even slightly off, they'll scrap the shoe and start again.", "It's time for the foam midsoles.", "The workers cut the foam with dies based on the individual's feet.", "The foam is dual density for maximum performance.", "He sands each midsole, beveling the tips.", "This will make for a smoother landing when the foot hits the ground.", "The outsoles are next.", "The worker sculpts these treaded rubber soles along the same lines as the midsoles, so they'll fit together perfectly.", "He glues the mid and outer soles together.", "To make sure this job really sticks, they squeeze the two soles together using a hydraulic press.", "In a custom shoe, the athlete can also choose the tread.", "A deeper tread is more appropriate for trail running, and a shallower one will grip pavement better.", "The worker now glues the bottom of the shoe to the top.", "The sole is made a little larger than the fabric upper, which allows her to fold it around the upper for a neat finish.", "A machine they call the claw applies pressure to enhance the bonding of the sole to the shoe.", "Then they insert a memory foam insole which melds to the shape of the foot.", "This insole is also breathable and has been treated with an antibacterial agent.", "The athlete's name on the heel is the final personal touch for these custom running shoes.", "They've taken about five days to make, but they're ready for a marathon.", "Ever since primitive times, humans have been using axes to chop wood.", "The first axes were simple, sharpened stones, but when a handle was added about 35,000 years ago, it increased the force that could be applied with each strike, and that gave the ax much greater impact.", "Today, the ax hasn't lost its edge.", "Despite the proliferation of mechanized tools, it offers a low-tech, hands-on way to get the job done.", "A modern ax starts as a cylinder of high-quality steel.", "A ram nudges it into an induction furnace.", "The intense heat makes the steel white hot and pliable, allowing it to be stretched and shaped.", "A powerful press then pounds the steel into a series of dies to further define the ax profile.", "A cutter head trims the edges.", "Operators now transfer the ax to another ram, which presses it into a die to straighten and level it.", "Then it's on to a revolving rack for a half-hour to cool down and harden, just enough so they can be handled.", "A worker loads dozens of the axes into a tumbler.", "They are tossed about with tiny steel pellets, and the resulting friction rubs scale from the surface of the steel and also smoothes the edges.", "Then this worker presses the back of the ax head against a sanding belt to bevel the edges.", "He sands the sides of the ax head for a smooth finish.", "In just seconds, he sharpens both sides of the cutting edge.", "It takes well-honed skills to do this with such quick precision.", "He then polishes the neck of the ax against a narrower, finer-grit sanding belt.", "And it's time for a dip in a special solution, heated to 1,500 degrees fahrenheit.", "They then quench the red-hot steel in warm oil.", "The abrupt temperature change hardens the metal so it's tough enough for any wood-chopping job.", "At the next station, a worker assembles prepunched leather and plastic rings to build the ax grip.", "She places the black-and-white plastic rings at each end of the leather pad, to give the grip a customized look.", "The rings get progressively smaller as she tapers the grip to fit the throat of the ax handle.", "It takes about 36 of the leather rings and 6 plastic ones to make one grip.", "She transfers the grip pack to an assembly press...", "And inserts the lower part of the ax, which has been lubricated with bees wax, into the grip's center holes.", "A hydraulic ram drives it through.", "The lubrication ensures this job doesn't hit any snags.", "She now flattens metal prongs at the base of the handle to secure the grip.", "The axes rotate as a long, abrasive belt rocks against the leather.", "It sands the grip to make the layers flush.", "A worker finishes off the job with a particularly aggressive sanding.", "His handiwork makes this grip look really smooth.", "A dip in clear lacquer brings out the grain of the various pieces of leather, and they appear to merge into one.", "Once the lacquer dries, another worker polishes the exposed steel against a belt with a very fine grit.", "The result is a glossy sheen that ensures this ax will definitely look good on the job.", "It takes about two days to make one of these axes, but they're designed to last a lifetime.", "Kart racing is an international motor sport that has a huge following, especially in europe.", "The karts look a bit like miniature formula-one racecars but have no suspension system.", "Kart racing can be even more exciting than f-1 because of their small size and increased maneuverability.", "this italian-made racing kart-- with its one-cylinder, 125cc engine-- reaches speeds of 110 miles per hour.", "An aluminum case houses all the engine components.", "A computer-guided drill bores various holes for installing them.", "First in-- the engine's six steel gears.", "Each gear is actually comprised of several gears.", "They thread them onto a shaft.", "Then everything goes into the gear box.", "Behind the gears goes the gear shifter, which the driver operates with a lever.", "Next comes the drive shaft.", "It turns a chain that rotates the axle on which the rear wheels are mounted.", "On the other side of the engine case, they install the drive-shaft gears.", "These ensure the shaft rotates at a stable and controlled rate.", "The red markings help the technicians align the gears.", "The clutch cover closes up the gear box.", "The clutch's main housing, called the drum, contains the clutch disks.", "These disks transmit crankshaft motion to the gear box, which turns the drive shaft, which moves the chain that rotates the rear wheels.", "Thick steel springs grip and release the clutch disks.", "This flap component, called the lameli pack, controls how much fuel enters the engine.", "Stepping on the acceleration pedal creates a vacuum that opens the flaps and sucks in more fuel.", "The cylinder houses the piston that rotates the crank shaft.", "This engine head seals the cylinder in which the combustion cycle occurs.", "The ignition goes on the left side of the engine.", "The engine is now finished and ready for a bench test.", "Technicians use special instruments to monitor and calibrate its performance.", "The racing kart's chassis is made of steel tubing.", "At the back, they mount bearings to hold the rear axle.", "Then they mount the axle itself and on it-- brake disks.", "They attach brake calipers to the chassis.", "Under braking, they squeeze the disks to stop the wheels from turning.", "After measuring again, to ensure the rear axle is perfectly centered, they lock it into position in a way that enables it to rotate, of course.", "Now for the steering system.", "At the front of the chassis, technicians mount a spindle on each side.", "The spindles turn the kart's front wheels.", "Once technicians fasten the steering column up top, they connect tie rods to the spindles.", "Tie rods transmit the rotation of the steering column, via the spindles, to the front wheels.", "Next, technicians mount two spring-loaded pedals in front of the chassis.", "The brake system is hydraulic, meaning that pressurized fluid activates the calipers to grab or release the brake disks.", "Next come the wheel humps on which the tire rims go.", "Then the engine...", "Followed by the tires...", "And a fiberglass driver's seat, which, due to the lack of suspension, lets the driver feel every inch of the track.", "Finally-- the steering wheel and a data recording device that tracks everything from speed and lap time to tire and exhaust temperatures.", "Animatronics is the construction of robotic puppets that move in a lifelike way.", "You often see animatronic characters in science-fiction movies, as well as theme parks and carnivals.", "Please be advised that this segment contains images which may not be suitable for younger viewers.", "When it comes to the horror genre, the more gruesome the animatronic character, the better.", "Meet crazy kristen.", "She starts out as a hunk of clay.", "Her creator sculpts her form on a vertical table.", "Once he finishes her shape, he switches to finer tools to craft her gory features.", "He uses water and a sponge to give her skin realistic texture.", "Once the clay is hardened, they lay crazy kristen on her back and drown her in gypsum plaster.", "In an hour or so, the plaster sets, and they remove the sculpture, creating a mold from which they'll produce multiple crazy kristens.", "The mold is quite heavy, so for easier handling, they sever the body in two.", "Then they'll fill each mold cavity with liquid latex rubber.", "A three-millimeter skin soon hardens against the mold cavity wall.", "They suction out the remaining liquid latex.", "Meanwhile, they weld together a steel skeleton, a grate for her rib cage, a strip for her spine, chains for her arm bones, ball bearings for her joints, and steel reinforced rubber for her neck.", "So far, crazy kristen has skin and bones.", "Now she needs flesh.", "They fill each mold cavity with expanding polyurethane foam.", "To control the expansion, they cover the top with a plastic sheet and guide the foam with their hands.", "The lower body doesn't require an inner support structure because it's immobile-- just steel chains in the legs to hold them in place.", "Once the foam hardens, it's safe to extract crazy kristen's body from the molds.", "They trim off excess latex along the perimeter.", "Then sit her upper body on a large swiveling ball bearing mounted on a vertical metal base.", "They insert a pair of rods through holes in the base.", "Each rod is bolted to a plate sitting on those ball bearing joints in her skeleton.", "The other end gets welded to the base.", "These cylinders are pneumatic, meaning air pressure opens and closes them, making crazy kristen thrash about.", "It's all controlled by this digital device they mount on a guitar amplifier.", "It sends electric pulses that control the pneumatic cylinders.", "An actress records the accompanying shrieks and moans.", "they transfer the soundtrack to the digital control box.", "The box triggers the sound effects, along with the movement.", "It's time to apply crazy kristen's makeup.", "For her skin colors, they use a half-and-half mixture of house paint and liquid latex rubber.", "For her eyeballs, they use off-white opaque ink.", "Then they airbrush the iris...", "And paint in the pupil with the stick end of a small brush...", "A few veins with a red pen...", "Airbrushed ink on her mouthguard...", "And finally clear epoxy over her eyeballs, to make them glassy.", "They top her off with a wig, mount her lower body to the base, then complete her look with a straitjacket, because crazy kristen's home is the insane asylum." ]

{ "things": [ "Clay", "Pitted Prunes", "Spurs", "Polyurethane Tires" ] }

[ "The origin of so many useful things is muddy-- from bricks to tiles to dinnerware.", "Even the kitchen sink can be made from clay.", "Clay is a component of soil that, when wet, has a certain plasticity that allows it to be shaped into hundreds of things.", "There are many shades of clay.", "The whitest is the purest and used to manufacture things like dinnerware, sinks, and tiles.", "Clay isn't just dirt.", "It's one of the most valuable resources on earth.", "To find it, they excavate topsoil and gravel at this site in kentucky.", "They dig down as far as 80 feet.", "The deeper they go, the whiter the clay.", "A loader transfers it to a truck for transport.", "Fresh from the earth, the moisture content of the clay is between 15% and 22%.", "The particles of clay clump together, but the clumps can be easily broken up.", "The clay will now be processed to a workable form.", "It's a short drive from the clay pit to the factory.", "They unload it in a building without walls so it will air dry a bit.", "They do a visual inspection of the color and consistency.", "Every few loads, they also do a chemical analysis of the mineral content.", "This allows them to categorize the clay for specific purposes and for blending in different clay recipes.", "Next, they transfer the clay to a revolving tub.", "The tub has knives that protrude up into it.", "As it spins, the knives hit the lumps of clay to chop them into smaller pieces.", "These smaller clay chunks flow out of the chopper and ride a conveyor into a hopper.", "The hopper feeds the clay to a mill.", "En route to the mill, the clay travels through fire-- a flame generated by a furnace below.", "This is called flash drying, and it brings the moisture content down to 1% to 2%-- the right consistency to now grind it into a fine powder.", "The grinding mill is a shaft with numerous hammers sandwiched between steel plates.", "As the shaft turns, the hammers will swing to grind the clay lumps into a powder.", "The mill will also blend different kinds of clay to create specific products.", "They put the cover on the mill and set it in motion.", "The hammers pulverize the different clays into a powder.", "Overhead, a machine sucks up the ground clay, using spinning blades and a vacuum.", "The cyclone effect lifts up the clay particles and leaves heavier impurities like sand behind.", "The result is a purer clay blend.", "Here are various clays now dried, pulverized, and purified.", "They run numerous tests on clay.", "For this one, the technician presses the clay powder into a cake-like disc, using a hydraulic press.", "At the same time, he weighs the clay.", "Weight can indicate the clay's pliability and the speed at which it can be cast.", "He fires the clay disc in an oven overnight and examines the color to confirm that it's the desired hue.", "Over at the packaging station, a worker hangs open bags on spouts, which will fill the bags full of dry powdered clay.", "The customer will add water and other ingredients to turn this particular blend into a glaze for things like tiles and sinks.", "In powdered form, the clay is lighter and cheaper to ship.", "Some customers prefer wet-processed clay, even though it's heavier.", "For that, they add water and chemicals to make a slurry.", "They pump the slurry through a sieve to screen out impurities.", "The clay slurry now flows into big mixing tanks, where it remains in a constant state of agitation.", "Continuous mixing keeps it fluid.", "Without it, the clay would thicken to the consistency of peanut butter.", "On delivery day, they pump it into tanker trucks.", "At another factory, this particular batch will be used to make sinks or tubs.", "The next trucks will likely be headed somewhere else.", "You never know what will be made from this product of the earth.", "Among dried fruits, none inspires a gut reaction like prunes.", "Eating them is one way to kick-start a lethargic gastrointestinal system.", "High in fiber, sweet and chewy, prunes are actually dried plums, and they're a delicacy that's as old as civilization itself.", "Prunes have been found in ancient egyptian tombs, placed there to snack on during the journey to the next world.", "Fast-forward to today, and people are still snacking on prunes.", "They also add them to salads, muffins, and main-course recipes.", "It all starts with the growing stock.", "Not all varieties of plums are suitable for drying.", "At this california orchard, they grow the d'agen plum-- a european variety.", "Harvesting machines shake the trees by the trunks, and the fruit rains down onto a conveyor, which delivers it to bins.", "They then truck the plums to the receiving plant...", "And unload them directly into a washing system.", "Tree leaves float to the surface of the water to be removed.", "The plums exit onto a table that vibrates to distribute them evenly so they land on trays in fairly equal amounts.", "A paddle overhead levels them on the trays.", "Machinery stacks the trays of plums on racks.", "The plums are now ready to dry.", "They're about 80% water when they enter the dryer.", "16 hours of heat exposure brings the moisture content down to 19%.", "Plums were once sun-dried as a means of preservation, but a modern industrial dryer produces more uniform results.", "The dried plums travel under a vacuum that sucks out sticks or stems.", "Then the prunes travel to a shaking conveyor with a lot of different-sized holes.", "The first holes are the smallest, and they become progressively larger to sort the prunes by size.", "They fall into separate bins below.", "The smallest fruit will be used for breakfast or diced product.", "The largest prunes will end up as snack food.", "Preserved by drying and now sorted, they can be stored for months until processing.", "At the processing plant, the prunes head into a super-sized steam cooker.", "They spend 18 minutes in there.", "The steam cooking partially rehydrates them, softening the prunes so the pits can be removed more easily.", "They must now remove the pits before the prunes start to lose moisture and become too dry for the job to be done efficiently.", "The prunes speed towards the pitting operation and flow into five lanes.", "Each one leads to a separate pitting line.", "With five different pitting lines, they'll process hundreds of prunes a minute.", "Clamps close around the prunes, securing them for knives to push out the pits.", "The pits will be ground up and added to animal feed.", "The pitted prunes make a soft landing on a rubber conveyor, which takes them into a laser-detection center.", "The laser finds pits or pit fragments and relays the information to a computer.", "The computer activates air jets that blast out the unwanted material.", "It happens so fast, it's all a blur.", "On another shaker conveyor now, the prunes bounce towards a big drum.", "The drum revolves slowly to gently toss the prunes as they pump in a preservative, flavorings, and oil.", "The prunes absorb the ingredients as they tumble around in the drum.", "At this point, they sample the moisture content of the prunes every 15 minutes.", "The technician grinds and compresses some prunes into a disc.", "She drives an electrode into it to gauge the moisture.", "It should be between 28% and 32%-- enough to improve the texture, but a lot less than fresh fruit.", "It's time to wrap things up.", "Sectioning arms open the bags.", "Feeders dispense a precise amount of pitted prunes into them.", "A heated device then melts the ends of the plastic bags together to seal them.", "They produce 120 bags of prunes a minute at this factory, so adding fiber to one's diet shouldn't be a problem.", "If you ride horses regularly, chances are you own a pair of spurs.", "Spurs strap onto the heels of riding boots.", "Each spur has a small wheel, usually spiked, with which the rider prods the horse to get it to start moving or move faster.", "The anatomy of a spur is elementary.", "The wheel, called the rawl, is mounted in the shank.", "The shank is connected to the heel band.", "The heel band is held to the boot by a leather strap.", "The metal parts are made from a strong, yet flexible, type of steel.", "A computer-guided laser cuts the starting shape for the heel bands.", "A quick strike of a press stamps them with the company name.", "Next, workers smooth and bevel the edges, using a sander outfitted with a special belt for grinding metal.", "Next, they hammer the piece around a steel block, cushioning the blows with a piece of wood to avoid marring the surface.", "The block is shaped exactly like the heel of the boots for which the spurs have been ordered, ensuring a custom fit.", "They heat evenly with a torch.", "This relaxes the steel around the block so that the heel band permanently registers this shape.", "Then, some final taps to lay the band completely flat against the block.", "This perfects the shape.", "They submerge the heel band in cool water.", "This tempers the flexible steel, rendering it hard and stiff.", "Then, with a fine-grit belt, they sand away any surface imperfections.", "A pair of spurs is made up of some two dozen steel pieces, all of which go through the same prep as the heel band.", "Once all the parts are ready, workers precision weld the shank to the mid-point of the heel band.", "Next, to each side of the heel band, they weld a pin, which holds a pivoting arm.", "These swingarms, as they're called, hold the leather strap that retains the spur to the boot.", "To make the rawls, they trace a template on steel, then cut along the lines with a metal band saw.", "If the rawl shape is elaborate, a computer-guided laser cuts them out.", "After sanding the rawl thoroughly to smooth sharp edges which could cut the horse, they mount it to the shank with a stainless-steel pin.", "Then they weld the back of the pin.", "Now the artistry begins.", "A craftsman creates decorative overlays in sterling silver.", "He cuts their shapes with a jeweler's saw, draws a design, then, using an array of engraving tools, meticulously carves it out.", "He cleans the back of the overlays with flux-- an acidic chemical-- then coats them with solder.", "The trick is to apply just enough to bond the silver to the steel.", "Too much would overflow and ruin the front.", "By the time he gently applies each overlay to the spur, the solder has cooled and solidified, so he warms the steel with a torch from underneath.", "This reheats and liquefies the solder, which then cools and resolidifies, bonding the silver to the steel.", "The heat causes some discoloration, which he easily removes with a bit of flux.", "Once all the silver overlays are soldered to the spur, workers polish them on a cloth buffing wheel.", "The finishing touch-- they submerge the spurs in a tank containing a chemical solution called gun bluing.", "It turns the shiny steel parts black.", "To produce an antique brown, rather than black finish, workers heat the spurs in an oven, then apply a chemical which tints the steel.", "Now for the leather straps.", "An artisan tools the leather entirely by hand, dyes it, attaches a stainless-steel buckle, then sews tabs on both ends that hook to the swingarms on the heel band.", "This shiny set of spurs is ready for some horsing around.", "Many low-speed vehicles have tires made of polyurethane foam, rather than air-filled rubber tires.", "Polyurethane doesn't deteriorate in sunlight, nor does it dry out over time.", "And if the tire is made entirely of the closed-cell type of foam, the tire won't go flat.", "Polyurethane tires are designed for low-speed vehicles, such as baggage carts and ride-on lawn mowers.", "This particular type of polyurethane foam has a closed-cell structure, which prevents a flat, even if the tire gets punctured.", "Millions of air bubbles encapsulated within the foam give it the required bounce factor.", "The first step is to take an aluminum model of the tire and make a production mold with it.", "This one's for a forklift.", "The mold will have two halves-- each one lined with a tread ring to prevent the cast tire from getting stuck in the cavity.", "To make each half of the mold, they center the model in a base, then fill the space around it with polyurethane elastomer, which is a solid type of polyurethane, as opposed to the foam type they use to cast the tires.", "They stir gently to move air bubbles to the top...", "Then heat those bubbles with a small propane torch to burst them.", "With the help of a heated table to speed things along, the material solidifies in approximately 15 minutes, at which point, they extract the half-mold...", "And, with the utility knife, trim its rough edges both inside and out.", "Then they mate the two halves, and the production mold is ready.", "Whereas most companies buy foam mixtures ready-made, this one blends its own, in order to have strict control over the formulation.", "Technicians weigh out the chemical ingredients manually with a high-precision industrial scale that's accurate to within 1 1/2 ounces.", "A propeller-shaped blade mixes the ingredients for half an hour, moving everything from top to bottom more than 300 times and drawing it out of the corners of the container.", "This ensures the mixture is evenly blended throughout.", "Before using this foam to cast the tires, a quality-control test.", "They take a sample from the batch and let it rise and set, which takes about a minute.", "Then they cut a piece of a specific size, weigh it, and calculate the density.", "If the sample meets specifications, the batch is a go.", "Just before filling the two halves of the mold with polyurethane foam, they lubricate the cavity with a release agent.", "This prevents the tire from sticking to the mold when they extract it.", "A press keeps the mold closed and in place on the filling machine.", "The machine spins the mold while the foam flows into the cavity through a hole at the top.", "The spinning creates centrifugal force that distributes the foam into every nook and cranny.", "In less than a minute, the foam, although not yet fully cured, is solid enough to be extracted.", "They open the mold, remove the tread ring, then dislodge the cast tire with a short blast of an air gun.", "They trim the excess foam from the center.", "It can be ground up to make other products, such as floor mats.", "Here's what the tire looks like before...", "And after trimming.", "The polyurethane foam takes 24 more hours to fully cure, then the tires are ready to roll.", "This company sells tires with and without painted steel rims.", "Rim installation is simple.", "They place the rim on a base, followed by a mounting cone, then the tire.", "A press snaps the center of the tire over the edge of the rim.", "Besides making the tire flat-resistant, the closed-cell structure of this polyurethane foam doesn't absorb water, meaning wet conditions don't hamper performance.", "The tire is also u.v. resistant and withstands high abrasion, so it typically lasts two to three times longer than an air-filled tire used on the same vehicle." ]

{ "things": [ "Peaked Caps", "Custom Water Heaters", "Electric Boats", "Fencing Foils" ] }

[ "Throughout europe in the late 1700s, peaked caps were traditionally worn by industrial workers.", "Today, they are worn by professionals such as security personnel, members of the military, and police officials that wear uniforms.", "In the united kingdom, some police officers still wear the classic custodian helmet, but now many officers have chosen to wear the lightweight, comfortable, and practical peaked cap.", "To make these caps, a hat maker, or a milliner, assembles a number of components using patterns to cut out the required pieces of wool, foam, and plastic.", "A milliner bends a strip of polypropylene plastic into a circle.", "She sews the joint with a high-strength thread, creating the hat band that will go around the head.", "She positions a smaller piece of polypropylene, known as the badge support, and sews it in place.", "The support will prevent the weight of a police badge from distorting the shape of the hat.", "These crescent-shaped components are pieces of wool glued to thin, flexible foam.", "She sews the crescents together, creating a circular piece, which will form the bevel.", "She uses a specialized, long-arm sewing machine, which has been customized to make hats.", "The seams are carefully ironed flat to prevent any bulging.", "If the iron is too hot, the foam will melt.", "Too cool, and the wool won't flatten.", "She aligns two strips of 100% wool fabric and sews them together at the ends.", "This piece will cover the plastic stiffener forming the outer band.", "To ensure the sizing is correct, the milliner places the wool cover over the stiffener.", "The stiffener is installed at the end of the production process.", "Next, the milliner irons the seams of the band covers.", "She finishes the band covers on a sewing machine known as a flat bed and creates a fold to hold the plastic stiffener and sews the edges together.", "Then the band cover is sewed to the bevel.", "While it's difficult to attach two pieces of cloth at different angles, this step creates an even seam that runs 360 degrees.", "It takes at least six months of training to learn how to make hats.", "The crown is made from three materials-- a combination of wool and foam, a polyester lining, and a protective-grade p.v.c. layer.", "Once the three materials have been sewn together, the machinist trims the perimeter of the crown.", "She marks the side edges and aligns them with the seams on the bevel.", "Then she sews the crown to the bevel.", "Having spent a great deal of time perfecting the skills, this milliner makes it look easy.", "Finally, the components begin to resemble a hat.", "Using a polypropylene template, the machinist positions and marks two spots on the bevel.", "She places two small brass rings on a special device and aligns the marks with the device's posts, which cut out two holes through the fabric.", "Then she places two cup-shaped rings on the posts, and the machine punches them down, forming eyelets for ventilation.", "Next, the polypropylene stiffener is inserted into the hat.", "Finally, the hat begins to take on its final shape.", "The tag containing the hat's size is sewed on hat band.", "She places a checkered-pattern band on the brim of the hat, called dicing or the sillitoe tartan.", "The milliner inserts a replica badge through holes in the badge support and secures it with a pin.", "This is a replica, since we can't show real police badges on tv.", "Next, the milliner sews the peak onto the band.", "It took a highly skilled milliner more than half an hour to sew this hat.", "They might look straightforward, but peaked caps are surprisingly complex.", "A home water heater stores and heats water in a tank.", "This is how it works.", "When you turn on a faucet, hot water flows out of the tank from the top, while cold water flows into the tank from the bottom.", "Conventional water heaters are fueled by natural gas, electricity, propane, or oil.", "This company custom-builds several types of water heaters for use with different types of heat sources, such as boilers, heat pumps, and solar panels.", "Each work order includes a picture outlining the pipe configuration and the connecting valves, along with a list of the water heater's specifications.", "To make a copper tank, a technician cuts a thick sheet of copper to a specified length.", "He aligns the end of the sheet to the gradation on the table that corresponds to the tank's circumference.", "Then he actives the guillotine blade with a foot pedal.", "A computer-guided machine punches holes for the valves.", "This water heater requires two valves at each end of the heating coil and one that will connect the water pipe to the tank.", "The technician inserts the copper sheet into a mechanical roller.", "The rollers apply pressure, forming the sheet into an open cylinder.", "One end of the cylinder is clamped into a machine that welds linear seams.", "The technician inserts the other end of the cylinder through the machine and joins it against the clamped end.", "The machine is programmed to weld a seam to the length of the connected ends.", "The technician monitors the welding arm through a u.v. lens to protect his eyes.", "The machine stops automatically when it reaches the programmed seam length.", "This process closes the cylinder with a strong, pressure-resistant seam, creating the water-heater tank's structural component.", "Another technician places the tank's top on a press.", "The press punches a hole for a threaded pipe fitting.", "The fitting connects the pipe to the hot water.", "Using a different press, the technician makes another hole into the cylinder for a threaded fitting.", "This fitting connects to an electrical element that heats water in conjunction with a boiler.", "Another technician makes the tank's heating coil by running a straight copper tube through three rollers.", "The tube is bent under pressure, forming it into a coiled shape.", "The heat from the boiler, pump, or solar panel flows through the heating coil, heating the water stored in the tank.", "Since the copper-tube wall is too thin to weld, a technician uses a fusing technique known as brazing.", "This metal-joining process brazes a flow fitting on one end of the heating coil and a return fitting on the other.", "Next, the heating coil is placed in the tank.", "The fittings protrude through a hole at the top and bottom.", "The technician secures each one with a nut, then tightens the nuts with an impact wrench.", "Like the dome top, the bottom component's edges are grooved, allowing the tank to fit perfectly into the cylinder base.", "Once the top and bottom components are installed, the tank goes back to the brazing station for final assembly.", "A welder brazes the top and bottom components to the cylinder, then he brazes a feed fitting to a hole near the bottom of the tank.", "This location is where cold water enters the tank to be heated.", "Next, a technician conducts a quality-control test.", "He blocks the three fittings, fills the cylinder with air, then submerges the tank in water to check for air bubbles, which would indicate a leak.", "A stainless-steel water heater is constructed just like a copper heater, except that they don't require any brazing.", "A robot sprays the tanks with expandable polyurethane foam for insulation.", "The customer selects the degree of insulation, one to four inches thick.", "The foam takes just five minutes to cure.", "As the tank stores hot water, the insulation reduces the amount of heat the tank loses over time.", "Electrically powered vehicles may seem like a 21st-century phenomenon, but they were actually first invented in the 1880s.", "During that time, they were very popular, until combustion-engine vehicles became the new normal.", "Today, these electrically powered alternative-fuel vehicles are making a comeback.", "This manufacturer produces a wide range of electric boats.", "Thanks to powerful batteries, some of these vehicles can travel over 35 miles per hour.", "Craftspeople apply a gel-coat skin to a mold, using a product derived from vinyl.", "Then they layer on a dry fiberglass fabric and vacuum-bag the entire assembly.", "The vacuum suction draws in liquid resin, infusing the material.", "A craftsman marks a dry spot as a test point to monitor and ensure complete saturation.", "The infusion process takes about two hours.", "Once complete, the assembly will cure for four to six hours, depending on the general humidity and temperature levels.", "Once cured, the assembly is removed from the mold.", "Despite the structure's light weight, this deck is incredibly strong, rigid, and durable.", "The fiberglass decks and hulls make up the boat's shells.", "A craftswoman applies a high-strength marine glue to a recessed area of the deck.", "She installs an anti-skid deck insertion.", "This material is a composite designed to resemble wood.", "Unlike real wood, this composite material will last the lifetime of the boat and won't require any additional maintenance.", "The craftswoman uses a roller to apply pressure evenly across the entire decking surface.", "This step will eliminate any unwanted air pockets.", "Next, a mirror-image decking section is applied to the other side.", "A specialist installs the electrical-wiring harness.", "To avoid corrosion, marine-grade wiring is stored in a sealed environment under the deck.", "Since the decking is lightweight, it only takes two people to lift and install it on the hull.", "The lip of the deck fits snugly into place.", "The most powerful boat models require lithium-ion batteries.", "These boats are built with military-grade foam.", "The density of the foam adds structure, causing the boat to become unsinkable.", "Using a hoist, technicians install the deck of a large, powerful electric boat.", "The deck lip slides over the top of the hull.", "Depending on the boat model, the manufacturer uses either lithium-ion or lead-acid batteries as a power source.", "A specialist installs a series of marine-grade dc31 lead-acid batteries.", "At 6 volts, 225 amps, they're similar to batteries used in cars.", "By contrast, the 7.7-kilowatt lithium-ion batteries pack a charge of 48 volts.", "The batteries are installed under the seats.", "To create a watertight seal between the deck to the hull, a craftsman installs a rubber bumper around the perimeter of the boat.", "Holes have been pre-drilled to avoid cracking when installation is complete.", "This manufacturer sources their motors from an outside electric-motor company, which also builds motors for cars.", "The fin, made of aluminum encased in marine-grade rubber, is installed on the bottom of the motor.", "The propeller attaches to the motor with a zinc nut.", "Two circuit boards located on board will send instructions to the motor.", "A waterproof cover is placed on top of the circuit boards for added protection.", "Locknuts with nylon washers will prevent unnecessary vibrations while the motor is on.", "With the steering cables installed, the entire unit pivots right and left, allowing the pilot on deck to steer.", "The powerful motor is equivalent to a 10-horsepower combustion engine, and because it sits in the water, it stays cool and quiet.", "Finally, a craftswoman places the boat's sun canopy over the framework.", "This will allow customers to add solar panels for charging the boat.", "Also, a customer can choose the colors for both their canopies and upholstery.", "There's no denying that electric boats are the future of fun on the water.", "Modern fencing is a sport consisting of three disciplines, one of which is foil fencing.", "While in play, a lightweight foil sword is used to score points.", "Points can be scored when the tip of a player's sword makes contact onto their opponent's torso.", "A fencing foil is a piece of equipment that should only be used by trained professionals.", "This sword doesn't have a sharp edge or pointed tip.", "It's all about scoring hits.", "Fencing foils are made out of thin steel bars.", "The steel is a low-carbon, nickel-rich alloy that's strong yet flexible.", "An automated saw cuts the bars to a length of 35 inches.", "The bar will be stretched and shortened as it's transformed.", "A forge heats and hammers the hilt end to a round shape, leaving the rest of the rod rectangular.", "Here you can see the difference in the rod's shape.", "Another forging machine softens the end of the rod and pushes the blade through a series of hammers.", "This tapers the blade and stretches the steel, doubling it in size.", "An operator clamps the tapered blade in a jig to hold it straight while the steel cools.", "Then the operator slices the hilt end to length.", "The excess steel will be recycled into new swords.", "Next, the blades are heated in a 932-degree oven.", "This step removes stresses and makes the metal less brittle.", "After a second heating, the blades soak in oil to cool and harden.", "The exposure to intense heat causes a rusty scale to form on the blade, so technicians clean it off.", "A sword maker clamps the blades in a disc grinder.", "The grinder carves a fine groove from the hilt to the tip.", "The groove will house a wire for the electric scoring system.", "The blade is cleaned to remove any remaining surface imperfections.", "A spinning belt coated with an abrasive grinds all four sides of the blade.", "Then the sword is polished using a buffing wheel and polishing compound.", "You can see the difference this makes in the blade on the right.", "The craftsman hammers the blade against an anvil to straighten out any kinks.", "Then he inspects the blade.", "If needed, the craftsman will make adjustments to the blade with a hammer.", "Now it's time to work on the hilt end of the blade.", "Another craftsman locks the end of the blade in a threading die, applies lubricant, and activates the automated system.", "The system turns the sword in the die, carving out threads.", "Then the threaded hilt is cut to length.", "At the next station, a computerized laser engraves the company logo into the steel.", "After the sensor barrel is installed on the end of the sword and the electrical scoring wire is placed in the groove, the technician applies glue to keep the wire secure.", "The sword blade is placed in a rack that holds it in a bow-like bend.", "This step will give the glued wire the flexibility it needs to bend with the rest of the sword while in use.", "After the blade has cured, a pressure sensor spring is inserted into the barrel and capped with a sensor button.", "The technician uses screws to hold the components together.", "To assemble the hilt, the scoring wire is threaded through a hole in the guard so it can easily slide into place.", "Then the sensor wire is connected to a socket.", "The wiring assembly is covered with a plastic pad that allows the socket to protrude.", "Finally, the pistol-grip handle is screwed into the threaded end of the blade.", "This fencing foil is now ready for testing.", "The technician plugs the fencing foil into testing equipment, then he places a one-pound weight on the sensor button and checks to see if it responds.", "And the results are in.", "This fencing foil is now ready to stand up to its competition." ]

{ "things": [ "Trucks", "Adhesive Bandages", "Computer Circuit Boards", "Liquors" ] }

[ "Today on \"how it's made\"...", "Trucks-- we'll tell you haul[all] you need to know about them.", "Adhesive bandages-- we'll stick to the facts in this report.", "Computer circuit boards-- letting the chips fall where they may.", "And liquor-- we distill the whole process for you.", "Whether your rig of choice rides on 8, 10, or 18 wheels, trucks have got the goods, and they get them to where they have to go.", "Trucks not only transport most of today's consumables, they're the undisputed kings of the road.", "Fabricating these massive trucks requires many highly complex steps since the parts are usually heavy and tricky to handle.", "Assembly begins with the fabrication of the bearing frame, the main part on which the truck's cab, motor, and transmission will rest.", "They begin by assembling these tempered-steel stringers, beams varying in length between 25 and 43 feet.", "The chassis is made as a huge meccano set.", "The stringers are solidly attached together with nuts and bolts and tightened with powerful pneumatic tools.", "Once assembled, the main chassis is transported to another stage of construction.", "Now they're going to install the mechanical parts.", "They start with the differential, the axle, and the springs' leaves.", "The brake mounts are then put in place.", "The plates installed in the mounts allow the truck to brake.", "They install the wheel hub onto which the wheels will be attached.", "Then the transmission shaft, which will power the driving wheels, is inserted.", "They finish the rear-wheel assembly by mounting the heavy brake drum made of cast iron.", "To facilitate the mounting, everything is assembled upside down.", "With an overhead crane capable of lifting a 26,000-pound load, they then turn the part right-side up.", "Next step, the motor-propulsion elements.", "The transmission is bolted to the motor, seen here in yellow.", "The motor-propelling elements comprise the clutch and the transmission, installed at the front end of the truck chassis.", "A truck has between 6 and 10 wheels 22 inches in diameter.", "The tire and wheel together weigh about 120 pounds.", "Because of this heavy weight, the wheels are installed with the help of this powerful tool.", "This bolt fastener allows tightening of all the wheel nuts at the same time.", "The mechanical part is ended, and they now proceed with the cab assembly.", "This begins with painting.", "The cab is moved toward the front to facilitate the installation of various components.", "This worker attaches the support for the horn to the roof of the truck cab.", "Now for the cab's interior.", "They begin by installing the dashboard, which weighs about 80 pounds.", "Following this, they attach all the wires, the turn indicators, the speedometer, and the pedals.", "The seats are then installed.", "The cab work is now all completed.", "It is bolted onto the chassis.", "Now for the motor's hood.", "They finish off with the lights, the exhaust pipe, and the mudguards.", "The truck is now almost ready to hit the road.", "They start it up and verify that everything's operating properly.", "And it's now ready for delivery to the customer.", "It requires 95 to 100 hours of work to assemble a truck like this.", "In spite of their 11,000-pound weight, these trucks can move along at a top speed of 75 miles per hour, and they can carry a load of some 30 tons.", "Cut your finger?", "Well, you've got a couple of first-aid options.", "You can wrap it up in bulky gauze or you can apply a flexible adhesive bandage.", "If you're like most people, you'll take the bandage and save the gauze for your mummy costume next halloween-- from boo-boo to boo.", "Adhesive bandages are made of various materials, among which is the main support called e.t.s.-- a fabric that's elastic in only one direction.", "It's a fabric that will become the adhesive portion of the bandage.", "This 6,000-foot roll of fabric can make 1.8 million small bandages or 300,000 large bandages.", "A thin coating of glue is applied to one surface of the fabric.", "Then it's heated to 120 degrees in an oven to puff it up, creating holes in the glue coating.", "Then the fabric is newly rolled up into around 1,000-foot lengths.", "Bandages are different sizes.", "These blades cut the glued rolls into strips of varying widths.", "These rolls are taken away and stacked, ready for the next step-- application of the little cushioned protective pads.", "The material used for the pads is shown here as a large roll of fabric which will have to be cut.", "Here, a machine cuts the fabric pads.", "These extremely sharp blades have to be sharpened every six months.", "The cushioned fabric is separated into narrow strips which will later be glued to the e.t.s. fabric.", "The strips of cushioned fabric are now ready to be applied to the bandages.", "This is the machine that fabricates the bandages.", "The roll of bandage components is unrolled.", "The machine assembles them, then cuts and individually wraps them.", "The bandages are wrapped one by one.", "This machine applies the unprinted white wrapping paper that protects the bandages.", "And now they proceed to packaging.", "Packaging speed depends on the product, varying between 300 and 1,500 bandages a minute.", "This roller perforates holes that allow the bandages to be easily separated from one another.", "Strips of bandages are then placed into boxes.", "Here we see other small bandages that are made in a different way.", "The cushioned strip is positioned at the center of the e.t.s. fabric strip.", "The cushioned pad isn't sterile at this stage.", "They will have to be sterilized right at the end of the fabrication process.", "Next step, applying two plastic paper protectors over the glue-covered ends of the bandage.", "This done, the bandage is drawn by suction with a robotic arm and placed between two wrapping papers.", "In slow motion, we see the wrapping action better.", "This machine is much faster than the eye.", "At full speed, it can wrap 300 bandages a minute.", "The bandages exit the machine perfectly wrapped.", "Certain types of bandages have to go through a sequential bandage machine to have aeration holes pierced in them.", "These holes allow air to circulate and thus help promote healing.", "These bandages are now ready.", "Sometimes they print instructions on bandage wrappers.", "This paper-printing machine is used with bandage machines.", "Two polymer plates receive ink from a series of rollers in order to reproduce the desired design.", "The bandages pass through at high speed.", "Before being packaged, the bandages are finally sterilized 10,000 at a time.", "Bandages are automatically counted here, placed in a chute, and fall into the packaging box.", "The large role of e.t.s. fabric seen at the beginning will have allowed them to make nearly 2 million bandages.", "Each year, this facility produces a staggering 4 billion bandages in 65 different models.", "Computer technology changes quicker than just about any other industry on earth, so watch fast.", "Electronic circuits have shrunk from miles of wiring to the size of a computer circuit board, and they're still getting smaller.", "An electronic circuit board is a computer component that can produce spectacularly realistic scenes.", "Animating this particular three-dimensional graphic took four months of work by artists and programmers with the aid of a g400 graphic processor by matrox.", "A printed circuit board can be compared to a building composed of fiberglass floors, copper passageways, and stairs that link the floors between them.", "Cards are assembled with two technologies-- surface wiring and wiring through the card.", "The components are placed into the holes and soldered in place.", "A stencil is used to apply soldering paste onto the card.", "This paste will solder the surface components.", "Here they place the stencil into the printing unit.", "It is through these holes that the soldering paste will run.", "The machine spreads the soldering paste, which contains, among other elements, a tin-lead alloy.", "The printing blades go into action.", "They spread the soldering paste onto the stencil.", "This paste runs through the stencil holes and covers the metallic surfaces of the printed circuit board, which will establish the electric current.", "Here's the difference between an unprinted card and another printed one-- the unprinted card's surface is much more shiny.", "Now they're going to install the surface-wiring elements.", "They're automatically positioned by this rapid-placement machine.", "About 36,000 components are installed per hour.", "That's about 10 per second.", "This incredibly sophisticated machine is equipped with a viewing camera which verifies the alignment and dimensions of each part before installation, and it unerringly positions the part at the exact spot.", "Another machine, slightly less precise than the previous one, installs parts where the space between two placement points is less than 2/100 of an inch.", "It can install 8,000 parts in 60 minutes.", "The card continues on its way toward the oven, which accomplishes an essential operation.", "Once the parts are secured, the card goes into a convection oven, where the heat will solder the parts to the card.", "Different circuit connectors through the card are inserted into their respective holes.", "This operation requires great dexterity and is entirely done by hand.", "The metallic placement points need to be soldered to the card.", "The soldering of the circuit components through the card is done with a bath of molten tin-lead alloy at a temperature of 465 degrees.", "Now everything is installed.", "They have to do an initial electrical test.", "The card is placed on a bed of electrified pegs.", "These pegs make contact with the card's connecting points, allowing them to check for short circuits or open circuits in the card.", "And then a final test-- a computer-aided operating test to see if the card is functioning perfectly.", "This company fabricates 200 different circuit board models and produces about 4,000 cards each week.", "The secrets behind the world's finest spirits and liquor all boil down to one simple recipe-- mix grain and water, then ferment and distill.", "Add a few hundred years of tradition, and you begin to understand why these bottles are worth their weight in gold.", "The principle of distillation was known to ancient romans who mastered the process.", "However, we still don't know the precise ingredients they used.", "In the middle ages, stills produced the first alcohols from wine.", "The 7th century saw people making ethyl alcohol, and by the 15th century, the process was further refined, leading to the production of today's brandy, bourbon, cognac, and whiskey.", "Dried corn kernels are the main grain used in making spirits.", "Every day, 7 truckloads empty out 230 tons of it.", "This corn will produce the basic ingredient for spirits such as whiskey, gin, crème d'amande, and amaretto.", "The kernels are stored in these 80-foot-high silos, which can hold up to 275 tons.", "This is the distillery control room.", "They're going to make a recipe that's 95% corn and produces a neutral alcohol to which they will add other grains for color and flavor.", "We see here the first step on this screen-- the milling of the grain.", "Some 9 tons of corn flour and 5,000 gallons of water are introduced into this autoclave and cooked with live steam for 90 minutes.", "Enzymes transform starch into sugar.", "Then they add the yeast, which converts sugar into alcohol.", "Fermentation lasts 60 hours at 100 degrees.", "The bubbling we see is created by the action of the yeasts.", "This cone removes the carbon dioxide, a natural by-product of fermentation.", "Nearly 80 tons of carbon dioxide are drawn off daily.", "Everything is monitored by computer.", "Some 24 hours have now passed since the start of fermentation.", "When this stage has ended, corn oil will come to the surface and is clearly visible by its reddish color.", "The fermented mash has a 13% alcohol content.", "They now move on to the next step-- distillation, which condenses the vapors of the mix.", "It's in this three-column distillation system, at a temperature of 185 degrees, that the mash ferments and is distilled by live steam to separate the alcohol.", "All the distillation columns are continually monitored.", "During distillation, they dry the grains used in the recipe in this rotating drum.", "The resulting product is called draff, and it will be used to make animal feed.", "Distillation is now ended.", "To aromatize certain gins, they add dried lemon skins, some cinnamon, or coriander.", "Rum and whiskey will be aged in these 350,000 oak barrels.", "While aging, these spirits will lose about 3% of their alcohol content annually through evaporation.", "Also, the color gradually darkens.", "They're now ready to draw out the liquid from the barrels and put it into bottles.", "But first they have to verify the quality of the spirits.", "They compare the standard product with the new production.", "This test is highly important in order to assure the quality of the final product.", "Bottling begins.", "Here, 140 750-milliliter bottles of rum and spirts are filled every minute.", "Clean bottles circulate continually on the conveyor, leading them to the filling machine.", "Bottles are then filled automatically by this machine.", "It allows an exact quantity to flow into each bottle.", "The next step, a capper places caps on the bottles and crimps them onto the necks.", "Then the sealed and labeled bottles head for the packaging department.", "This other machine fills 120 bottles with 1.14 liters of canadian whiskey every minute.", "In this distillery, some 20 different spirits are produced.", "With 37,000 tons of corn kernels, they produce 44 million 750-milliliter bottles of spirits annually." ]

{ "things": [ "Mini GP Motorcycles", "Fig Cookies", "Tool Boxes", "Pipe Bends" ] }

[ "They're called mini g.p.s-- pint-sized motorcycles whose design is identical to that of the full-size motorbikes that race on the grand prix circuit.", "Mini g.p.s are designed for kids 9 to 12 years old who aspire to one day race the big bikes.", "A mini g.p. can reach speeds of 80 miles per hour.", "Its chassis is made of steel tubing, to which they mount the handlebars along with the clutch and brake levers.", "At both the front and back of the chassis, they attach a fork.", "Then, between each fork and the chassis, they mount a shock absorber.", "With a steel pin, they mount a wheel on each fork.", "The black circle at the center is a brake disk.", "Next, they install a brake caliper on each wheel.", "When the rider applies the brakes, the caliper grabs the brake disk, immobilizing the wheel.", "Now mechanics begin assembling the engine block.", "Using a special tool, they install bearings that enable the gear shafts to turn.", "The engine has six gears, each of which is comprised of several steel gears.", "These go into the gearbox.", "Next comes the gear shifter.", "It connects the gears to the gear pedal that the rider operates with his foot.", "Next they install the crankshaft.", "The combustion cycle rotates the crankshaft, which turns the gears.", "They close up that side of the engine and assemble and install the desmodromic spring.", "When the rider selects a gear, this spring keeps it locked in position until the rider switches gears.", "The engine turns a driveshaft that, via this pinion gear, moves a chain that turns the rear wheel.", "On the other side of the engine, they assemble the primary couple and the various components that go into the clutch, such as clutch plates and the springs that stop and start clutch movement.", "When combustion drives the piston up and down, it rotates the crankshaft.", "The primary couple transmits power to the gearbox and clutch.", "This is a one-cylinder engine.", "They install the piston that drives the crankshaft, then mount the cylinder over the piston.", "They close up the cylinder with a cylinder head, then mount the spark plug that ignites the fuel mixture, driving the piston up and down.", "A head cover closes everything up.", "Next they install the ignition.", "It consists of two magnets called a rotor and a stator.", "When the rotor turns, it generates an electrical charge that sets off the spark plug.", "Time to install the finished engine.", "They mount it to the chassis with support pins, front and back.", "Next they install the water pump that prevents the engine from overheating along with the belt that drives the pump.", "Then they mount the carburetor.", "It mixes the fuel entering the engine with just the right amount of air.", "Next they install the air filter.", "It keeps out debris that would clog the engine.", "Now the exhaust pipe, the fuel tank, the seat, and fairing, a plastic enclosure that shields the driver.", "The final component is the chain connecting the driveshaft to the rear wheel.", "The engine turns the shaft, which turns this chain, which rotates the rear wheel.", "Mini g.p.s come in different sizes.", "This particular model has a 50cc, 14-horsepower engine.", "Pretty impressive for a kid's motorcycle.", "The fig cookie is one of life's sweet mysteries.", "Who hasn't wondered how they get the figs in that seamless pastry wrap?", "It turns out that the automated system for producing fig cookies actually dates back to 1891, and it's what makes the fig cookie a snacking success.", "Fig cookies are a modern way of packaging a fruit which has been consumed for millennia.", "Making the fig cookie's pastry wrap begins with bags of sugar, which they empty into a big mixer.", "A couple of buckets of corn syrup follow.", "Then they add an emulsifier called lecithin and some vanilla flavoring.", "The bowl tilts up for a quick mixing.", "A worker adds organic bread flour and leavening ingredients to the mix.", "They reactivate the mixer, which blends everything into a thick, sticky batter.", "Once properly mixed, they transfer the batter into a large holding tank.", "Meanwhile, they prepare the fig filling.", "A worker loads big blocks of figs into a mixer, then adds a generous amount of crumbled cookies for texture and flavor.", "They mix the two ingredients, then pour in corn syrup to add moisture and sweetness.", "They add some salt and give the batch another quick mix.", "They sweeten the fig mix some more by adding plenty of sugar.", "And now the jam for the center of the fig cookie is complete.", "The fig jam and the pastry are now positioned for a merger.", "It will be a neat trick, and a special piece of equipment makes it possible.", "It's essentially a funnel within a funnel.", "Rollers press the jam through the inner funnel while pushing the pastry through the outer one, encasing the fig filling in a seamless pastry jacket.", "Here's the process in action.", "The system generates long rows of fig-filled dough, and that's how they get the fig jam in the pastry.", "Next a technician carves through the dough and removes a few uncooked fig cookies.", "It's time for a quick weigh-in.", "This confirms that this batch of fig cookies will be exactly the right size.", "Now it's into an oven that's longer than a bowling alley.", "It bakes and browns the fig-filled ribbons of dough.", "Here, a roller compresses the baked cookies so they'll fit into packages later.", "An ultrasonic frequency makes this blade vibrate for a clean cut as it carves the rows of fig-filled pastry into cookies.", "The fig cookies are still a bit warm from baking, so they now chill out on a trip through a freezer.", "This cooldown avoids condensation problems after packaging, preventing mold growth.", "The trip through the freezer also firms up the fig cookies so they're less likely to crumble during handling.", "As she packs them, this worker examines each fig cookie for imperfections, and there's not one reject in the lot.", "The next step is packaging, where a machine parcels up the snacks.", "It moves trays full of fig cookies into a sleeve of metallic film.", "Finally, rotating jaws heat-seal the package at both ends.", "It's taken about an hour to make this package of fig bars, and it's about time for a snack break.", "If the crowd is hungry, the whole package could be gone in minutes, but that's the way the cookie crumbles.", "Thinking inside the box can be a good thing if you want to organize your tools, and of course we're referring to the toolbox.", "Proper tool storage keeps any work site running smoothly and efficiently, and today you can really go big on the concept with units designed for mechanics and other pros.", "With a professional toolbox, you'll never have to rummage around for the tool you need.", "There's a place for practically everything in one of these mega tool chests.", "It starts with a coil of heavy-duty steel.", "It unwinds into a punch press that cuts the metal into panels and punches holes for later assembly.", "Each of these panels will be transformed into a toolbox drawer.", "They feed the panels into an automated bending machine.", "It folds them on three sides to create the back and sides of the drawer.", "It also folds over the rim.", "This adds strength to the drawer and gives it a smooth edge.", "The assembler slides the front panel onto the drawer, then an automated welding gun reinforces the seams and secures part of the lock mechanism.", "To build the toolbox cabinet, a worker arranges stiffeners and lock-bar grids on the back wall.", "Then it's over to a lineup of computerized welding guns.", "These guns fuse the stiffeners and grids to the panel.", "Each part gets numerous welds to ensure the unit really holds up.", "The cabinet's side walls are next.", "Workers prop them up with supports as they weld the panels to the back wall.", "With the toolbox right side up, they install the top.", "They turn the cabinet around and, working from the open front, slide the lock bars into their slots.", "They then build the front framework and weld ledges for the drawers to the support grid.", "They add a panel to the bottom end of the cabinet and weld the entire perimeter.", "Now it's into the paint booth, where spray guns coat everything in a layer of powder paint.", "The paint is tough and solvent-resistant so it will hold up to oil spills in a garage environment.", "They install the rest of the locking mechanisms on the front of the cabinet.", "Then, using a guide, press the adhesive-backed logo into place.", "They now snap the drawer slides into holes on the cabinet's side walls.", "These slides are equipped with roller bearings that will enable the drawers to open and close smoothly.", "Here they make use of the holes punched into the drawers earlier.", "A quick click, and the drawers are fastened to the sides.", "The drawers come in a range of sizes to accommodate tools of different proportions.", "The shallow compartments will hold wrenches and screwdrivers, while the larger ones have been made for the big power tools.", "Workers now encase this mega tool chest in plastic and cardboard.", "But this job is not quite wrapped up.", "They tip the unit on its side and send it down the line to get wheels.", "The prepackaging prevents dents and scratches along the way.", "A worker bolts casters on each corner of the cabinet to allow it to be easily moved around in a garage or any other work site.", "Add-ons can be purchased for these tool chests, so the storage possibilities are virtually endless.", "That's an organizational approach you can't really mess with.", "Natural gas and crude oil travel worldwide through underground and undersea pipelines.", "These rugged pipes are manufactured in straight lengths, but of course a pipeline's route never runs in a straight line, so every turn or change in elevation requires a piece of pipe that's bent.", "This factory specializes in bending steel pipe, which is manufactured in straight lengths.", "A piece of pipe is typically 40 feet long and weighs up to 20 tons, so workers use a crane to move it from one operation to the next.", "The first stop is a blasting machine that cleans the pipe.", "To heat and bend properly, the surface must be clean and uniform, but pipe usually arrives at the plant dirty and wearing a coat of varnish to prevent rusting during transport and storage.", "The blasting machine shoots grains of steel at high pressure for about an hour.", "The pipe exits with its surface now clean and smooth.", "From the blaster, it's on to the blender, which heats the pipe to about 1,800 degrees fahrenheit, then makes the bend.", "A technician installs the induction-heating coil.", "Induction heating allows greater temperature control, which is key to preserving the quality of the steel.", "The coil doesn't actually touch the pipe, because that would cause a short circuit.", "Next they clamp a pivoting arm to one end of the pipe, then power up the coil.", "This generates a magnetic field that produces intense heat.", "Cold-water jets confine it to the target area.", "As a technician monitors and measures, the arm pulls the pipe through the hot coil at a specific speed, curving the softened steel to the same angle.", "Water cools the pipe at a controlled rate, a process called quenching.", "They must control heating and cooling precisely.", "Otherwise, the steel will weaken.", "Once the pipe exits the bender, workers verify the angle again.", "They also verify the pipe's dimensions to make sure the bending process didn't distort them.", "Now they cut off the straight ends, leaving just the curved portion.", "Next the pipes go into a furnace for tempering, a 10-hour reheating and cooling cycle.", "This relieves stress in the steel that bending created.", "After tempering, pipes designed to go underwater go through a second quenching.", "This gives the steel the right properties to withstand deep-seawater pressure.", "Then, using an ultrasonic gauge, workers measure the thickness of the pipe walls, which changes with bending.", "After another trip through the blast cleaner, workers apply a liquid that highlights even the most minute surface cracks that bending can induce.", "If they find cracks, they scrap the pipe.", "But defects are rare because the factory first performs test bends on sample pieces of pipe, then subjects those samples to a battery of tests.", "The lab measures dimensions and wall thickness, then tests how much weight the sample can support before collapsing and how much stretching it can withstand before snapping.", "Back on the factory floor, the pipe goes through another blasting.", "Then workers heat it and spray on a protective coating that prevents corrosion.", "It melds to the hot pipe.", "Once the pipe cools, they stencil on technical specifications.", "Then these pipe bends go off to join their straight counterparts." ]

{ "things": [ "Leather Basketballs", "Flood Gates", "Wood Panel Canvases", "Shoelaces" ] }

[ "In the early days of basketball, players used a soccer ball to play the game.", "In 1894, a special basketball was designed.", "It was laced and larger, with a circumference that was about 4 inches greater than the soccer ball.", "For players, the new ball was a game changer.", "Basketballs have evolved, but one manufacturer still makes them the old-fashioned way.", "These laced brown leather balls honor the beginnings of the game.", "To make this traditional basketball, a craftsperson cuts eight panels out of tough american cowhide.", "These are rough cuts.", "The shape will now be more precisely defined.", "He places a sharp steel die on one of the panels.", "Using a tool known as a clicker press, he applies pressure to drive the die through the leather and punch out the shape, cookie-cutter style.", "He now cuts strips of nylon to a workable size using a utility knife.", "The craftsperson then stacks up a dozen of the nylon strips.", "Using the clicker press and same die, he cuts out patterns.", "Because nylon is softer than leather, he can punch out many more at once.", "He places one of the nylon patterns on the underside of a leather one and stitches them together.", "The nylon backing stabilizes the leather, preventing stretching.", "He now punches lace holes and notches in the nylon-padded leather panel.", "Using a template, the craftsperson locates the spot for an air-valve hole and nicks it with a sharp tool.", "He places a punch on the nick and strikes it with a hammer to cut out the air-valve hole.", "He clamps a stamp of a company logo in a heated press.", "As the stamp heats up, he moves it into a downward position and then slides the leather panel under it.", "He lowers the hot stamp, and it burns the company logo into the leather.", "Next, with the liner side up, he sews the basketball panels together, two at a time at first.", "Doing this right takes practice.", "The craftsperson then trims the polyester thread and then pounds the thick seam flat with a hammer.", "He sews vinyl reinforcements to the two panels that have lace holes.", "This will give the laced area of the basketball more structure.", "The stitching will also frame the lace holes from the leather side to define and accentuate the lacing.", "He adds another strip of vinyl.", "This one will protect the inflated bladder inside the basketball.", "He assembles the panels four at a time.", "He leaves the section around the lace holes open to provide an entry point for the inflatable bladder.", "He stitches the two halves together, again working from the inside of the ball.", "This completes the basketball's outer casing.", "The next craftsperson places the basketball casing on a steel post and pulls and tugs the casing to turn it right side out.", "He now inserts the synthetic rubber bladder into the basketball.", "He manipulates it so that the bladder's air valve lines up with the corresponding hole in the leather.", "Using needle-nose pliers, he grabs the air valve and pulls it through the hole.", "The craftsperson then rearranges the inner flap so that it's in a position to protect the bladder from the lacing.", "He partially inflates the bladder.", "Using a thick brass needle, he pulls a rawhide strip through the holes to neatly lace up the opening.", "He then fully pressurizes the basketball, and the pressure from the bladder holds the laces in place.", "He simply clips the end of the lace and tucks it in.", "A replica of the original, this leather basketball is ready to bounce back.", "Floodgates are sliding gates that are engineered to resist rushing floodwaters.", "When installed at wastewater or water treatment plants they can be used to control the outflow and inflow of water in order to make operations more efficient.", "That's why floodgates aren't just for emergency situations.", "Sliding floodgates close to varying degrees to reduce the flow of water or stop it completely.", "Making these sliding gates starts with a stainless-steel plate.", "A crane lifts it over to a conveyor in front of a chamber that has a laser cutter inside.", "The crane releases its suctioning grip, and the conveyor takes it into the chamber.", "It's dark inside, but the laser doesn't need overhead lighting to do its work.", "Computer software guides the laser as it cuts out parts for the floodgate frame.", "It also precisely locates holes for assembly purposes.", "Workers stack the laser-cut pieces and number them to categorize them for the next operation, called forming.", "A worker inserts a part in a press brake numerous times to make multiple bends.", "He shapes this particular piece into the bottom frame of the floodgate.", "After forming the side frames the same way, a worker evenly spaces reinforcements along the entire length of them.", "He tack-welds the reinforcements to the frame.", "Using a carpenter's square, he measures the angle of the reinforcement to the side frame.", "Satisfied that each reinforcement is perfectly perpendicular to the frame, he does the full welds.", "Then the worker joins the two side frames and the bottom rail and welds the structure together.", "He positions a stainless-steel ceiling frame at the midpoint of the structure and welds it in place.", "Another worker tucks a polyethylene strip into the frame to seal it.", "The strip also has a groove in it to accommodate the gate's sliding door.", "He clamps the strip to the frame and then taps it with a hammer to entrench it more firmly into the frame.", "He drills through holes in the side frame to make corresponding holes in the polyethylene strip and inserts the bolts in the holes.", "He screws nuts onto the ends that protrude from the outside of the frame.", "He now inserts a polyethylene strip in the horizontal ceiling frame, and he marks the strip to indicate the location for bolt holes.", "He removes the strip and drills tapered holes for countersunk bolts in the locations he's marked.", "He inserts a silicone strip in a recess in the seal, and he bolts it all together.", "Once the frame is complete, another worker installs the floodgate's sliding door.", "It will be raised and lowered using crank-operated gears.", "The next worker closes off an opening used for an unneeded drive gear with silicone glue and a plastic stopper.", "He slides a washer and bearing on the center shaft opening.", "He places the upper housing on the bottom one to enclose the gears.", "He secures the gearbox housing with numerous long bolts.", "Next, powerful ridged rollers press a thread into a very long stainless steel rod.", "This rod will serve as the floodgate's operating stem.", "It's ready for installation.", "A worker bolts one end of the stem to the slide gate while the other worker threads the gearbox onto the other end.", "With the crank not yet installed, he uses a drill to spin the gears and test the operation of the sliding floodgate.", "He confirms that the floodgate meets design specifications.", "Then workers flood the surface below the floodgate with water and verify that nothing seeps through.", "This proves that the floodgate is watertight and ready to hold strong in the event of an emergency.", "Before artists put their brush to their blank canvas, they have to choose what type of canvas to use-- rudimentary, economical cotton or finer, more expensive linen, unstretched, or pre-stretched?", "If pre-stretched, affixed to a wooden frame or glued to a wooden panel?", "This type of artist canvas is made of fine-weave linen.", "It's stretched over and affixed to a wood panel.", "The hard backing prevents the linen from flexing under the paintbrush.", "The face of the panel is made of a quarter-inch-thick baltic birch.", "After cutting a piece with the dimensions of the finished canvas, a worker cuts pieces of sturdier basswood for the cradle.", "After cutting a long strip in the required width, he measures and marks the lengths of the cradle's five parts, which include four perimeter pieces and a cross brace.", "Then he cuts the parts.", "He miters the edges of the perimeter pieces.", "That means cutting the ends at a 45-degree angle, so the pieces mate when assembled into a rectangle.", "To assemble the cradle, a worker spreads wood glue on the mitered edges of the perimeter pieces, then joins them to form a rectangle, clamping two of the corners to a 90-degree block to ensure the angles are perfectly square.", "He reinforces the corner joints with v-shaped nails.", "He removes the clamps and squares and glues the cross brace across the middle.", "Once the worker checks that the cross brace is installed squarely, he nails it to the perimeter.", "He applies a line of wood glue on top of the cradle perimeter and cross brace.", "Then he places the panel onto the cradle.", "The worker sets clamps all around the perimeter, then puts the cradle aside overnight to let the glue dry.", "The next day, the worker sands any panel overhang flat, rendering the edge of the panel flush with the cradle.", "They burn the manufacturing information into the back of the finished panel.", "The linen they're using for this canvas is portrait grade, the finest and smoothest weave.", "It's been primed with linseed oil to allow oil paint to penetrate enough to adhere but not absorb into the fabric.", "He measures and marks the wood panel's dimensions, adding about 4 inches all around to have extra linen to wrap around the cradle.", "Then he cuts along the lines.", "The worker centers the cradled panel upside down on the linen and traces a line around it.", "He flips the panel right-side up and coats the surface with special ph-neutral archival glue because ordinary adhesives contain acid which degrades the linen over time.", "He flips the panel upside down again, carefully positions it within the trace lines and presses the panel firmly against the linen.", "He mounts the assembly on a stretching machine.", "Canvases must always be stretched to prevent contraction and expansion due to changes in humidity.", "Starting with the longest sides first, the machine yanks the linen tight and folds it over the edge of the cradle.", "A line of staples secure the stretched linen to the wood.", "After stretching and stapling both long sides, the worker folds the corners neatly and staples them as well.", "Then he rotates the canvas to stretch the short sides.", "Once those are stretched and stapled, the wood-panel canvas is finished, and now it's the ready recipient of artistic inspiration.", "The oldest shoe archaeologists have ever found is a 5,500-year-old leather hide moccasin with leather-cord laces.", "Today we don't have to go hunt an animal to lace our shoes.", "We can buy our shoelaces ready-made in a variety of materials, styles, lengths and colors.", "This company produces shoelaces and shoelace-type drawstrings in a wide range of materials, including cotton, rayon and acrylic.", "This run is producing polyester shoelaces.", "A worker installs cones of fine polyester thread on what's called a creel, which feeds the bobbin-winding machines.", "She groups the strands from eight cones and feeds them through one side of one machine and onto a bobbin.", "Then she groups the strands from another eight cones and feeds them through the other side of the machine onto a second bobbin.", "Each group of eight strands will produce one thicker polyester thread.", "She programs the machine to wind a specific length of it.", "Each cone holds enough fine thread to wind a 71-mile-long thick thread.", "For this particular shoelace, the machine is programmed to wind 8,200 feet of thick thread per bobbin.", "Another worker installs 20 of those bobbins on a braiding machine.", "For each one, she passes the end of the thread through three eyelets, the second of which regulates the tension of the thread.", "She gathers half the threads and ties knots in them so that they'll catch when she feeds them into the machine.", "She starts up the braiding machine.", "It draws in the knotted threads, which pull in the unknotted ones.", "Then the machine begins braiding a continuous round shoelace cord.", "These wheels apply tension to pull any loose braids tighter so that the corrected diameter is uniform.", "The finished cord, which is about a mile long, collects in a barrel.", "Some shoelaces are made of knitted, rather than braided, cord.", "The cones of thread feed the knitting machine directly.", "The machine's four latch needles can perform two types of knitting stitches to produce round cord.", "Once the knitted, or braided, cord is ready, a worker adjusts four metal pegs of a winding device to the shoelace length they're making.", "Then she winds the cord around the pegs up to 250 times, depending on the cord diameter.", "She cuts the end and ties the cords together so that she can easily transfer them to what's called a tipping machine.", "She runs the center of each cord over an acetone-saturated felt pad, then inserts it in the machine's die.", "The die wraps a piece of acetate film tightly around the cord, then cuts it in the middle, producing a shoelace with a stiff tip, called an aglet, on each end.", "This press applies a nickel-plated steel tip, a kind used on bag drawstrings.", "The worker manually positions two tips directly on the cord with a slight gap in between them.", "She activates the press to force them on, then cuts the cord in the gap.", "This factory also makes rickrack, a flat zigzag trim that's sewn onto clothing.", "These rickrack-braiding machines are 120 years old.", "Each one holds from 13 to 73 bobbins of thread.", "The more bobbins used, the wider the rickrack.", "There are two ways to make multicolored rickrack or braided shoelace cord.", "Mount different shades of solid color bobbins on the braiding machine or wind multicolored thread on each bobbin.", "And for multicolored knitted shoelace cord, mount different shades of solid-color thread cones or multicolored thread on each cone.", "To produce different shapes and sizes, this manufacturer uses different types of braiding and knitting machines, varying the number of bobbins or cones from eight to as many as 73.", "An even number produces a round shoelace.", "An odd number produces a flat one.", "With so many possibilities, shoelaces can be fashionable as well as functional." ]

{ "things": [ "Metal Nail Files", "Birch Bark Canoes", "Cruiser Boat Hardtops", "High Voltage Circuit Breakers" ] }

[ "Today on \"how it's made\"...", "Metal nail files.", "Birch bark canoes.", "Cruiser boat hardtops.", "And high-voltage circuit breakers.", "Throughout history, people have wanted nice nails.", "And they used whatever they could get their hands on to make them look good.", "Marie antoinette is said to have used a pumice stone file to shape her fingernails.", "By the end of the 19th century, metal nail files became the norm.", "Metal nail files can be used to grind and shape fingernails with a few strokes.", "Their abrasiveness is the secret to their popularity.", "Making metal nail files starts with a thick spool of stainless steel.", "The steel unwinds at a steady pace.", "A punch press wields 88 tons of hydraulic pressure to cut out nail file blanks.", "The blanks spill into a bin and accumulate.", "The blanks bounce around with ceramic stones and a mix of water and polishing solution.", "This smoothes the rough bits on the blanks and also cleans them.", "The nail file blanks then slide down a chute into a dryer.", "This dryer doesn't use hot air to do the job.", "Instead, a pulsating mass of hot corn grain soaks up the lingering liquid on the blanks.", "As the blanks exit, some of the corn falls through a perforated conveyor to be reused.", "The blanks continue on and land in a bin, ready for the next phase of production.", "It involves the cutting of an abrasive grid on both sides.", "It's a three-stage process.", "First, a worker places the blank under a sharp tool that's angled at 52 degrees.", "The tool pounds the blank repeatedly to cut angled grooves into it.", "Here is the blank before and after the first cut.", "He switches the cutting tool, and it carves over the first cuts on the opposite angle.", "The third cut goes straight across the other two.", "The ridges and valleys created by the cross cuts make the surface of the blank sharp.", "The grid cutting has bent the still-pliable steel out of shape, so the worker now bends the nail files in the opposite direction, using a round form as a guide.", "This restores their linear profile.", "The carving process has also caused steel to bulge on the edges of the nail files, so he grinds them against a fine abrasive sanding belt to make the edges smooth again.", "Next, he places the metal nail files in perfect alignment in a tray.", "He transfers the tray of files to an oven.", "The files bake for an hour at a temperature of 1,832 degrees fahrenheit.", "The intense heat begins to alter the physical properties of the steel and is the first phase of a hardening process.", "When the hour is up, he takes the red-hot tray of nail files out of the oven using tongs and then immerses them in a vat of cold saltwater.", "This is called quenching.", "The shock of the quench completes the hardening process.", "Shielded by an enclosure, he sandblasts each nail file to remove stains left by the hardening process and to make the steel around the triple-cut grid shinier.", "He places the handle into the nail file beneath a plastic stencil.", "A stamp applies acid to the open areas of the stencil to etch brand information onto it.", "Some nail files have plastic handles.", "To make the handles, this machine melts plastic and injects it into molds.", "The handles are stuck together by hardened flow lines or runners.", "A few tumbles in this revolving drum knocks off the runners, separating the handles from them.", "The worker places each handle under an automated printing head that soaks up ink from a pad and then stamps brand information onto the plastic.", "Another worker heats the end of each metal nail file using copper elements.", "She inserts the hot metal into the plastic sleeve, and the plastic melts a little to bond to the metal.", "These metal nail files are ready for the grind.", "For centuries, the canoe was indispensable to the indigenous people of north america.", "Essential for hunting, fishing, transportation, and commerce, indigenous people often crafted their canoes from birch bark, which is lightweight, strong, waterproof, and rot-resistant.", "Historically, different indigenous tribes constructed different styles of birch bark canoes.", "This one is the type crafted by both the algonquian and eastern ojibwe.", "Even today, the canoe builder crafts every component from water- and rot-resistant plant materials found in the forest, such as the exceptionally strong roots of black spruce trees.", "After scraping off the bark with a tool crafted from a moose rib, this craftswoman cuts a slit in the top and pulls, splitting the long root into two strips.", "She coils up each strip and puts it aside to dry out.", "The canoe builder uses spruce root to bind structural components and lace together sections of birch bark.", "To build the canoe's cedar structure, the builder connects end frames at the front and back with long strips of cedar called gunwales, then he lashes crossbars called thwarts to the gunwales with spruce root.", "To make each end frame, he splits a piece of cedar many times to let it bend, soaks it in boiling water to soften the wood fibers, and binds the shape with spruce root.", "Then the builder checks this curved part, called the stem, against the straight part, called the headboard.", "If the proportions are right, he notches the bottom of the headboard to fit over the base of the stem, then lashes the parts to each other with spruce root.", "He laces together several pieces of birch bark to make a sheet large enough for the canoe.", "The builder saturates the bark sheet with boiling water and bends it up around a wooden template.", "Then, on each side of the canoe, he sandwiches the top edge of the bark in between the two cedar strips that form the gunwale.", "The builder shaves pieces of cedar to make straight, vertically laid planks and u-shaped horizontally laid ribs that line the inside of the canoe.", "He uses a gauge to make sure each piece is the required thickness.", "He lays each rib piece across the structure and makes a mark on each side in line with the bottom edge of the floor.", "That's where he'll bend the piece.", "Just as he did to bend the stem portion of the end frame, the builder ladles boiling water onto the wood to soften the fibers.", "He positions his knees on the charcoal marks and pulls up the ends.", "He bends two ribs at a time, as this reduces the chances of them cracking.", "After checking that he cut and bent all the ribs correctly, the builder begins the process of securing the birch bark.", "He drills holes in the gunwales at nearly six-inch intervals.", "Then he takes pegs carved from hardwood such as ash or maple and hammers one through each hole.", "Then he pierces holes through the bark with a traditional awl made from deer antler.", "He threads spruce root through the holes to lash the bark to the gunwale.", "With an assistant's help, he fully lines the canoe with straight cedar planks and installs the remaining ribs.", "The tight fit presses the planks against the bark, stretching it taught, which strengthens it.", "The final step is known as pitching the seams.", "He melts down dried resin gathered from scars on spruce trees and mixes in two ingredients-- ground charcoal and oil rendered from bear fat.", "He applies this hot mixture to all the lacing holes in the birch bark, making the canoe water-tight.", "The canoeist carries a small supply of dried pitch and lights a stick to remelt and apply it.", "The repair dries quickly, so in about five minutes, the canoeist can be back in the paddle.", "A hardtop encloses the cockpit of a cruiser boat.", "It provides shelter from water spray, wind, and sun, and a roof on which to mount antenna for marine and satellite radio and gps.", "On the inside, it provides walls and a ceiling for recessed lighting and other features.", "This cruiser hardtop has windows that wrap around the front and sides.", "The tall one in the middle is retractable so you can walk through to the front deck.", "Workers use two molds to make the inner and outer parts that form the hardtop.", "First, they spray white gelcoat to a thickness of just .", "6 millimeters.", "Next, workers shoot shredded fiberglass strands into the mold along with a stream of resin which saturates the fibers.", "When the fiberglass is about 3/4 of an inch thick, they let the resin cure for an hour or so.", "Then workers apply bonding putty to the fiberglass in the outer mold.", "They mate the inner and outer molds and let the putty set, which takes about an hour.", "Finally, it's time to extract the fiberglass from the molds.", "It comes off relatively easily because prior to spraying the gelcoat layer, workers have applied a release agent on the mold's surface.", "The inner and outer parts are built in the mold upside-down so the gelcoat gives the coarse fiberglass a smooth and shiny surface finish.", "Then they cut openings for the windows and for the various components to be installed into the hardtop.", "They install the retractable front window.", "Workers then position the window and mark the screw holes, then remove it in order to apply adhesive, which also functions as a sealant to prevent water infiltration.", "They reset the window and screw it to the hardtop.", "Workers install a non-opening window on each side of the retractable one.", "After taping off the area, a worker applies primer.", "Once the primer dries, they remove the tape and apply an adhesive-backed foam gasket that's about 1/4-inch high.", "A worker applies a 1/4-inch high bead of adhesive sealant next to the gasket and sets the window.", "The primer gasket and adhesive sealant are all black to match the window frame.", "On the roof of the hardtop, workers install a thin molded fiberglass cover.", "The retractable window, when opened, slides under it.", "Workers fill the gap between the cover and hardtop with sealant.", "This adheres the cover and makes it watertight.", "At the rear, workers install the radar arch.", "This, too, is made of molded fiberglass but with a black gelcoat finish.", "They mount various components on it, such as the horn, navigation light, and antenna.", "Inside the hardtop, after passing wires for lighting, workers connect the wiring to the retractable window.", "The window comes as a self-contained unit with an incorporated motor and intricate pulley system.", "The hardtop is now ready to be mounted to the cruiser's deck.", "Workers install a windshield wiper on each non-opening front window.", "The last step is to install a large window on both sides of the hardtop.", "Its middle section opens.", "Like a giant windshield, the hardtop transforms the cruiser boat's otherwise open cockpit into a weather-protected lounge.", "Electrical substations play a critical role in the grid as they distribute electricity to entire communities.", "The circuit breakers at these stations routinely interrupt short circuits to prevent damage to the system.", "They perform the same function as the ones in a home electrical panel, but on a much larger scale.", "The size of a car or even a large truck, these circuit breakers troubleshoot high-current situations at electrical substations.", "This protects the grid and prevents power outages.", "Making one starts with a cast-aluminum tank that has receptacles for bushings.", "A worker inspects the tank for dirt or flaws and then places protective covers on the bushing receptacles.", "He installs bases for current transformers on these receptacles.", "The worker applies adhesive to the outside of these metal bases.", "He presses squares of plastic insulation to the glued areas.", "With the help of an overhead lift, the worker installs the two current transformers on the insulated bases.", "These current transformers will act as sensors, enabling the circuit breaker to detect short circuits in an electrical system in mere milliseconds.", "Another worker brushes lubricant on the moving part of the interrupter that will break the electrical current when needed.", "He inserts the exhaust tube that helps direct the flow of gas used to break the current.", "He sets the interrupter module in an upright position on the floor and returns to the workbench.", "The worker dabs thread lock liquid in the mounting holes of the stationary contact assembly and installs a resin ring in the base.", "He inserts the stationary part into the moving one, leaving the end protruding.", "The worker applies thread lock to the assembly holes of a large tube that will shield the entire interrupter once it's installed in the tank.", "It will also direct the flow of interrupting gas.", "After assembling it to the interrupter, he inserts a synthetic insulating tube.", "Then with the help of a lift, he flips the module over in order to work on the other end.", "He installs another insulating tube in this end.", "He then sets the module to a stand to steady it as he inserts the contact assembly that opens to interrupt the electrical current.", "He caps one end of the interrupter with the unit that houses the bell crank.", "He slides the bell crank into the housing.", "This crank will convert the rotary motion from the operating mechanism to a linear motion.", "He turns the crank to confirm that it rotates freely.", "He now clamps leads to test probes inserted in the interrupter and applies 100 amps of current.", "The testing device measures the interrupter's resistance to the current to confirm that it's within an acceptable range.", "With a lift bearing the load, the other member of the team guides the interrupter module into the cast-aluminum tank.", "He bolts the bell crank's housing to the tank opening and places cylindrical electrical shields in each of the bushing receptacles.", "He then encases the transformers at the base with aluminum covers.", "They'll protect the transformer wiring from rain, snow, or dirt.", "Lifts now hoist the silicone-rubber-wrapped bushings into the receptacles.", "The worker bolts them in place...", "And caps the rear of the tank.", "This interrupter is now ready to be mounted to the steel support structure.", "Each high-voltage circuit breaker will be equipped with three interrupters.", "The team connects the bell cranks to the operating system in the control cabinet.", "And workers equip each bell crank with a pressure gauge.", "A worker grounds the circuit breaker to the support structure with copper cables.", "This will prevent shocks to anyone who touches it.", "In one last test, towering transformers apply high voltages to the circuit breakers.", "These high-voltage circuit breakers are ready to interrupt situations before they become problems." ]

{ "things": [ "Life Casting", "Downdraft Cooktops", "Compression Hosiery", "Electric Motorcycles" ] }

[ "Egyptian pharaohs were likely the first to have molds made of their bodies and the images cast.", "Today, anyone can have this done.", "The experts have it down to a fine art.", "It's called life casting, or body molding, and it's in demand because every body is different.", "Need a body double?", "Life casting creates replicas of body parts that can be used as personal mementos or movie props.", "They start by applying cold cream to the body part.", "The cream will serve as a release agent, allowing the mold to be removed whole.", "This orange goop is the molding material.", "It's a seaweed-based substance called alginate.", "It's the same stuff the dentist uses to take molds of teeth, but it's formulated to set more slowly.", "The life caster spreads the alginate liberally onto this young actor's clenched fist and arm.", "Alginate cures in five or six minutes, so there's no time to waste.", "He works at a steady pace.", "He applies wet plaster bandages to the alginate.", "The bandages adhere and form a stiff shell similar to a cast for a broken limb.", "The cast-like shell supports the alginate as it cures to the shape of the boy's fist to produce a mold of it.", "When cured, the alginate has a firm yet rubbery consistency.", "It takes a few tugs to pull off the mold, but the rubbery nature of the alginate means it can be done without cracking or crumpling.", "The casting material is durable dental plaster.", "He pours it into the mold.", "He tips out a bit to get rid of bubbles that have accumulated on the surface.", "It's hands off now as the plaster cures because a chemical reaction makes it dangerously hot.", "A half-hour later, the plaster is cooled and hardened into the shape of the boy's fist.", "The plaster has picked up all the little details, including the tiniest of creases.", "He picks out bits of alginate lodged in the creases.", "He defines the fingernails and cleans up a few pits and bubbles.", "This is the actor's real hand, and this is the replica.", "Next, they make a mold of the actor's face.", "They apply cream to his hair to prevent it from becoming stuck in the alginate.", "The team completely coats his face, ears, and upper chest with blue alginate.", "It must be hard not to wince, but he can't budge in order to create a good impression.", "They leave the back of his head uncovered for an open mold and create two small holes for breathing.", "They layer the plaster bandages over the alginate to give structure to the mold.", "It also makes him look mummified.", "After several minutes, the mold has solidified.", "The team removes it from the subject.", "Now that his features have been successfully transferred to the alginate, he can breathe easy.", "The life caster trims excess alginate, then wraps fabric around the mold to build a kind of wall to contain spills as he fills it with plaster.", "The plaster casting may not be the final one.", "Depending on the client's wishes, they may make a mold from this bust and then cast the image in a more flesh-like material like silicone, foam, or rubber.", "The plaster is cured and the wait is over.", "It's time to peel off the layers and find the face within.", "It's a bit like he's removing an intricate mask.", "The face behind it is instantly recognizable.", "He cleans out the eyes and nose...", "And scrubs the entire plaster face.", "Here's the actor and his plaster doppelganger.", "They'll use it to create a silicone version, and once it's painted and given hair, it will be ready for the movies.", "In contrast to a big, traditional hood, which is separate from the stove, a downdraft system vents smoke, steam, and cooking odors without being conspicuous.", "The ventilation unit is actually part of the cooktop, and that opens up a lot of kitchen-design possibilities.", "Invented in the 1960s, the downdraft cooktop can solve some design dilemmas.", "Installed in a center island, it offers a clear line of view where a traditional hood would block it.", "Production starts with the burner box.", "They'll make three from this steel sheet.", "A computer guides tools as they cut holes and notches in the steel.", "It also roughs out the shape of the boxes and makes slots for the downdraft ventilation intake.", "After the sheets have been cut into individual units, a worker serves them up to a computerized brake press.", "The computer controls the stops that position the sheet to be bent at the correct angle.", "This transforms the steel sheet into a box.", "They're now ready to build the downdraft ventilation system.", "The worker inserts the fan blower and motor into an assembly fixture.", "He then places a metal part, known as the plenum, over it.", "The plenum is the intake duct.", "He places a mesh guard over the opening through which steam and cooking fumes will flow.", "He secures everything with four nuts and studs.", "He caps the nuts with rubber plugs to seal the gaps.", "He now transfers the fan and duct assembly to another fixture.", "It allows him to correctly position the burner box on the ventilation system.", "He plugs the blower motor into a junction box.", "He places a metal frame around the plenum and screws it in place to secure the plenum to the burner box.", "Next, he assembles the knob switches that turn the burners on and off.", "He adds rubber insulators to keep water out of the switches.", "He covers them with a metal plate with holes for the knob shafts to protrude.", "He installs the lighting system that indicates whether the burners are on or off.", "Next, an employee slots the switch system into the ceramic cooktop through the back.", "He inserts the radiant heating elements into the holes in the cooktop.", "The elements are different sizes to accommodate different pots, and they have different heating capacities.", "He wires the switches to the elements, and he ties them to the main power cord.", "Another worker screws the elements to a metal bracket that's glued to the underside of the ceramic cooktop, and he completes the wiring work.", "The ceramic cooktop is complete and ready to be joined to the downdraft ventilation unit.", "He aligns the hole in the center with the intake duct.", "He feeds the wires from the cooktop through holes in the burner box to the junction box.", "He screws the junction box to the bottom of the burner box.", "He pulls the main power harness through a hole in the burner box and secures it to the box with a metal bracket and screws.", "He adjusts the ceramic cooktop, which moved out of alignment a bit during the wiring, and then equips the cooktop with knobs which fit snugly to the protruding pins.", "And it's over to a test station.", "The operator connects a computer to the downdraft cooktop.", "She turns the knobs, and the computer measures the power consumed by the elements.", "Some elements are the same size but different wattages.", "The test confirms that the elements are in the correct slots and that all burners are operational.", "It's taken 25 minutes to assemble this downdraft cooktop.", "The downdraft ventilation unit will get rid of moisture and odors discreetly.", "It's now time to turn up the heat with no worries about the fallout.", "If you've got varicose veins, leg fatigue, ankle swelling, or other circulation disorders, your doctor may prescribe compression hosiery, pressured stockings that squeeze your legs primarily at the ankle and, to a lesser extent, in other areas to help the blood in your veins travel back to the heart.", "They don't look like ugly old-lady stockings anymore.", "Today's compression hosiery comes in a range of colors and pantyhose, thigh-high, and knee-high versions.", "The doctor prescribes the compression strength you need.", "That's the pressure at the ankle in millimeters mercury, the same measuring unit used in blood-pressure readings.", "The hosiery is knitted out of stretchy spandex and nylon yarns.", "The computerized knitting machine interlocks yarn strands vertically and horizontally.", "This two-direction knit gives the stocking a two-way stretch.", "However, it's the horizontal yarn in the knit that provides the doctor's strength prescription.", "They program the knitting machine to produce a run of a specific size and prescription.", "It automatically varies the stitch and yarn tension to apply 100% of the prescribed pressure at the ankle, 65% at the calf, and 30% at the thigh.", "Stronger pressure at the bottom point forces blood upward toward the heart.", "The machine outputs stocking-length tubes, which sewers skillfully transform into the final shape.", "The first sewer turns the tube inside out and stitches the toe closed.", "Then she stretches those stitches to flatten the seam so it'll be comfortable on the foot.", "If they're making pantyhose, another sewer slits that tube partway down the inside of the leg so it can be joined to another leg.", "The next sewer takes a leg and stitches it to a triangular cotton gusset, which forms the crotch of the pantyhose.", "These are maternity hose, so she also sews in a stretchy stomach panel.", "Then she sews a big u-shaped seam at the front, joining the second leg to the other parts.", "Whether it's a multiple-component pantyhose or a simple single thigh-high or knee-high stocking, the production steps from this point on are the same.", "Workers slide each stocking onto a heated aluminum leg form in the size they're producing in this run.", "Laser lines show exactly where to align the heel and other parts on the form.", "Then, one by one, the forms enter a pressurized steam chamber for about four seconds.", "This quick steam treatment is enough to permanently lock the form's shape into the nylon.", "The form then enters a dryer, where it stops for about 15 seconds.", "The hot forced air evaporates the steam-infused moisture.", "When the stocking finally comes off the form, it's dry and leg-shaped.", "Workers now group the stockings into 10-pair stacks, put each stack inside a specific color bag to identify its style and size, then load the bags in this high-tech dye machine.", "They key in the program which automatically controls every aspect of dyeing the stockings from water levels and temperature to dye injection.", "For one hour, the machine washes the stockings.", "Then, over the next five hours, it dyes them, adding chemicals to make the water acidic, which draws the dye like a sponge permanently into the yarn fibers.", "The compression stockings knit, sewn, shaped, and dyed are now ready to be inspected and packaged.", "The factory pulls a set number of random samples per day from the production line and tests them on this extension machine.", "It stretches the hose to test the tensile strength, and it measures the compression at the different points of the leg.", "Every single pair of stockings undergoes a visual inspection prior to packaging.", "Then the packager neatly folds it around a cardboard insert, slips it inside an adhesive-sealed plastic bag, and inserts it into the retail box.", "Compression stockings are classified as a medical device.", "The sealed bag assures the customer that the stockings are a brand-new, unused pair, and therefore, hygienic.", "Looking to drive motorcycle without ever having to stop for a fill-up, change the oil, top off the fluids, or repair a transmission, clutch, and cooling system?", "And do you want a quiet motor that doesn't contribute to air pollution?", "Then an electric motorcycle may be just the set of wheels you're looking for.", "An electric motorcycle lends a whole new meaning to the term \"plug and play\".", "You charge the bike's battery by plugging in to a standard 120-volt household electrical outlet.", "A full charge takes eight hours, but you can buy an add-on device to cut that charging time in half.", "The bike's journey begins on a sketch pad.", "An industrial designer draws an artistic conception, creating the aesthetics such as lines and colors as well as the ergonomics, such as seat and mirror positioning.", "The designer transforms the sketches into a computer model to which engineers then add the mechanics.", "The motorcycle's battery contains four cell boxes.", "To link all the cell boxes, they install two interconnect boards.", "Then, into each board, they plug the connectors from two cell boxes.", "They use lots of grease to waterproof the battery and protect it against corrosion caused by road salt or sea air.", "Next, they plug wires coming from the two interconnect boards into a circuit board.", "This circuit board is the battery's brain.", "It regulates the voltages of the individual cells to prevent overheating.", "Then the charging components.", "Technicians now close up the fully assembled battery with protective covers and run it through a function test.", "The test simulates the discharge of the battery that happens when you ride the bike, then the recharge that occurs when you plug in.", "All the cell voltages must balance in the process.", "The motorcycle frame is made of high-strength, lightweight, aircraft-grade aluminum.", "At the tail end, they install the controller, the link between the battery and the throttle, which controls the electricity flow to the motor.", "They mount the suspension system, an aluminum swingarm that attaches to the rear wheel on one end and to the frame on the other via a spring-shaped shock absorber, which expands and contracts to dampen bounce as the wheel moves up and down over bumps in the road.", "They mount the motor.", "The battery's electrical current rotates the motor via the controller, which turns the drive belt, spinning the bike's rear wheel.", "This belt's maintenance-free because it's made of high-strength rubber, further reinforced with the material used to make bulletproof vests.", "They install the upper triple clamp, which carries the dash, horn, turn signals, and ignition switch.", "Then the handlebars.", "There are several components already mounted to them, including the front brake lever, the throttle, and control switches.", "Then technicians slide the battery into the frame and connect it to the motor and controller.", "This motorcycle has no transmission, no gears, no clutch, no cooling system to maintain or repair.", "The motor's fins adequately dissipate heat buildup.", "Next, two aluminum forks to hold the front wheel axle.", "Workers position them inside the upper triple clamp and a second triple clamp lower down.", "But they don't install the front wheel just yet.", "They first mount the rear wheel.", "It has a rubber tire, hydraulic brakes activated by a foot lever, and a sprocket for the drive belt.", "They place the drive belt around the sprocket.", "Now, when the motor runs, the rear wheel turns.", "After mounting the front wheel, they install the bike's plastic body parts.", "There's a storage area where gas motorcycles would have their fuel tank.", "There are four chargers located underneath the battery.", "Their wiring culminates in a single port in which you plug a cable to recharge.", "Every motorcycle this factory produces undergoes an extensive indoor road test on a dynamometer, a driving simulator that assesses the performance of every component.", "Although very quiet, the bike's as powerful as a midsize, gasoline-run motorcycle and can reach speeds of up to 100 miles per hour.", "When the battery needs a quick recharge, you can pull over at a roadside electric-vehicle charging station and fill her up in less than an hour." ]

{ "things": [ "Ceramic Tiles", "Nuts", "Steel Forgings", "Skateboards" ] }

[ "Today on \"how it's made\"...", "Ceramic tiles...", "Nuts...", "Steel forgings...", "And skateboards.", "Ceramic tiles are a popular choice for flooring, kitchen backsplashes, and bathroom walls.", "They can withstand humidity and won't absorb liquids or odors.", "They're also fireproof, fade-resistant, and stain-resistant.", "And no matter how much you walk on them, ceramic tiles never wear out.", "This factory specializes in wall tiles.", "Floor tiles are made using the same process but with different materials.", "The starting material here is talc-- a soft, powdery mineral.", "They blend it with four different powdered chemicals, the names of which are a company secret.", "The ingredients go into a mixer, where they're hydrated until they're 6% water to 94% powder.", "The mixer runs for precisely 12 minutes.", "Any longer would heat the mixture and dry it out.", "The mixture is now slightly damp and quite lumpy.", "A conveyor belt transports it to a grinder that mills it to a fine texture.", "This mixture is now ready to be formed into various models of tiles.", "The factory uses fully automated machinery to produce its 1.6-square-inch tiles-- a standard wall tile size.", "A moving tray first deposits a batch of mixture into a mold.", "The mold's cavity is in the shape of six upside-down tiles.", "A press descends, applying both heat and pressure.", "This compacts the mixture into the cavity, solidifying the shape.", "As the press rises, the mold automatically pops out the tiles.", "They roll off the machine onto a conveyor belt.", "The belt now flips the tiles right side up without breaking them-- which is quite a feat, considering that these yet-to-be-baked tiles aren't fully hardened.", "The equipment is precision-adjusted to handle the tiles gently at all production phases.", "A revolving brush now sweeps the tiles clean.", "Their surface must be free of dust and other contaminants for paint to adhere properly.", "The factory uses a water-based paint that's specifically designed for ceramics.", "It continually circulates in a vat, keeping the color well-blended.", "The painting process resembles an automatic car wash.", "The tiles travel through four spray zones, each of which applies a thin coat of paint.", "Then they pass under powerful heating elements, which dry the paint in mere seconds.", "All that's left is to bake the tiles, which we'll see shortly.", "The factory uses the same ceramic mixture to produce these square border tiles.", "They look just like the other wall tiles, except that two of the sides are rounded.", "When you install a row of these border tiles above the regular tiles, the rounded edges produce a clean, finished look.", "While the factory uses the same painting process for border tiles, the molding process, as you just saw, is somewhat different.", "Rather than being fully automated, it requires some manual labor due to the tiles' complex shape.", "That's why border tiles are often more expensive than regular tiles.", "When the tiles come out of the dryer, workers stack them on wooden racks.", "They load the racks onto mobile carts and then roll the carts into a gas-powered oven called a kiln.", "This factory's kiln is 190 feet long-- longer than an olympic-size swimming pool and large enough to bake 50,000 wall tiles at once.", "The firing, as it's called, takes 14 hours.", "Any sudden change in temperature could produce thermal shock and crack the tiles, so the kiln starts out at 390 degrees fahrenheit, climbing gradually to a peak of 1,970 degrees, then descends slowly back to the starting temperature.", "After a cooling period that lasts roughly an hour, the tiles come out.", "They're now fully hardened and ready to have their back to the wall.", "Scan the snack-food aisle of your local supermarket, and you'll notice that barbecue, ketchup, and salt-and-vinegar are no longer limited to potato chips.", "Nuts come in tantalizing taste choices, too.", "But if you're a traditionalist, you can still buy them plain, salted, or unsalted.", "The botanical definition of a nut is a dry, one-seed fruit in a hard shell that doesn't open on its own.", "Most peanuts have two seeds, so even though we call them nuts, they're technically a legume-- a type of pea.", "One way to prepare peanuts for sale is to roast them whole, right in their shells.", "This is known as dry-roasting because they cook the peanuts without using any oil in a large convection oven.", "The oven temperature is 300 degree fahrenheit.", "The roasting process takes about a half-hour.", "When the peanuts come out, they're fully cooked and ready to be eaten.", "Before the peanuts go off to be packaged, a worker inspects them, removing any shell fragments and foreign matter.", "Another way to prepare peanuts or other nuts for sale is to dry-roast only the seeds.", "These peanut seeds arrive at the factory with their shells and skins already removed.", "A conveyor transports them to a revolving drum called the tumbler.", "As the tumbler spins, the nuts are sprayed with a liquid seasoning mixture, one of 10 flavors this company produces-- salted, smoked, ketchup, barbecue, and salt-and-vinegar, just to name a few.", "The rotating action ensures the seasoning coats the nuts thoroughly.", "Now a conveyor transports the peanuts to a convection oven.", "The conveyor turns from side to side, spreading the peanuts in a thin layer so that they'll dry-roast evenly.", "They roast for the same length of time and at the same temperature as peanuts in the shell-- about a half-hour at 300 degrees fahrenheit.", "As they exit the oven, a worker breaks up any clumps.", "When they use the other method of preparing shelled nuts, they tumble on the seasoning after cooking.", "Instead of dry-roasting the nuts, as we saw earlier, they fry them in oil.", "This process is called oil-roasting.", "It gives the nuts a greasier, fried taste.", "These cashews are on their way to be oil-roasted.", "They go into a huge frying tank containing 580 gallons of canola oil heated to 320 degrees fahrenheit.", "The nuts come out fully cooked 15 minutes later, and they're steaming hot.", "A powerful ventilation system draws the heat outdoors, cooling the cashews to room temperature.", "This process takes about 15 minutes.", "By now, the nuts have absorbed any cooking oil that remained on their surface, so they receive a light spray of vegetable oil.", "This makes their surface sticky again so that the salt or seasoning mix will adhere.", "This factory also produces nut mixes.", "Here the mixer is combining various nuts with dried fruit.", "From there it's on to a packaging machine, whose eight computer-programmed scales automatically weigh out a specific package portion.", "But before each portion goes into a bag, it passes through a metal detector.", "This ensures that no shards of metal have worn off the equipment and fallen into the food.", "The machinery hermetically seals the plastic packages.", "This keeps the contents fresh for at least six months.", "When does forging not involve fraud?", "When you're talking about metal.", "Many industrial machines contain steel parts that have to withstand great stress.", "The metalworking method that produces the strongest steel parts is forging-- heating the metal, then forming it to the required size and shape.", "Steel forgings are made from scrap iron-- pieces of used iron recovered from demolished buildings and old cars-- as well as bits of new iron left over from the manufacture of iron products.", "Forge workers maneuver a gigantic magnet to lift almost 6 tons of scrap at a time until they've filled a 28-ton scrap bucket.", "The bucket empties two such loads into a fiery furnace, whose temperature peaks at 3,000 degrees fahrenheit.", "This is called an electric arc furnace because the heat is created by a strong electric current running in an arc between three electrodes.", "There are about 20 main grades and 100 subgrades of steel.", "They're produced by adding specific metals or nonmetallic chemical elements, such as aluminum...", "Nickel...", "Chromium...", "Vanadium...", "Manganese...", "Carbon...", "And molybdenum.", "They also add the mineral fluorite to help fuse the metals, some of which are in the form of blocks called ingots.", "Throughout the 3 1/2-hour meltdown, they test and adjust the chemical composition.", "They try to attain the lowest hydrogen, oxygen, nitrogen, and sulfur levels-- the key to producing strong, high-quality steel.", "Then they pour the sizzling molten metal into a 50-ton ladle that's lined with heat-resistant brick.", "They add aluminum and lime to chemically counteract oxidation-- rusting caused by air exposure.", "Now they cast an ingot-- a block of steel that they'll shape into a forging.", "The molten metal flows out the bottom of the ladle into a mold below.", "This bottom pouring, as it's called, makes for a smoother casting because liquid flowing downward doesn't swill around as much as liquid poured sideways.", "This forge can cast ingots weighing up to 46 tons.", "After several hours, the ingot solidifies, and they turn the mold upside down to extract it.", "Then, over 12 hours, they reheat the ingot to 2,200 degrees fahrenheit.", "This makes it soft enough to hammer or press into shape.", "To make large forgings, they use a machine called a forging press, mounted inside a forming die or a pair of dies, depending on the technique they're using.", "The press applies thousands of tons of pressure, crushing the ingot and forcing it against the die.", "The steel is quickly oxidizing with all this air exposure.", "They use a high-pressure water gun to remove the scales of rust.", "An ingot often passes through a die several times or through a series of dies arranged in sequence.", "Each pressing forms the metal bit by bit into the final shape.", "Metal is composed of microscopic crystals.", "Squeezing it in a press bends these crystals, destabilizing the metal structure.", "But reheating the metal creates new crystals to replace the deformed ones.", "This restabilizes the structure, and, because the new crystals are smaller, makes the metal stronger than before.", "That's why finished forgings require heat treatment in what's called an annealing furnace.", "They heat for a day or two, depending on the grade of steel.", "Then they soak in a water-and-chemical bath for about five hours.", "This strengthens the steel even more.", "Finally, workers mount the steel forgings on lathes and milling machines.", "They remove the rust scales that formed during heat treatment, then precision-machine the forgings into what the client ordered-- usually industrial parts such as rotors, spindles, and shafts.", "Many factories prefer to buy forgings in the shape of blocks or bars and machine the parts themselves.", "Skateboarding may have started out as a simple outdoor pastime, but in the last few decades, it's evolved into a popular thrill sport.", "Professional skateboarders are known for performing spectacular aerial maneuvers, achieving speeds and heights the early skateboarders could never have imagined.", "In the 1930s, thrill-seeking kids began attaching their metal roller-skate wheels to wooden crates.", "Little did they know this would one day spawn a worldwide phenomenon.", "The boxes evolved to boards in 1958, when some california surfers invented sidewalk surfing-- something to do when bad weather prevented them from riding the waves.", "They attached roller-skate wheels to wooden planks, then coasted through the streets.", "Pretty soon, the fad caught on in cities throughout the united states.", "The deck-- the part of the skateboard you stand on-- is made up of several thin sheets of wood called \"veneers\".", "Inexpensive boards use fewer sheets and lesser-quality woods.", "These high-end boards use a full seven sheets of top-quality maple.", "Only the top and bottom veneer sheets will actually show, so their exposed side is sanded smooth, and the other side gets a coat of glue.", "The inside sheets, meanwhile, go through the glue spreader, which saturates both sides.", "This adhesive is specially formulated to withstand vibration and shock.", "Workers stack 35 sheets of veneer-- the equivalent of five skateboard decks-- and place them in a mold.", "Skateboards vary in size and shape, so there's a different mold for each model.", "A press applies 44 tons of pressure, compacting the sheets and bending them to the shape of the mold.", "Excess glue squeezes out the sides, binding the five decks into one block.", "They'll be separated later.", "The block comes out after three hours.", "Now they drill two sets of holes through the block.", "These are for mounting the front and back trucks-- the pivoting, metal axles that enable the skateboard to turn.", "Now it's time to give the rectangular block a skateboard contour.", "They select a template in the general shape of the model they're making.", "It has pins underneath that fit snugly in the truck holes they've just drilled.", "This holds the template still while they do what's called the rough cut-- sawing around the template, leaving a 1-inch margin.", "Cutting off the excess separates the five decks.", "Now they contour each deck individually.", "Using a precise template, they run the deck against a cutting blade until they have the final shape.", "Now, using a router, they round off the top and bottom edges.", "Then they smooth all the surfaces against a drum sander.", "Now they switch to a buffer, which uses a combination of brushes and fine-grit sandpaper to remove any rough wood fibers.", "The deck is now perfectly smooth.", "The next stop is the finishing room, where they first spray the decks with a colorless primer.", "This seals the pores in the wood veneer so they won't absorb the coat of lacquer that comes next.", "The primer takes two hours to dry.", "Next, they spray on a coat of clear or colored lacquer.", "It leaves a protective, high-gloss finish.", "The lacquer also takes two hours to dry.", "The final step of the finishing process is applying the decoration.", "The bold graphic designs are printed on plastic sheets.", "The skateboard factory either buys them ready-made or produces them in-house, using its own silk-screen printing equipment.", "Workers center the design sheet, then feed the deck through a machine that applies heat and slight pressure simultaneously.", "The heat-- 390 degrees fahrenheit-- induces a chemical reaction that melts the ink and lacquer.", "When the plastic comes off, the deck is finished.", "Decks of this caliber are sold unassembled in specialty stores.", "They're designed for serious riders who want to customize their skateboards.", "They pick and choose from different types of trucks, wheels, bearings, even the bolts that hold everything together.", "All these factors determine how fast or how fancy their skateboard will move and maneuver." ]

{ "things": [ "CNC Assembly Machines", "Lemon Tarts", "Miniature War Figures" ] }

[ "Today on \"how it's made\"...", "Automated machines changed manufacturing forever when they began assembling parts.", "Cnc assembly machines have taken automation to the next level.", "Cnc is an acronym for computer numerical control.", "The machine is automated by a computer rather than by mechanics.", "To design a cnc assembly machine, engineers first analyze the sequence of tasks required to assemble the product.", "They then match each task to a pre-designed processing engine.", "The processing engines are linked together in a custom assembly sequence.", "Each engine is programmed to control its computer-guided motors, which perform the precise motions required to execute a task.", "The cnc machine's engines are mounted on a sturdy base frame.", "To construct it, workers cut steel tubes to the required lengths.", "They grind a joint in each piece...", "Then weld the pieces together by melting steel welding wire into the joints.", "They bolt a steel tabletop onto the base frame.", "It has cutouts for each engine.", "It's been ground perfectly flat.", "So the engines will be level with each other.", "Meanwhile, an electrical technician is assembling the machine's main control cabinet.", "It contains one industrial computer for each engine.", "A cnc machine has engines for performing rotary movements, linear movements, and for picking up and placing parts.", "The motors inside each engine have their own computers.", "They're programmed to perform movements at specific speeds and forces.", "Once the main control cabinet is assembled, workers bolt it to the base frame.", "Then they install steel bases for the engines.", "Some cnc machines require robotic arms.", "A computer-guided milling machine cuts rectangular bars of aluminum, shaping them into robotic arm components.", "This precision-measuring device ensures each milled part meets strict specifications.", "After the aluminum components receive an anti-corrosion coating, workers assemble them into a robotic arm.", "These self-lubricating sleeve bearings give the arm the ability to rotate.", "They add a second assembled arm to create a pair that works together to perform an assigned task.", "Each arm is controlled by its own motor, which follows the commands of the engine's computer.", "This coupling securely connects each robotic arm to the shaft of its motor.", "Each engine on the machine can have up to eight motors.", "The motors can operate independently or in unison.", "This engine has robotic arms that can pick up, hold, and release parts.", "To test the completed machine, a high-speed video camera captures images at 1,000 frames per second.", "The quality control team slows down the video to analyze and fine-tune the accuracy and efficiency of every motion.", "Just a few simple taps on the operator's touch screen can adjust the arm to move a millisecond faster.", "Or a millimeter further.", "Cnc machines can assemble small products at high speed.", "They also provide something traditional assembly equipment can't-- flexibility.", "A single machine can be reprogrammed multiple times for assembling different products.", "When life gives you lemons, why bother making lemonade when you can indulge in a luscious lemon tart?", "Not too sour, not too sweet, a lemon tart is a delectable dessert that you can make yourself.", "Or even better, leave it to the baking pros and buy ready-made.", "This thaw-and-serve lemon tart has a shortbread shell and creamy lemon filling topped with buttercream.", "Each batch of dough produced in this industrial mixer yields 449 tart shells.", "The first step is to lightly blend margarine, sugar, and salt for 2 or 3 minutes.", "Next, add pasteurized eggs and mix for about 2 minutes at slow speed.", "Fast mixing makes the dough too tight, causing it to crack.", "They add white flour while continuing to mix slowly until the ingredients are well-blended.", "Once the dough is ready, workers put it through what is actually a hamburger forming machine.", "It extrudes 1/4-pound dough patties.", "Workers place them in the middle of a nonstick aluminum tart pan three at a time.", "They mount the pan on a press, covering it with plastic.", "A die strikes the pan, flattening and spreading the dough evenly.", "The pans go into the oven, where they rotate for 23 to 24 minutes at 350 degrees fahrenheit.", "The dough bakes into a shortbread tart shell.", "Lemon juice and lemon oil are the key ingredients in the creamy filling.", "First, workers melt margarine on a stove...", "Then mix in sugar, lemon powder...", "And food starch to thicken the mix.", "They blend for 2 minutes, then add eggs.", "After another 5 to 8 minutes of mixing, they pour in boiled lemon juice and lemon oil.", "Boiling these acidic ingredients prevents the fats from curdling.", "The filling is ready.", "So they move the bowl from the mixer over to the depositing line.", "A pump transfers the contents to a hopper feeding a depositor.", "The depositor is pre-set to squirt 22 ounces of lemon filling in each tart.", "The filled tarts go into the oven for 11 minutes.", "The lemon tarts come out of the oven, cool at room temperature for 2 to 3 hours, then go into a freezer overnight.", "The next day, workers remove the frozen tarts from the pans.", "They gently remove any specks of browning, then spray on a light layer of glaze made from apricots.", "This adds a hint of sweetness.", "The glaze also prevents the filling from cracking when it's thawed for serving.", "Next, they put the tart in an automated cake slicer.", "The turntable rotates as the tart is cut into 12 slices with papers in between each one.", "This is for restaurants who serve the dessert by the slice.", "Workers embellish each slice with a flower made of buttercream, a decadent mixture of butter, egg whites, and sugar.", "They complete each flower with a dot of lemon filling in the center.", "This lemon tart is finished.", "They wrap it in a cardboard cake band printed with the brand name.", "They seal the tart in plastic film, insert it into a retail box, and ship it frozen to a store or restaurant.", "To serve this tasty dessert, you simply defrost at room temperature for about a half hour.", "Toy soldiers aren't just for children.", "They're a hobby for grown-ups that dates back over a century.", "The science-fiction novelist h.g. wells published the first set of rules for toy solider war games in 1913.", "The game is on.", "It's time to rally the troops.", "These mini soldiers are made of either metal or plastic and hand-painted by the game players.", "No detail is overlooked in making these war figures true to the historical period of the game.", "Players move the figures around tabletop scenery like chessmen on a chess board.", "And like chess, this is a game of strategy.", "It's a way to engage in the tactical elements of war without the violence of a real battle.", "Making miniature war figurines starts with the construction of a model.", "With only one hand and his prosthesis, a modeler expertly bends tin copper wire into a framework for the model.", "Each soldier needs to be 1.1 inches in length.", "So he shapes and trims the wire accordingly.", "Once he completes the wire skeleton, he sticks the leg prongs into a cork.", "This enables him to get a firm grip on the skeleton as he builds up the figure with epoxy putty.", "He sculpts a base layer using a dental tool that's usually used for scraping plaque.", "After the base layer cures, he builds up the chest and calf areas.", "After more curing time, he sculpts the soldier's tunic.", "Using a tool with a fine point, he pits the surface to simulate medieval chain mail armor.", "With skillful artistry, the miniature soldier takes shape.", "He inserts a wire into a drilled shoulder socket and applies putty to create a muscular effect.", "He builds up the sleeve and pierces it all the way around to continue the chain mail effect.", "He carves the rounded rim of the hat.", "This small-scale soldier is in fighting form.", "He's used to make a mold for tin soldiers that will look just like him.", "Meanwhile, another member of the team sculpts epoxy putty models that are three times larger.", "These models are used to mass-produce plastic war figures.", "Going large first and then scaling down is the only way to transfer all the details.", "As he carves hair details into the head of this french cavalry figure, he's careful to not leave any protruding bits.", "Otherwise, plastic could snag on molds made from them, jeopardizing the production of the plastic versions.", "With curing time between layers, it takes about a week to sculpt this french cavalry model.", "They're ready to make molds from the smaller scale models now.", "The mold maker arranges the epoxy models on a silicone rubber disk.", "He presses each one into the rubber.", "The ends leave little dents.", "He removes the model and slices it into the rubber with a surgical scalpel, cutting holes where the figures have left the indentations.", "He removes the silicone cutouts, then carves a narrow channel to connect the two slots.", "He inserts the model into the niche.", "He repeats this process with the other soldiers on the disk, then places the disk in a preheated steel vessel.", "He puts a lid on the vessel and transfers it to a vulcanizing press.", "In the press, heated plates squeeze it using pressure.", "This softens the rubber inside, melting around the figures, picking up the contours.", "This transfers the disk into a mold.", "Coming up next, the miniatures emerge from the mold shell battle-ready.", "In the age of video games, tabletop war games still have plenty of fans.", "The challenge begins with the acquisition of small armies of miniatures.", "Players hand-paint the soldiers and build elaborate backdrops with scenery.", "Then the games begin.", "As production continues, the mold-maker carves channels into the silicone disk.", "He links the channels to the impressions of miniature soldiers and military machinery that have been created by the models.", "The channels allow molten metal to flow into the impressions in order to cast copies.", "In the storeroom, there are thousands of silicone molds, each depicting different characters and props.", "When the order comes in, an apprentice makes the selection.", "Next, an operator puts the mold in a casting machine.", "As the mold spins in the machine, he adds molten tin through an opening in the lid.", "The spinning throws the liquid tin into the mold crevices.", "After the casting solidifies and cools, he extracts the little tin soldiers.", "These tin war figures are on their way to the gaming front lines.", "Making plastic war figures starts with an epoxy resin for a pattern.", "They add a hardener and blend the batch to the consistency of pancake batter.", "They transfer it to a larger bucket and place it in a vacuum chamber, which pulls out the air.", "In the process, the epoxy swells.", "Once the epoxy mixture deflates, a team brushes it onto sculpted military models arranged in a steel box.", "After filling all the crevices, they dispense more epoxy.", "A chute ensures a gentle flow, preventing the buildup of more bubbles.", "They repeat this on the other side of the models to create a two-part pattern.", "Once the epoxy hardens, they mill the outside of the pattern to pre-determined measurements.", "An employee then opens it and discards the models.", "He inspects the impressions they've left.", "They use this pattern to make a smaller-scale mold from steel.", "Using an automated saw, they carve smaller pieces from a block of nickel chrome steel.", "An automated milling tool machines the smaller blocks so the two of them will fit together to create one mold set.", "A carriage shunts the block back and forth between an abrasive wheel to grind the surface to precise measurements.", "A mold-maker follows the impressions in the epoxy pattern with a stylus, which moves a needle-like cutter.", "The cutter etches a template into the steel block that's three times smaller than the one in the epoxy pattern.", "Using a wand that generates high-frequency vibrations, he polishes the etchings in the steel mold.", "It's a gentle polish that doesn't damage any of the etching in the mold block.", "They drill channels in the steel to allow plastic to flow to the impressions.", "They also insert water-cooling pipes.", "They're ready to mass-produce plastic war figures.", "The machine melts plastic and injects it under pressure into the mold set.", "The plastic hardens, and the machine ejects the little soldiers connected by runners.", "This particular production includes miniature rifles and other military paraphernalia.", "They pack the plastic soldiers, their horses, and their guns into boxes for retail along with instructions for painting.", "After painting, the plastic soldiers and their tin comrades are in tip-top military form and ready for battle.", "There will be casualties.", "But of course, it's all just for fun.", "These miniature war figures are survivors.", "They will live on to fight many more battles." ]

{ "things": [ "Ceramic Fireplaces", "Synthetic Corks", "Parking Garage Floor Slabs" ] }

[ "The first fireplaces were strictly functional for heating the home, cooking meals, and warming water for bathing.", "Over time, fireplaces appeared in other rooms of the house and acquired ascetic features such as wood, stone, or tile work.", "This ceramic fireplace is a heritage model inspired by fireplaces of the late 19th and early 20th century.", "Certain tiles are exact replicas of originals.", "At the ceramic factory they mix water with clay, feldspar, and silica in a pugmill.", "Together, these formulate a clay blend.", "Once the mix is the right consistency, the operator presses a button, and the mill switches to extrusion mode.", "This forces the clay blend through a mantel shaped die and produces a 10- to 15-inch long extruded mantel piece.", "They trim the piece with a cutting wire to the precise length required.", "They use this extrusion method for making longer pieces.", "If they need shorter ones they often cast them individually in a mold.", "When casting they add significantly more water to the clay blend to produce a liquid clay called slip.", "They pour the slip into a plaster mold.", "The porous plaster gradually absorbs most of the water, leaving a layer of clay about 6 millimeters thick on the walls of the mantel-shaped cavity.", "After a few hours, they pour out the excess slip and open the mold to extract the cast mantel piece.", "Once the clay becomes firm enough to handle they carefully trim off the excess around the opening in the mold.", "Then they gently smooth down the seam along the junction between the two halves of the mold.", "On the opposite side of the pour hole, they cut out a matching hole.", "This will help the clay dry faster by enabling air to flow through the inside of the piece.", "To compensate for shrinkage, the molds and extrusion dies are designed 11% larger than the size of the finished piece.", "Clay shrinks as it dries.", "To make the fireplace's ceramic tiles, they produce a rubber mold of two adjoining tiles and place it inside a metal casing.", "They also include a release system to help with extraction.", "They fill the casing with an exceptionally strong type of plaster.", "It sets in about half an hour, taking on the shape of the rubber mold.", "This plaster casting is the die they'll now use to produce the tiles.", "They mount the die on what's known as a ram press because it literally rams a block of clay in the die and compresses it with 30 tons of pressure.", "The tile die is also 11% larger than the final size to compensate for shrinkage during drying and firing.", "They remove excess clay and send it back to the pugmill to be recycled.", "Then they position a board under the die and activate the release system, which extracts the clay with a blast of compressed air.", "They trim off the excess clay.", "Once dry, the tiles and mantel pieces are ready to be glazed.", "Glaze is a chemical formula containing finely ground silica combined with different combinations of metallic elements to produce specific colors.", "They use a spray gun to apply glaze to the mantels and a tube tip applicator to glaze the tiles.", "The tiles design has raised borders between its components.", "These are called cuenca lines.", "They prevent the different colored glazes from flowing into each other.", "The glazed mantel piece and tiles now go into a gas-fired kiln for 12 to 14 hours.", "The high temperature, 2,100 degrees fahrenheit, triggers chemical reactions which harden and strengthen the pieces.", "The clay's mineral composition transforms into a completely new configuration of crystals and glass.", "As for the glaze, its precise formulation of metallic elements produces a specific color, and the silica melts into a glass surface.", "The ceramics are now smooth and shiny and ready to transform an otherwise ordinary fireplace into a work of art.", "Many winemakers choose to seal their bottles with synthetic closures instead of natural cork from tree bark.", "This prevents cork taint, which happens when natural cork gets contaminated by the tca molecule.", "Cork taint is completely harmless to humans, but spoils the taste of the wine.", "This engineered cork is entirely synthetic and therefore resistant to tca contamination.", "It's made of a food-grade polyethylene foam core encased in elasticized polymer skin.", "Both materials contract to squeeze inside the bottleneck but then regain their original shape to seal the opening.", "To make the foam core, they mix talc with pellets of low density polyethylene, a pliable type of plastic.", "Then they add pellets of dark brown and beige colorant to mimic the wood grain look of natural cork.", "For each customer's order of corks, a computerized system automatically releases the right amount of each ingredient into an industrial blender.", "The blender feeds a specially designed dual extrusion machine.", "The machine melts the foam mix to a liquid state then injects carbon dioxide.", "This produces bubbles, which create the cellular structure of the foam.", "The liquid foam enters the machine's horizontal extruder, while elasticized polymer enters the machine's angled extruder.", "Both extruders squeeze their materials through the same shaping die, which outputs a continuous rod of skin-encased foam.", "The foam core immediately expands.", "The elastic skin stretches with it.", "A water bath cools the rod, halting this expansion at a specific diameter.", "Then, an underwater ultrasonic gauge measures the thickness of the outer skin to make sure it meets specifications.", "The rod exits the water bath and continues cooling and shrinking as it drip dries.", "A laser gauge then verifies that the rod is perfectly round and measures a specific diameter by this point.", "When any of the measuring gauges detects an area that doesn't meet specifications, that part of the rod is flagged in the system and is discarded at the end of the production line.", "The rod now enters the final cooling phase.", "It travels in several loops past nozzles spraying cold water.", "As the rod cools, it shrinks to its final size, a diameter of between 22 and 23 millimeters.", "It's designed to fit snugly inside the standard 18.5-millimeter bottle opening.", "They had to calculate exactly how wide to extrude the rod so that after expansion then shrinkage, it would end up at this precise diameter.", "The rod now enters a cutter.", "The blade is so sharp that a safety cover is mandatory.", "It's removed here only for the camera.", "The winery placing the order specifies the cork length.", "Air jets automatically blow off any corks cut from areas the measuring gauges flagged as being problematic.", "The cutter slices about 10 standard-length corks per second.", "All the good corks land on the conveyor belt and travel to the end of the line, where computer sensors count them as they drop into a collection bin.", "Additional machines print on the winery's name and logo, and lubricate the surface with silicone so the corks will glide in and out of the bottle with ease.", "The factory's on-site lab tests samples from every order.", "Sensory specialists sniff each cork and compare it to a control sample.", "There must be no discernible odor that might affect the aroma or flavor of the wine.", "If there is, the entire order of corks fails inspection.", "While natural cork is designed by mother nature, a synthetic cork manufacturer can engineer the closure to fit more or less snugly according to the amount of air the particular wine needs to develop correctly.", "Multi-tiered parking garages have become an urban phenomenon.", "With each floor added to the garage the number of parking spaces increases.", "In crowded cities where land is limited, garages like these are a necessity.", "They build parking garages one concrete slab at a time.", "These slabs are known as double-t's because the two support beams are in a double-t configuration.", "Double-t's are often factory made and transported to the construction site later.", "They are designed to hold up under very heavy loads.", "They make these slabs outdoors.", "Wind blows dirt onto the molds, so they sweep it clean.", "This mold is about 500 feet long and will be used to make several slabs.", "They spray an oil-based release agent onto it.", "The release agent will allow the slabs to be easily extracted when complete, preventing cracking.", "They spread it more evenly using mops.", "This release agent bonds to the metal quickly and won't wash off easily if it happens to rain.", "They're now ready to assemble the floor slab's elaborate support structure.", "They prop up the ends of each slab with galvanized steel stirrups.", "They place l-shaped bearing plates in strategic locations along the mold.", "Then they insert wooden blocks in the mold.", "These blocks will form notches in the cast concrete that will be used to join the slabs during construction.", "Next, workers thread high-strength steel cables called tendons throughout the beam sections of the mold.", "They pull the ends through holes to the outside of the mold and clamp them.", "A worker tucks another wood block between two tendons to complete the notch part of the mold and hold the tendons in place.", "The team threads more tendons throughout the mold, weaving a strategic support structure.", "To separate each cast slab, they insert wooden dividers with slots that accommodate the tendons.", "They adjust the location of each of the stirrups so that they sit at a specific spot near the dividers.", "With the final tendons in place, they bring in a hydraulic jack.", "The worker attaches it to one of the protruding steel tendons.", "He activates the jack, and it pulls the tendon until it's stretched tight like a rubber band.", "He pulls the rest of the tendons with the jack and checks the tension to confirm that it's exactly the same for each one.", "Pulled tight and later released, the cables will hold the concrete under compression, adding strength to it.", "Without it, the concrete slabs would never be able to support the weight of many vehicles.", "The next worker ties a plastic bracket to the stirrups to set them at the right height.", "He inserts metal mesh into the mold where each slab will end.", "This will help disperse some of the concentrated bearing stresses.", "He stabilizes the mesh, and reinforces it with the support structure.", "The team places plastic pockets along the tops of the beam sections of the mold.", "These pockets will be used to chain the slab to the truck during transport.", "They'll also act as entry points for electrical wiring and hold controls for parking space counting equipment.", "Coming up next, the deck section gets plenty of extra support, and then it's set in concrete.", "The average car weighs well over 2,000 pounds, so each parking garage floor must hold up many times that weight.", "Double-t concrete slabs make this possible.", "Each slab has two reinforcing beams, and each beam has a tense steel skeleton that compresses the concrete, making it stronger.", "With the steel tendons stretched through the beam parts of the mold, workers now lay metal mesh across the deck.", "This mesh is known as welded wire fabric, and it will reinforce the surface of the parking slab.", "They tie the welded wire together for full coverage across the deck.", "They use plastic clips to prop up the wire so that when they pour the concrete, it will envelop both sides.", "They insert handles that will protrude from the ends of the completed slab to allow it to be lifted for transport and installation.", "There are four double handles in each parking floor slab.", "They enmesh the prongs of weld plates in the steel grid.", "The plates are strategically positioned for the welding of the slab to other pieces of concrete.", "All the prep work is finally done, and they pour the concrete.", "The concrete flows into the beam sections of the mold first, and then workers spread the overflow across the deck.", "This is a high-performance formula that's known in the industry as self-consolidating concrete.", "It flows evenly into tight spaces and compacts better without the need for much vibrating.", "This leveler vibrates the surface of the concrete only slightly as it evens it out.", "They then rake the surface of the slab to allow another layer of concrete to adhere to it later during construction.", "They now insert arced metal bars into slots on the sides of the mold to form a ribbed framework down the length of it.", "This serves as a support structure for a tent.", "They unroll the tarp from a huge spool and drape it over the ribbing.", "They secure the canvas to the sides of the mold with hooks.", "The tent will shelter the concrete from the wind and rain as it cures.", "Along with an additional plastic layer, it will contain the hot and humid conditions created inside.", "The heat accelerates the curing of the concrete, and the humidity prevents cracking.", "The cure takes 16 hours, and then they roll up the tarp.", "Using a torch, they cut the steel tendons and place the concrete under compression.", "The cuts also separate the slabs.", "A driver now parks his crane over one of the slabs.", "Workers attach the hooks of the crane to the protruding handles at the ends of the slab.", "They signal the crane operator, and he activates the lift.", "Thanks to the release agent applied earlier, the concrete slab easily dislodges from the mold.", "It's a heavy load.", "Each slab weighs 40,000 pounds.", "The crane sets it down and the team inspects the slab for defects.", "Satisfied that the slab is free of flaws, a worker trims the protruding steel tendons flush to the concrete.", "Another worker spreads a concrete-like paste on the exposed ends of the severed steel to seal it from the elements.", "Then a worker glues rubber pads to the bearing plates.", "They'll act as cushions when the slab sits on another concrete beam.", "He wraps some tape around them while the adhesive sets.", "This parking garage floor slab is now ready to join the rest.", "Side-by-side, the slabs will form one large parking surface to create even more spaces." ]

{ "things": [ "Sails", "Walnuts", "Wheel Immobilizers", "Honeycomb Structural Panels" ] }

[ "A sail is essentially a vertical wing that provides forward thrust and lift to propel a boat over water.", "It's impossible to know who came up with the concept because boats with sails have been plying waterways for thousands of years.", "But there's no doubt that when it comes to their design and construction, today's sails have come a long way.", "For thousands of years, sails were square, but in the 3rd century, triangular sails appeared on the mediterranean.", "The shape enabled boats to sail into the wind, as well as with it.", "Modern racing sails are made of laminated synthetics.", "They start with a plastic membrane.", "Rollers apply a hot liquid adhesive to one side in measured amounts, because even a couple of extra grams would weigh down the sail.", "They press a scrim onto the hot adhesive.", "It's a superstrength synthetic called aramid, which will keep the sail from tearing.", "Then it's over to a computerized laser that cuts patterns out of the scrim-reinforced plastic.", "A worker rolls up each panel to transport it to the next worktable.", "Here, they tape 10 to 20 of the panels together, using heavy-duty p.e.t. plastic with an acrylic adhesive.", "Now hundreds of small jacks stretch aluminized plastic around a framework, pulling material into a curved aerodynamic shape.", "This mold will be used to shape the sail.", "The team stretches clear plastic film over it.", "Then they drape the joined panels over top.", "They use ropes and clamps to pull it to the contours of the mold.", "And now they're ready for some supertough synthetics-- aramid and carbon fiber yarns.", "The yarns have been coated with adhesive so they'll stick to the plastic film.", "A robot rolls the yarns onto the film, while a worker follows in a harness overhead to keep an eye on the job.", "The robot applies the yarns in a pattern plotted by an engineer to anticipate the wind load on this sail.", "The robot now switches from a vertical path to a horizontal one, applying yarns in a transverse pattern.", "The team installs a long, narrow pocket over that section.", "A batten will later be inserted in this pocket to control the sail's shape.", "They pull another layer of scrim-enhanced plastic on top.", "And now all the layers of this sail cloth are in place.", "A worker hovers overhead to inspect the surface for defects.", "They now seal the assembled sail in a vacuum bag and attach hoses.", "The hoses suck out the air, pressing the layers of the sail together.", "Now the robot applies heat to the sail.", "It activates the adhesives and the plastics to laminate the layers together.", "And it also sets the three-dimensional shape of the sail.", "A worker inspects the job with a magnifying glass.", "Then it's over to a revolving sewing turret.", "As the sewing machine turns, it pulls the sail forward, allowing the operator to stitch hems, grommets, and reinforcements onto it.", "They apply the corporate logo.", "Next, a worker walks the length of this enormous sail to inspect it.", "No imperfections will be tolerated.", "After all, this is a big-ticket item.", "Large racing sails can retail for hundreds of thousands of dollars.", "Sophisticated engineering and high-tech materials have produced a racing sail that's lightweight yet incredibly strong.", "There may be rough water ahead, but with technology on their side, this crew should be able to sail right through it.", "The walnut has been cultivated for thousands of years, but its actual discovery remains a mystery.", "Some of the earliest evidence of the walnut comes from the region of persia in 7th century b.c. back then, royalty had dibs on this nut, and commoners were forbidden to eat it.", "Thankfully, that's ancient history.", "Today, the walnut is mass-produced to meet a global demand.", "It starts in an orchard like this one in california.", "Walnuts take five years to grow, and they emerge shrouded in protective husks.", "Using mechanical shakers and sweepers, workers harvest the walnuts.", "Once the husks have been peeled off, it's over to the receiving pit at the processing plant.", "This machine separates out any rocks or sticks, then drops the walnuts into a conveyer.", "At the end of the line, the nuts spiral off and land softly in cooling bays below-- 8 bays that hold over 13 tons of walnuts.", "The walnuts are funneled into these sealed chambers for fumigation to eliminate insects.", "After 28 hours, they're on the move once again.", "They fall between rollers.", "The gaps between these rollers are tapered to allow the small, medium, and large nuts to fall into separate lanes.", "This sorting system will allow them to be cracked by machines geared to specific nut sizes.", "These large walnuts head up a conveyer called the cracker belt.", "At the top, they enter the cracker.", "It's a revolving machine with pistons, one for each walnut.", "The technician activates the pistons to press against the nuts.", "The pistons apply a precise amount of pressure to crack the shells without damaging the nuts inside.", "The nut cracking has been slowed for our camera, but in reality, this is a high-speed operation.", "The nuts, shells and all, fall onto a conveyer.", "The pistons have cracked between 80% and 90% of the walnuts.", "To capture the rest, the whole pile shakes its way toward a second group of sizing rollers.", "The smaller pieces drop through the gaps and go for further processing.", "The larger ones continue on to a machine called a re-cracker.", "There, the nuts travel through slats in a revolving cylinder.", "Inside those slats are little knives that break up the whole nuts.", "After some of the larger shells have been removed, it's on to a giant sifter.", "The nuts and shells bounce on a shaking screen.", "The smaller bits fall through, and the larger ones remain on top.", "The holes in the screen become progressively larger to sort the pieces into eight sizes which differ by a fraction of an inch.", "The bigger, choicest walnuts fall into a separate chute.", "The smaller pieces will be used in baking, among other things.", "A high-speed belt sends nuts and shells flying through the air to allow a computerized camera to detect shell fragments and activate a system to blast them off the production line, leaving the prized kernel, the walnut half.", "An inspector removes any remaining shells or unacceptable nuts.", "Then the walnuts enter a vacuum chamber, which suctions away any last crumbs.", "They exit on a spiraling slide and land in a box.", "This packer portions out bulk product for the food industry.", "He removes nuts from the box until it reaches the correct weight.", "These walnuts are on their way to adding crunch and flavor to cookies, cakes, and other good stuff.", "The walnuts in this box have taken years to grow and a couple hours to process, but in the end, the wait should be more than worth it.", "On the street, it's known as \"the boot\".", "Accumulate a few unpaid parking tickets, and you may very well find your car wearing one.", "Municipalities use wheel immobilizers to clamp down on offenders, while universities use them to deter illegal parking on campus.", "The boot's dome goes over the rim.", "On the other side, its inner arm hooks in between the rim and brake.", "A secure bolt clamps those outer and inner parts together, immobilizing the wheel.", "Boots must be strong and tamper-proof, so the main components are made of steel.", "This steel tube will become the boot's outer arm.", "This steel bar will become the stand that props up the boot during installation.", "This flat steel bar will become the inner arm that hooks between the rim and brake.", "They bend it lengthwise to give it strength.", "Then they bend it into the final shape.", "Now back to the tube they cut for the outer arm.", "After bending it in two spots, they drill two holes for the tube that will house the secure bolt.", "They bend a flat steel bar to make a stiffener that reinforces the inner arm.", "Meanwhile, that steel bar they cut to make the stand goes onto a machine called a rod bender.", "A welder now fuses the tube to the outer arm...", "Then welds that assembly to a part called the body box.", "After welding the stiffener to the inner arm, he welds a pin through holes in both the arm and the other end of the body box.", "So now the inner arm hinges on the box.", "After a coat of baked-on enamel, the boot's body is complete.", "The dome measures 12 inches in diameter.", "First, they weld a bracket to it.", "Next, they fit a sleeve into the bracket and thread a pin through them both.", "Then they weld the pin to the bracket.", "So now the sleeve pivots.", "This, too, receives a baked-on coat of enamel.", "Now they glue a rubber trim over the dome's edge so that booting a car doesn't damage the rim.", "It's time to assemble all the parts.", "First, the mechanism that clamps the boot's inner and outer arms around the tire.", "Using a special key, they screw into a stainless-steel nut inside the bolt tube.", "This spring holds the inner arm in the correct position.", "The stand goes on with a bolt.", "The stand elevates the boot off the ground, enabling the installer to turn the secure bolt key.", "In this cutaway, you can see how turning the key moves the secure bolt forward, pushing the inner and outer arms together to clamp the tire.", "Next, they slide the dome sleeve over the body's outer arm.", "They align the hole in the sleeve with the hole in the arm, then bolt the parts together.", "The arm has several holes so the boot can accommodate wheels of different sizes.", "Every boot gets a metal plate bearing the model and serial number.", "The boot manufacturer records who owns the boot and won't issue a new secure bolt key without proper identification.", "From the mechanics to the cabin, aircraft are made with the most lightweight, high-strength materials, such as honeycomb structural panels.", "These make up the support structure hidden beneath the flooring and behind the walls of, among other areas, the lavatories, galleys, and stow bins.", "The cells at the center of the structural panel are hexagonal in those designed to lie flat and rectangular in curved panels.", "Producing the core begins with giant printing cylinders.", "Etched into their surface is a pattern of lines.", "They rotate in heat-activated adhesive, printing the line pattern onto paper that passes between them.", "This paper is made of thermoplastic, but depending on the type of panel, it can be another kind of paper or even aluminum foil.", "This machine cuts the paper into sheets-- anywhere from 500 to 2,000 sheets, depending on how thick the cores will be.", "The machine then stacks the sheets in a specific sequence.", "Every other sheet is offset by half a line.", "This back-and-forth pattern is what forms the core's honeycomb cells.", "The stack now goes into a heated press, which activates and cures the lines of adhesive, bonding the sheets.", "After an hour, they remove the stack and attach aluminum-foil loops along its perimeter.", "Then they stand the stack on its side and hook those loops onto the steel pins of a device called an expansion frame.", "It slowly pulls apart the sheets, opening the honeycomb cells that the special stacking sequence formed.", "To ease the expansion process, they soften the paper with water.", "This is a time-lapse shot.", "The full expansion takes about 15 minutes.", "Next, the block goes into an oven, where it bakes for about a half-hour at 527 degrees fahrenheit.", "That heats sets the thermoplastic paper, locking in the honeycomb shapes.", "Now they repeatedly submerge the block in a vat of resin, baking it after each dip.", "Here, an aspirator sucks out the excess resin.", "Then, after a final baking, an automated saw slices the block horizontally into several cores.", "Then it's over to the assembly table.", "They construct a structural panel like a sandwich-- the honeycomb core in the center.", "This one's made of aluminum foil.", "Then on either side of the panel's outer sheets, in this case, made of carbon fiber.", "On the top and bottom, workers position a sheet of release paper to prevent the panel from sticking to the metal sheets that hold everything in position for now.", "Workers load the assembly into a press.", "The heat and pressure combined bond all the layers.", "About an hour later, they take the sandwich out of the press and remove the metal sheets.", "Workers slap on labels identifying the product and manufacturer.", "Then they shear off the panel's rough edges.", "The factory subjects some samples to a series of quality-control checks.", "This load test, for example, assesses how much the panel can flex and how much weight it can withstand before snapping.", "Whatever the materials, thickness, or density, these structural panels all deliver maximum strength with minimal weight." ]

{ "things": [ "Gears", "Leather Watchbands", "Vitrelle Dishes", "Kitchen Shears" ] }

[ "If you've ever looked inside a wind-up watch or a car's transmission, you've seen a system of gears.", "A gear is a wheel with teeth that meshes with the teeth of another gear to transmit power on a continuous basis.", "Combining gears of different diameters affects rotation speed and force.", "This factory makes gears that go into transmissions for industrial machines.", "Production begins with a large, round bar of high-grade steel, which contains a certain amount of carbon to make it even stronger.", "An automated band saw slices off a piece that's the right thickness for the size of gear they're making.", "This piece is called a gear blank.", "They mount the blank on a computer-controlled blade.", "As it spins, a turret carrying a series of carbide tools moves in.", "One tool after another takes its turn machining the blank to a specific shape.", "A shower of coolant prevents overheating when the jumbo drill has its turn.", "It bores a hole right through the middle of the blank.", "The last tool carves a groove on the front of the blank.", "This final bit of metal removal lessens the gear's weight.", "Now the blank goes into a computer-controlled mill.", "The mill drills holes through which lubrication will flow when the gear is operating.", "These holes also lighten the gear's weight.", "When the blank comes off the mill, they stamp it with the company name and part number.", "Now for the gear's teeth.", "A machine called a gear shaper carves out the inner teeth-- the ones lining the center hole-- with its titanium-coated cutter.", "The machine's other components keep the cutter's movement correctly timed.", "The number of teeth and tooth size vary from gear to gear, so for each model, the factory has to fit the gear shaper with a specific cutter.", "Now for the outside gear teeth.", "The computer-controlled machine that cuts them is called a gear hobber.", "The gear turns against it as it cuts.", "If the hobber would cut the full depth of the teeth in one shot, the cutter would chip, so the gear keeps turning around and around again as the hobber cuts a bit more with each pass, until the teeth are the right depth.", "Then the gear undergoes a computerized inspection.", "A probe scans the entire surface, including every tooth.", "It sends data to a computer which then analyzes the dimensions and ensures they meet the engineering specifications.", "Gears that pass this quality-control inspection go into a furnace for heat treatment.", "This strengthens the steel.", "When the furnace reaches a certain temperature, they inject carbon inside.", "The gears absorb it, and the steel strengthens even further.", "A soaking in oil afterward hardens the metal.", "Heat treatment, however, distorts steel somewhat, so each gear now goes to a computer-controlled grinder.", "It restores them to very precise specifications for bearings to fit properly.", "This factory manufactures gears in various sizes, and not only in steel.", "It also makes gears in material such as nylon, aluminum, brass, and stainless steel.", "Some gears have straight teeth, others angled teeth, which makes less noise when turning.", "Gears are an essential component in everything from watches to heavy mining equipment, keeping machinery going at every turn.", "When it comes to wristwatches, there's nothing quite like a band made of genuine leather.", "It has a classic look that's versatile, working with both casual and formal attire.", "And a leather watchband is always comfortable against the skin because, unlike synthetics, leather breathes.", "These premium watchbands are made of alligator, a leather with an unmistakable texture and shine.", "The tannery dyes the croc leathers in classic shades, as well as in the latest high-fashion colors and styles.", "Nearly all the production steps are manual, beginning with cutting leather pieces for the band's two straps.", "Every watchband model requires a steel cutter for each strap in every size.", "Now they coat the back side of each piece with glue.", "Later, when it's almost dry, they center a watchband core onto it.", "This flexible form is made of synthetic material reinforced with fiberglass.", "Using a machine with a fine blade, they make small cuts at the ends to let the leather fold smoothly over the form.", "One side of each strap attaches to the watch face with a spring-loaded bar.", "They mark exactly where the bar goes, then punch a tiny hole for its tiny base.", "Next they apply superstrength glue and fold the leather over to encase the bar.", "The glue dries instantly.", "They now coat the rest of the form with glue, then lay it in a mold that pushes the leather against the edge tightly so they can neatly fold over the remainder.", "Now they run the open end through a machine that cuts a beveled edge.", "Next, they run a tiny sander over the leather on the back side.", "This roughens the surface, which will help the leather backing adhere.", "To make the loops which go on the buckle strap, they bevel the ends of small leather strips.", "They glue and fold them into a loop, making sure they're large enough to fit around both straps.", "One loop sits directly below the buckle.", "A glued-over flap of leather locks it in position.", "They press it flat with pliers to ensure a good bond.", "They machine-stitch each strap with strong, polyethylene-based thread.", "To prevent unraveling, they melt them right into the leather.", "On the buckle end, they pierce two holes for stitches that reinforce the locked-in first loop.", "Then they punch two holes in the back of the second loop for stitching to reinforce its glued-together ends.", "This loop has to be movable, so they don't stitch it to the band.", "They heat the edge of each strap.", "The iron's rounded tip molds an attractive, rounded edge.", "Using a heated tool again, they widen the channel through which the buckle will pass.", "Now they insert the buckle end into a stamping press.", "It cuts a slot for the buckle's tongue.", "A heat press burns the company's name into the leather lining.", "That same strap then goes into a press, which punches the sizing holes.", "From here, both straps go off to the buckle department.", "Random samples are subjected to rigorous quality-control testing.", "This machine pulls the ends of the strap in opposite directions, with up to nearly 50 pounds of tension, far more than anyone would ever apply to the watchband when they pull to buckle it.", "Vitrelle is a super-durable dinnerware material invented in the united states in the early 1970s.", "It's made of three layers of glass, fused together.", "Vitrelle dishes are thin and lightweight, yet they're stronger and far more break-resistant than ordinary dinnerware.", "In a perfect union of form, function, and food, this company serves up vitrelle dinnerware in several striking designs.", "The dishes are made of 65% recycled glass from earlier production runs.", "To make the other 35% that's new glass, the factory combines several raw materials-- sand...", "Salt...", "Limestone...", "Feldspar...", "And two more types of salt.", "The exact proportions are a closely guarded secret.", "The ingredients go into a furnace, where a fiery 2,500 degrees fahrenheit melts them into liquid glass.", "It exits the furnace.", "An extruder shapes it into a three-ply sheet that lands in a mold-- in this case, a plate mold.", "A trimmer cuts off the excess, while compressed air blows down from above to cool and solidify the glass.", "A vacuum arm then extracts each dish, and the leftovers are recycled.", "The dishes now undergo what's called fire polishing.", "Each one passes through a gas-oxygen flame, which seals the three layers of glass.", "It also melts the outer rim, smoothing and rounding out the rough edge created by the trimming.", "Oval dishes go on a different fire polisher, designed for an oval rim rather than a round one.", "Now the conveyor system flips each dish over for backstamping.", "The bottom of every vitrelle dish has the trade name and other information.", "A silk-screen machine applies the lettering.", "Then a gas-air flame bakes the ink into the glass.", "Once that's done, the conveyor system flips the dishes right side up again.", "To decorate the dishes, a machine silk-screens the design onto membranes.", "Robotic arms position a membrane above each dish.", "Then a press head pushes the membrane down onto the surface, transferring the paint.", "Robotic arms then move the dishes back onto a conveyor belt.", "Certain dishes have a design on the outside.", "An automated silk-screen machine applies the paint directly to the surface.", "The decorated dishes now travel through a tunnel oven for 5 1/2 minutes.", "The nearly 1,500-degree fahrenheit heat cures the enamel paint.", "At the end of the ride, a tempering process that makes the glass stronger.", "Then, nozzles spray the dishes in a soy-based silicone.", "This wash-off coating prevents scratches during packaging.", "The factory subjects a sample from each production run to a 6 1/2-foot-drop test and a rim-impact test.", "The sample mustn't break, chip, or crack...", "All to ensure this stylish dinnerware will withstand whatever your household can dish out.", "Shears are typically larger than scissors for heavier-duty cutting.", "And you can insert up to three fingers in the handle's finger ring.", "Using more fingers gives you a stronger grasp, which translates into more control and more cutting force.", "These high-end shears effortlessly slice through produce, snip fresh herbs, and open packaging.", "Outside the kitchen, they easily cut many materials, including thin aluminum and galvanized steel.", "The secret to their strength?", "Blades made of stainless steel, which contains a minute amount of carbon.", "To make them, workers feed a bar of this high-carbon stainless steel into a press.", "It stamps out blade shapes called blanks.", "Stainless steel can be heat-treated to make it more durable and corrosion-resistant.", "But first, a furnace softens the blanks for the forging process that transforms them into blades.", "Each blank goes onto a forging dye that has two blade-shaped cavities.", "One strike in each, and the blank is a blade.", "Once it cools, a trimming press cuts off all the excess metal around the perimeter.", "Heating and forging tend to warp steel, so another press makes the blade perfectly flat and straight again.", "Trimming the excess metal leaves some rough areas, so the next step is to smooth the surface with a sanding belt.", "To make the hole for the bolt on which the blades pivot, they drill a round hole partway through...", "Then pierce a rectangular hole through the rest.", "You'll see why later on.", "Now the blades undergo heat treatment-- first, to harden them, a slow heating and rapid cooling, then, to make them tough and durable, a reheat and slow cooling.", "A grinder shapes the round area next to the tang, the term for the metal core of the handle.", "With a sanding belt, they smooth out and blend the adjacent corners.", "Here, two polishing wheels give the surface an upscale satin finish.", "Then an etching machine uses electrically activated chemicals to imprint the company's name into the thumb-operated blade.", "Just one final step before the blades are finished.", "A computer-operated grinder serrates the inside edge of the thumb-operated blade.", "Workers now load six blades at a time into an injection-molding machine.", "The machine shoots molten plastic into the cavities, then rapidly cools the material until it solidifies.", "Each blade exits the machine with a molded handle firmly encasing the tang.", "Now for the final assembly-- first they drive a bolt with a rectangular head into the pivot hole of the finger-operated blade.", "Then they add the thumb-operated blade and press the bolt again into its final position.", "A self-locking, hexagonal nut secures the bolt from underneath.", "An automatic tightener does the initial fastening.", "Then workers do the final tension adjustment manually.", "The final step is to grind the excess plastic off the handle stops.", "This enables the blade to close fully and in perfect alignment.", "So, why the rectangular bolt?", "Watch closely.", "It allows you, with just one simple twist, to separate the blades for cleaning and then reassemble them.", "Now, that's cutting-edge design." ]

{ "things": [ "Fish Decoys", "Film Digitization", "Cylinder Stoves", "Concrete Light Poles" ] }

[ "When luring fish to a hole in a frozen lake, it helps to take a crafty approach.", "It's a handcrafted piece of folk art, and it's also a cunning piece of work.", "Often brightly colored with bold patterns, the decoy attracts the attention of fish-- an attraction that will likely prove fatal.", "Native north americans were the first to use decoys to catch fish in the winter.", "European settlers followed their example.", "And centuries later, decoy artists carry on this tradition of trickery.", "At this workshop, the decoy starts with a plank of white cedar.", "It's a wood with dense fibers, so it won't expand when wet.", "He draws a basic fish shape on the wood freestyle.", "This one is to resemble a herring.", "He carves out the shape with a band saw, producing the blank, which can now be transformed into a fish decoy.", "He cuts a narrow slot for attaching a metal tail fin.", "He draws a center line around the decoy blank.", "This serves as a reference point as he now tapers the edges with a sharp knife.", "If he cuts too deep, he could spoil the carving, so he whittles carefully, removing just a bit of wood with each stroke of the knife.", "The goal is to round the sharp edges and soften the profile without cutting too deep and gouging the wood.", "He sands the entire surface of the decoy until it's perfectly smooth.", "Sanding also opens up the pores of the wood so paint will adhere.", "He carves a mouth and then cuts slits for two sets of side fins.", "Using a power carver, he now bores into the wood to create fish eye sockets on both sides.", "He takes an equal amount of two epoxy clay components and kneads the two together.", "This activates the ingredients, turning it into a putty-like adhesive.", "He presses some of the adhesive into each of the decoy's eye sockets.", "He presses the glass eyes into the epoxy-filled sockets.", "Next he cuts six fish fins from a sheet of aluminum, creating one dorsal fin, two sets of side fins, and a large tail fin.", "He inserts the fins into slots in the carving.", "He then drills holes in the wood on each side.", "He presses nails into those holes using pliers.", "This secures the tail fin.", "The fins on decoys are larger than on live fish to enable them to swim well when weighted.", "He now carves a pocket for the lead weight in the decoy belly.", "He inserts the front side fins, so that they protrude slightly into the freshly carved pocket.", "He scoops up molten lead and pours it into the pocket.", "As the lead solidifies, it weights the decoy so it will sink, and it also secures the two side fins.", "He applies epoxy to the lead, sealing it so it won't be exposed to the water.", "He coats the entire decoy with lacquer.", "This seals the wood against water, which would have caused the wood to swell, cracking the final finish.", "Once the lacquer dries and the paint has been scraped off the eyes, the decoy is ready to take the plunge.", "He tests it to confirm that it sinks and that it sits level underwater and swims.", "Sometimes, more lead needs to be added.", "But in this case, the decoy performs fine underwater.", "He marks a spot for a screw eye for threading fishing line and then twists the screw eye into that spot.", "He paints the herring decoy a vibrant red, a color that isn't scientifically accurate, but one that should tantalize real fish.", "Decoys are often exact copies of fish.", "They're designed to simply pique their curiosity.", "Since fish are attracted by colors and shapes they don't normally see, decoy artists can be as creative as they like.", "Considered a form of folk art, fish decoys are often entered into competitions.", "But of course when it comes to their underwater allure, the real judges are the fish.", "Unless you're actually in a movie theater, you're likely watching a digital version of a film.", "A movie shot on film has to be digitized to be put on a disc or to be downloaded and viewed on an electronic device.", "Digitization also preserves the movie as film physically deteriorates over time.", "A movie has to be in a digital format to be viewable from a dvd...", "Or as a download to a computer...", "A smartphone...", "I repeat-- a nuclear war has broken-- ...", "Or a tablet.", "[ dog growls] [ electricity crackles] aah!", "This organization has produced 13,000 films since it was founded in 1939.", "And now it's in the process of digitizing the collection, as well as the 80 to 100 new films it produces each year.", "Once all the finished films are digitized, the next step will be to digitize stock shots and archival footage.", "The film board's archives contain many films which have deteriorated due to age and poor storage conditions such as exposure to cold or to heat, both of which deform film, and excess humidity, which causes fungus growth.", "Film's other enemy?", "A damaging chemical reaction which occurs over time between the acid in the film plastic and the colored dyes that make up the image.", "The first step is to repair any breaks in the film so technicians can view and evaluate its condition.", "They do this using a simple device called a splicer.", "They lay each broken end into the splicer's track and cut off the severed frame.", "A missing frame here or there isn't all that noticeable.", "Once the broken frame is removed, they lay both ends in the track, centering the meeting point.", "Then they tape the splice on both sides.", "This tape is specially designed for film splicing.", "Its chemical makeup won't damage the film over time as would ordinary adhesive tape.", "The splicer punches sprocket holes in the tape so that the spliced portion, like the rest, will thread onto the sprockets of the projector reel.", "Technicians evaluate all existing versions of the film, from the original, to the screening prints produced for movie theaters.", "They assess the general condition, note where the splices are and which frames are damaged, then they decided which version is in the best shape overall.", "That's the version they digitize.", "Later, they'll digitally edit out the damaged portions and replace them with identical but undamaged frames digitized from another copy.", "After threading the film through the scanner, they close the gate to hold the film flat and close to the scanning camera.", "Then they input the picture quality specifications and start her up.", "The scanner gently loops the film around its spools...", "And begins rolling it past the camera.", "For the picture quality they've selected for this digitization, the camera snaps three pictures of every frame.", "The scanner's control station displays what's being scanned in real time, along with all the technical parameters.", "This digitization process itemizes every single frame so when they digitally replace a damaged portion with an undamaged one from another copy they can match everything up to the exact frames.", "The final step is color correction.", "Because the digitized film is often pieced together from more than one film original, there are usually color variations.", "For example, the character's blue jacket will be a different shade of blue at different times.", "At this station, the technician manipulates the colors to render them uniform throughout the film.", "It's essential to resist the temptation to overcorrect the image.", "After all, film has a very different color and texture than video, and even though the digitized film will play on video devices, it must remain artistically and historically faithful to the film original.", "Do not remain seated.", "I repeat-- a nuclear war...", "A cylinder stove is designed for campers who like their creature comforts.", "Just pitch the tent and set up the stove inside.", "It keeps things warm and toasty for most of the night.", "It also has a cooking surface and a tank at the side to provide hot water for washing.", "No need to huddle around a campfire to stay warm.", "A cylinder stove can take the chill out of the wilderness experience.", "The cylindrical shape means it can take the heat.", "It will expand and contract with the temperature change and still maintain it's original shape.", "The cylindrical firebox starts with a flat sheet of steel.", "A worker feeds it through a roller repeatedly until it reaches the desired shape.", "Then a plasma cutter cuts an opening for the stove door in another sheet of steel, following a pattern overhead.", "The plasma cutter works by sending an electric arc through compressed air, and the result is a clean cut.", "He now places the stove body on the door framework and clamps the assembly in a special jig to secure it as he welds the two parts together.", "He then places the backplate on the workbench and positions the other end of the cylinder on it.", "He clamps them there and welds them together.", "Using the plasma cutter, he trims the front and back of the stove.", "The trimming rounds the ends nicely.", "From three flat sheets of steel to a cylindrical firebox, the transformation has taken less than 10 minutes.", "The welder now reinforces the underside of the stove top with several braces arranged in a grid pattern.", "This extensive bracing will prevent warping to keep the stove top perfectly flat under the intense heat of the wood fire below.", "This is the stove top before and after bracing.", "After cutting a hole for the stovepipe, he inserts a piece of pipe temporarily so that he can correctly install a stovepipe collar.", "Once the collar is solidly attached to the cooktop, he removes the stovepipe.", "He then bends the rim of the collar in four places, creating tabs to keep the stovepipe from sliding into the firebox.", "He's now ready to join the cylindrical firebox to the stove top.", "He locks them in position and welds the entire assembly.", "This final welded seam seals the stove for an airtight and long-lasting burn.", "Next he positions leg fittings on the belly of the stove using a sawhorse-style tool.", "Once he welds the fittings to the stove, he removes the tool.", "Then it's over to a computerized plasma cutter.", "It cuts damper holes in the stove door.", "Damper holes are used to regulate the flow of air to the fire.", "They also install a baffle plate on the back of the stove door to keep sparks from flying out into the tent.", "The worker attaches the door to the stove with a hinge.", "He tests it to confirm that it opens and closes easily.", "Another worker now roles pipe for the chimney, using galvanized steel because it doesn't rust.", "He interlocks the seam and flattens it.", "He crimps the ends to connect the pipe to the other pieces of pipe.", "There are five pieces of stovepipe in all, and they can be stacked together for transport.", "With the latch now attached to the stove door, he sprays black stove paint onto the cylindrical firebox.", "The paint job will prevent rusting.", "Finally he rivets a brass manufacturer's tag onto the stove front.", "Now it's time to pack it up.", "From the grate to the water tank to the stovepipe, everything can be stowed inside the fire box, making it completely portable.", "Assembly in the tent should take about five minutes-- a small job for a long-lasting burn.", "The biggest cylinder stoves are designed to hold a fire for an entire night.", "And with the proper setup, campers should sleep safe and sound.", "Installing a piece of heat-resistant rubber protects the tent around the stovepipe.", "Then it's time to hunker down for the night and enjoy a little warmth in the wilderness.", "Spun concrete light poles tower above our towns and cities, lighting the way.", "They're actually hollow structures with wiring or cable snaked through the cores.", "The concrete walls are reinforced by steel.", "Yet these poles are flexible enough to bend with the wind and snap back.", "When it comes to lampposts, the higher the light, the greater the area illuminated.", "Some concrete light poles are over three stories high.", "They start with a tenon, the part of the pole framework that anchors the light fixture.", "They place two in a mold because they're making two light poles at once.", "A worker strings four thick, steel strands from one end of the long mold to the other, threading them through the tenons and through spiral wire.", "This establishes the basic framework of the concrete poles.", "Another worker installs zinc boxes for electrical connections.", "He caps it with a block of rigid foam to protect it when the concrete is poured.", "The next worker attaches a stress gun to chucks that secure the steel strands.", "The gun pulls the strands one by one to a specific tension, and they stretch like rubber bands.", "They'll be pulled even tighter later.", "Every yard or so, he attaches stay rings for extra rigidity.", "He ties them in place with plastic-coated wire.", "Another worker stretches the spiral wire around the steel strands and tenons to round out the skeleton of the light poles.", "The spiral wire will also stop the pole from twisting too much in high winds.", "A crane transfers the long and hefty mold over to the next station and lowers it onto several stands.", "A hopper now swings into action, guided by workers.", "It's a traveling concrete dispenser.", "As it moves on a track, it funnels specially mixed concrete into the mold.", "The concrete has been made to order, with the customer specifying its color, strength, and other qualities.", "The concrete also has a low moisture content.", "This makes it the consistency of clay and therefore formable.", "As the concrete is dispensed, workers pack it around the light pole's steel skeleton.", "Using trowels, they scoop up overflow and smooth the surface of the wet concrete.", "One worker then cleans up the outer flanges and applies a nonstick substance.", "A crane moves the top half of the mold into position and lowers it onto the concrete-filled bottom part.", "The team bolts the two parts of the mold tightly together using pneumatic impact tools.", "They now pull the steel strands to their final tension, stretching them so tightly that they compress the concrete once it hardens.", "Concrete is much stronger when it's being compressed.", "The mold is now ready for the spinning machine.", "It's essentially a series of railway wheels.", "A crane lowers the mold's running rings into the grooves of the wheels, and then they crank up the speed.", "The wheels turn at 500 rpms, and the centrifugal force causes the concrete to migrate to the wall of the mold.", "The result is a hollow pole with dense, concrete walls.", "Transferred to a kiln, the concrete steam-cures in the mold for about five hours.", "The concrete light poles are ready for the big reveal.", "They open the mold and roll them out.", "At this point, the two poles are still attached.", "They examine them for flaws, and then they'll separate them.", "All they need now is some buffing up.", "Here, they polish a different octagonal pole to expose the pigments in the concrete.", "The different colored aggregates in this particular cement mix give the pole a mottled marble look.", "An i.d. tag has also been molded into the cement with the manufacturing date and the pole's height and mass.", "They test just how far they can take it to confirm the pole meets industry standards.", "They spray a special acrylic finish onto some poles.", "Graffiti can be easily scrubbed off of it.", "Even though it only takes about 5 1/2 hours to manufacture a concrete light pole, it should shine for many years." ]

{ "things": [ "Canvas Wall Tents", "Peace Pipes", "Shredded Wheat Cereal", "Cannons" ] }

[ "A wall tent is shaped like a cabin.", "It's tall enough and wide enough to stand up in and walk around.", "This type of tent is typically used as a base camp on overnight hunting trips.", "Unlike a smaller camping tent, you usually need to transport a wall tent by vehicle or by horseback.", "These premium wall tents are made of sturdy canvas.", "They have a zip-up screen over the doorway and windows to keep out insects.", "They also have a vent hole in the roof to accommodate a stove.", "They can be made with lightweight canvas for hunters who go out in the woods on horseback.", "Depending on the number of tent orders to be filled, the factory's expert fabric cutter layers up to 10 sheets of canvas on the cutting table.", "Following a pattern, he draws guidelines...", "Then aligns them one at a time on the track along which the cutting knife rides.", "He does the smaller cuts with scissors.", "Once he's cut all the canvas pieces for one tent, he hands them off to a sewer.", "She overlaps adjoining pieces by less than an inch and, using a double-needled sewing machine, binds them with two parallel lines of stitching.", "This produces a durable, weather-resistant seam.", "Next, the stove ventilation system-- she sews what they call the stovepipe shield to the roof, then cuts away the canvas underneath.", "The shield is a fiberglass fabric rectangle with a silicone ring in the center, through which you insert the stove's exhaust pipe.", "After neatly finishing the edges...", "She attaches a canvas flap that zippers shut to close off the stovepipe shield and rolls up and ties to open it.", "She also sews a canvas weather flap that closes over the tent's front door-- extra protection in bad weather.", "She sews a row of d-rings to the edge of one flap...", "Then hooks to the corresponding door flap.", "They're both made of stainless steel, which never rusts, even with repeated exposure to moisture.", "These sturdy hooks and rings keep the flap securely closed in windy weather.", "The cutter, meanwhile, traces templates on heavy-duty fiberglass screen, then cuts the screens for the tent's triangular rear window and rectangular side window.", "The sewer stitches webbing to the window's perimeter.", "Webbing is a cotton seal which keeps out rain, snow, and wind.", "Meanwhile, a different sewer stitches the zipper to the door screen.", "She also sews 3-inch-wide seatbelt material inside the roof hem.", "Workers then apply pairs of grommets roughly a yard apart along this reinforced perimeter.", "Once you've pitched the tent, you secure it by looping ropes through these grommets and tying them to stakes in the ground.", "The tent floor is made of vinyl.", "Workers join the floor pieces using a radio-frequency welder.", "It emits radio waves that melt the material, fusing the overlapping edges into a seam.", "They construct the tent's internal frame out of heavy-duty galvanized steel tubing, then connect the pieces with stainless-steel couplers secured with eyebolts.", "As a quality-control check, they assemble the tent before shipping it out.", "After laying out the couplers, they insert the frame pieces to form the roof, fit the tent fabric over the roof framework, and insert the legs to prop up the structure.", "Then they pull down the walls, the same way you pull a shirt over a hanger.", "After tying back the flaps, they lay down the floor, which simply snaps into place.", "If you're two people, the entire setup takes about 10 minutes.", "Then it's just a matter of installing the wood- or coal-burning stove, cooking up a hearty meal, and getting a good night's sleep.", "Long-stemmed with an elaborately carved stone bowl, this is a native north-american pipe.", "Historically, it was reserved for special occasions such as the signing of peace treaties.", "That's why european settlers called it the peace pipe.", "Legend has it that the mystical buffalo calf woman gave native people the first sacred pipe.", "It is believed to have spiritual powers.", "The wisps of smoke from the stone bowl are seen as prayers rising to the creator.", "The pipemaker starts with wood like ash or sumac.", "These species are soft at the core, so they can be easily hollowed out with the red-hot tip of a thick coat hanger.", "He plunges the smoking hot wire into the soft core of the wood, and it quickly burns through it, creating a passageway through which tobacco smoke can be drawn.", "Now, with a planer, he shaves off the tree bark and shapes the outside of the wood to create a smooth, slim stem.", "He carves angled swirls into the wood with a rasp, a long tool studded with numerous sharp teeth.", "He whittles one end of the stem to transform it into a fitting for attaching the pipe bowl.", "He now confirms the diameter is right by inserting the fitting into a template.", "Next, sanding between the swirls smoothes away gouges left by the rasp.", "He files a notch into the stem just below the swirls.", "Then it's over to the beadwork artist.", "She wraps fringed leather around the notch and places a brightly colored accent piece on top.", "She strings glass beads around the leather-wrapped notch, working with a pattern and color scheme in mind.", "Centuries ago, natives obtained beads through trade with european settlers and threaded them onto pieces of animal sinew.", "Their needle was a thin piece of bone.", "The colors of the beads can really make a statement.", "A string of red might signify vibrancy and a long life, while a mix of colors could represent a spiritual burst of energy.", "The pipe stem is now complete and ready for the stone bowl.", "For that, they mine red clay rock called pipestone.", "Natives have used it for sacred pipes for centuries.", "Pipestone is soft, and this means it's easy to carve.", "It's also smooth and takes a high polish.", "He splashes water onto a chunk to make any flaws more apparent as he evaluates it for carving.", "His selection made, he now begins to trace, following a basic template of a pipe bowl.", "He saws through the stone along the penciled lines using a hacksaw.", "The rock is fairly easy to cut.", "It's essentially compressed clay.", "He rounds the angular edges using a rasp file.", "Now nicely contoured, the stone is really starting to look like a pipe bowl.", "With a series of finer tools, he flattens one end and then sculpts the shape of an eagle head onto it.", "He wields a rotary tool with a fine bit to carve eyes and feathers.", "Traditionally, natives use sharp flint or bone to engrave details.", "Power tools get the job done faster.", "He now drills into the stone to hollow out the shank and the actual tobacco bowl.", "For early natives, this job was very laborious.", "They gouged out the stone with an arrowhead attached to a stick.", "He rinses the eagle pipe bowl and then sands it while wet for a smoother finish than dry sanding.", "He aims a torch at it to heat the stone.", "Once hot, it readily absorbs beeswax as he rubs it into the pores.", "Beeswax gives the pipestone bowl a satin sheen.", "After a dip in cool water to solidify the wax, he scratches away some of it along the detail work, including the eyes and feathers.", "This adds definition and contrast, and after a bit of fine-tuning, the wooden pipe stem fits snuggly into the stone shank.", "He peers down the pipe to confirm that the stem is perfectly aligned with the bowl.", "The sacred pipe is now ready for any special occasion.", "They've used a combination of traditional techniques and modern power tools to produce this pipe, reconciling old and new in the quest for peace.", "Shredded wheat is a breakfast cereal made of 100% whole wheat, shredded into a straw-like consistency, cooked, and shape under to a rectangle.", "It was invented by an american entrepreneur in 1893 after he met a man who was eating boiled wheat with cream to alleviate digestive symptoms.", "They may look like tiny bales of hay, but they're actually a tasty and nutritious breakfast or snack.", "Shredded wheat was the first mass-produced, ready-to-eat cereal, invented at a time when people typically ate a cooked breakfast.", "It all begins with whole grain wheat.", "The raw kernels are hard as rock, so to soften them up, the factory cooks them simultaneously in water and with steam for about 30 minutes.", "As the wheat exits the cooker, its moisture content is about 50%.", "Excess water drains away through holes in the conveyer belt.", "The wheat then travels through a dryer.", "Inside, nozzles blast the soggy kernels with hot air.", "By the time the wheat exits about 10 minutes later, the cooked kernels are dried.", "They drop onto a conveyer belt which transports them to the operation that puts the shredded in shredded wheat.", "The wheat goes into several fill tubes.", "Each fill tube drops kernels in between two rollers that apply pressure, shredding the kernels into delicate strands.", "The strands drop onto the conveyer belt below, forming a fairly even layer.", "Each pair of shredding rollers deposits another layer of strands on top of the previous one, until there's a specific number of stacked layers.", "The company won't reveal how many, nor will it let any camera photograph the next machine-- a especially designed cutter that divides the sheet of layered wheat strands into rectangular biscuits.", "The sheet of shredded wheat biscuits now travels through a tunnel oven for approximately 10 minutes.", "The specifics of what goes on inside this oven are top secret.", "All the company will reveal is that there are two cycles, baking and toasting.", "As you can see in this before-and-after comparison, the bake cycle makes the biscuits crisp, and the toast cycle lightly browns them.", "The next machine compresses the sheets with a belt, which breaks apart the individual biscuits.", "Shredded wheat comes in two varieties-- plain and frosted.", "At this point, the plain ones would be ready to proceed to packaging.", "However, this batch is designated for frosting, so the conveyer moves them along to the coating station.", "To make the frosting, they blend and heat sugar, water, and other ingredients.", "Overhead nozzles spray it onto the passing biscuits.", "The frosting takes about a minute to dry and set.", "Here's what the shredded wheat biscuits look like before they're frosted and after.", "On the packaging line, an automated machine forms a bag out of a continuous sheet of plastic film, fills it with a weighed-out portion of shredded wheat, then seals the bag and cuts it free.", "The next station inserts the bag into a cardboard cereal box, printing the \"best before\" date on the top flap.", "The box not only shows consumers a photo of the contents, it also lists the cereal's nutritional benefits-- that it's high in fiber, low in fat and sodium, and contains zero cholesterol and trans fat.", "Cannons are back on the battlefield, as history buffs re-enact scenes from the american civil war.", "The fighting isn't real, but these replica cannons aren't fake.", "They can do everything the originals could do.", "The attention to detail adds authenticity to re-enactments.", "On the front lines of any civil war re-enactment, you'll find the big guns, the cannons, built to various scales with all the original details, these replicas have real firepower.", "For safety reasons, they don't load actual cannonballs into the muzzles, just black powder.", "It's traditionally been used to propel cannonballs, but on its own, it still makes firing a cannon a real blast.", "Production starts with wooden molding boxes that have a cannon shape inside.", "There's a top half and a bottom one.", "Together, they're known as the pattern.", "They'll fill each box with lake sand that's been laced with bonding chemicals.", "The sand is soft and warm at this point.", "They pack it down and level it off.", "As the sand cools, the bonding agents cause the sand to solidify.", "This sand mold will be used for casting the actual cannon.", "While they complete the other half, they brush an alcohol-based wash into all the crevices of the sand mold.", "But they don't just leave it to dry.", "Instead, they ignite it.", "The fire burns off the alcohol, leaving a protective skin on the mold, one that will prevent seepage of the casting material into the sand.", "A worker then applies glue to the border of the cannon mold.", "The other half of the mold has by now taken shape, and they apply the same alcohol-based treatment to it.", "Using a crane, the team carefully aligns the two sand molds.", "The glue cures, and the mold is ready to receive the casting material-- iron.", "They pour flaming, molten iron into a large ladle.", "Then, suited up for protection, they transfer the fiery liquid to the sand mold and pour it inside.", "The iron cools in the mold for about six hours.", "The flames die down, and the liquid metal solidifies.", "Then it's into the shot-blast chamber, so named because there's steel shot inside.", "Once the door is closed, the tiny pellets bombard the sand mold and break it up.", "A vacuum sucks the sand and steel shot out of the chamber, leaving the solid cast iron cannon.", "A worker slices off unwanted gating, which was formed as the iron flowed into the mold.", "One section served as a reservoir to compensate for shrinkage as the iron solidified.", "He removes that, too.", "He then grinds the casting seam until smooth.", "At the finishing factory, a lubricating mix of water and oil flows from a drill bit as it bores into the center of the solid cannon casting.", "The operator switches bits twice for a gradual widening of the cavity, taking it to precise dimensions.", "Here's a look down the cannon's newly bored muzzle.", "With the nose of the muzzle now protected by plastic, he pours an epoxy adhesive into the barrel.", "He then inserts a steel liner.", "The liner is a modification to the original design-- a modern safeguard that will enable the cannon to better withstand the pressure of ignition.", "The cannon turns on a lathe, and this action drives the steel liner completely down the barrel.", "It also spreads the epoxy evenly for a good seal.", "A carbide bit moves down the spinning cannon, to taper the exterior.", "He grinds the area between the trunnions, which are cylindrical protrusions used for mounting the cannon to the carriage.", "He stamps the maker's mark into the metal and then sprays solvent-based primer onto the entire cannon...", "Followed by three coats of flat, black paint.", "From start to finish, it's taken about eight days to produce this full-scale replica of a revolutionary war cannon.", "It's now ready for a little historical re-enacting.", "It's sure to be a hit with the troops." ]

{ "things": [ "Laminated Wood Beams", "Sport Utility Vehicles", "Veggie Burgers", "Wood Boring Augers" ] }

[ "In architectural design, exposed wood beams use the structural components of a building in an aesthetic way.", "These beams are often made of glued laminated timbers.", "They're constructed by gluing together several layers of lumber and forming them into a particular shape such as a curved arch.", "These beams look as though they're a solid piece of wood.", "However, they're actually laminated wood-- several boards of lumber glued together to form one piece.", "The boards aren't layered haphazardly.", "Rather, the top-grade wood goes on the top and bottom, where the beam must be the most resistant, and lower-grade wood in the middle.", "The boards are far shorter than the finished beam, therefore the first step is to extend each layer to the required length by connecting several boards end to end.", "To do this, a conveyor system transports 10 boards at a time to a mill.", "Saw blades trim the edges to make them perfectly square, then revolving knives cut finger joints on both ends.", "When it comes time to connect the boards horizontally, the finger joints of one board will fit neatly into those of the next.", "The comb-like shape of the finger joints creates a far greater service area to glue compared to leaving the edges flat.", "More glue makes for a stronger bond between boards.", "The glue is high-strength and waterproof.", "It goes on brown but dries translucent.", "Workers line up the glued boards in a machine called a crowder.", "The machine's pressure rollers slide one board into the other, interlocking the finger joints.", "Then two plates clamp down on each joint, rendering the adjoining boards flush should one be sitting slightly higher than the next.", "About 15 seconds of heat cures the glue.", "The connection is barely visible because the glue dries translucent.", "Now that each layer is the required length, it's time to adhere them vertically to make the beam.", "First, a glue applicator coats one side.", "Then workers turn the layers on their sides and stack them in a steel frame called a jig.", "Once they've stacked the required number of layers for the beam, they activate high-strength steel pressure vices.", "These apply high pressure for six to eight hours until the glue between the layers has cured.", "To make an arched beam, it's the same process, but they stack then clamp the layers in a curved jig.", "Once the glue cures, this laminated wood beam is stronger than solid wood.", "However, there are still several more steps to go.", "A two-sided planer simultaneously finalizes the dimensions, evens out the ends, and removes excess glue that oozed out under pressure.", "Next, a computer-guided, multi-tool machine cuts, drills, and notches the beam according to the customer's technical drawing specifications.", "Then each beam gets a tag indicating the order number and part number.", "In the final finishing department, workers sand away any visual defects and smooth the surface in preparation for staining.", "Finishers apply one coat of wood stain with a roller, then work it by hand to ensure uniform absorption throughout.", "Once the beam is shipped to the construction site, the customer might apply a flameproof coating, which would significantly slow down the rate at which the beam would burn in the event of a fire.", "The customer may also stain it a deeper shade to match existing woodwork.", "The four-wheel drive utility vehicle was originally designed for war.", "It was world war ii, and the american-made military jeep quickly earned its stripes, plowing through mud and muck on the road to victory.", "Today's s.u.v.s are modern versions and proof that the concept has transitioned nicely into civilian life.", "When the road ahead is rough or disappears entirely, a four-wheel drive utility vehicle keeps on going.", "Production of this custom s.u.v. begins with a mandrel bent frame made of thick steel rails.", "A worker welds brackets to it for attaching parts-- this one for its shock absorber's nitrogen tank.", "He attaches a link for the sway bar and suspension arms.", "He then welds super-thick braces for shocks to the front of the chassis.", "He measures the space between them to confirm that there's adequate clearance and then fits heavy-duty calipers over the brake rotors installed at the front.", "The front brakes are a six-piston system for extra stopping power.", "He now fits the coil-wrapped shock absorbers to the front axle and bolts them to the braces we saw welded to the chassis earlier.", "This is a preliminary installation.", "The parts will all be tightened more precisely later.", "It's time to give this custom s.u.v. some supersized wheels.", "He positions the rims on threaded bolts protruding from the axles and then secures the installation with lug nuts.", "The tires are eight-ply with deep tread for off-road traction.", "This s.u.v. chassis is ready for power.", "The team wheels the chassis under the eight-cylinder drivetrain and carefully lowers it into position.", "This powerful engine will generate a lot of heat, so it needs a large capacity radiator to keep cool and prevent damage to the engine.", "Once the steel chassis has been coated with a protective finish and the fuel system has been installed, production shifts to the next stage-- piecing together the s.u.v. body.", "This pre-assembly will ensure all the aluminum parts fit together flawlessly.", "After this, the s.u.v. will be completely taken apart for painting and then put back together again.", "He hinges the doors to the body with thick steel pins that hold up to wear and make the assembly easy.", "He attaches each window frame to the lower door panel and checks the fit.", "Any gaps could allow the wind to whistle into the vehicle.", "He confirms the parts align and that the door latch works.", "He bolts the steel roll bars to the s.u.v. body.", "Once he's satisfied that the framework meets all the specifications, he'll take it apart.", "The paint is a powder-coat finish.", "It's ionically charged, so it gravitates to the negatively charged parts as it's sprayed.", "Once baked in an oven, the coating forms a skin that's tougher than conventional paint.", "They also coat the underside of the lower parts with a heat-cured finish to reduce wear and to muffle vibration.", "They now piece together the lower body of the s.u.v. and assemble the dashboard and the instrument panel to the front.", "They bolt the seats to the floor, and once other parts have been welded to it, they lower the assembly onto the chassis.", "The chassis has, by now, been completely wired.", "The parts mate perfectly.", "It takes about 250 person hours to build one of these custom s.u.v.s.", "We've shown just the highlights.", "When it's complete, they test everything from the sensor-activated step to the windshield wipers.", "Once they confirm that all systems are operational, this s.u.v. is ready to hit the back roads.", "High off the ground with four-wheel drive, it's equipped for whatever lies ahead, and there's sure to be a few bumps along the way.", "Craving a burger but yearning for a change?", "The veggie burger is a lower-fat alternative to the beefy favorite.", "Just hold the fries.", "Developed in the early 1980s in london, england, the veggie burger has gone from fringe food to the mainstream all in short order.", "Just add a bit of oil to the grill, and this meatless patty sizzles with burger appeal.", "Chock full of grains, nuts, and veggies, it somehow looks kind of beefy, but it tastes distinctly different from an actual meat patty.", "This particular burger is a non-soy version, but there are many kinds of veggie burgers available today, and an increasing number of people go meat-free or reduce the amount of meat they eat.", "They start with finely-minced frozen veggies.", "This recipe calls for carrots, celery, onions, and mushrooms.", "And that's safflower oil in the dish on the lower left.", "The safflower oil simmers on the bottom of this steam-heated mixer as they gradually add the ingredients.", "Blades stir the mix as it sautés.", "As the vegetables cook, their natural sugars are released.", "This causes the veggies to caramelize.", "The flavors deepen and become more complex.", "This technique is called mirepoix.", "It's a french culinary term for a sautéed mix of aromatic vegetables.", "The mirepoix is very substantial to add both texture and flavor to this veggie-burger recipe.", "They add the final ingredient, the mushrooms.", "And after more mixing and cooking, this veggie-burger mirepoix is complete.", "They transfer the mirepoix to a big mixing tub called the gondola.", "And now they add the dry ingredients.", "They include walnuts, cooked bulgur, oats, potato flakes, and pure gluten flour.", "The worker adds pails full of each of these ingredients to the mirepoix.", "Then, using a shovel, he folds all the dry ingredients into the mix.", "Moistened by the cooked vegetables, the gluten flour becomes sticky.", "This causes the ingredients to cling loosely together, taking on a consistency similar to that of cookie dough.", "He now loads the sticky mix into a hopper that leads to an automatic patty-making machine.", "It's a mold with a plunger-like mechanism that presses and shapes the mixture into perfect patties.", "A constant spray of water keeps things from becoming too sticky, allowing the patties to be cleanly ejected from the molds.", "Then it's a short conveyor trip to the next station, where workers retrieve the veggie patties and arrange them on baking trays.", "In the process, they inspect the patties and confirm that they've been perfectly formed.", "They roll stack trays of burgers into a preheated convection oven.", "When the oven door closes, the burger-ladened trays rotate inside so they cook evenly.", "After baking, they quickly freeze the veggie burgers to lock in nutrients and preserve freshness.", "Workers then load the frozen veggie burgers onto a conveyor as they head up into the packaging line.", "These burgers can't spend too much time outside the freezer, or they'll start to thaw.", "A hot iron seals the cellophane wrap around groups of four burgers and separates them into packets.", "Down the line, suctioning devices open cardboard boxes and transfer them to a conveyor.", "The boxes are now positioned to receive the burger packets.", "As they move forward, workers just slide them inside.", "The boxes of veggie burgers then head into a narrow lane to close the pre-glued flaps.", "This entire packaging operation takes less than a minute.", "In just one hour, this factory can wrap and package more than 9,000 veggie burgers.", "At the end of the day, that's a lot of meatless burgers, but it should be enough to feed a growing trend of vegetarianism.", "Used for centuries to drill holes for pegs and bolts, augurs have played a bit role in history and were critical to the construction of everything from tall ships to manor homes.", "Traditionally rotated by hand, today's power drills give the augur bit a more modern twist.", "Attached to a power drill, an augur bit can chew through wood in seconds to produce perfect screw holes.", "It spits out shavings through the corkscrew-shaped pathway, preventing it from clogging the freshly-drilled holes.", "Operated manually or by drill bit, the augur bit is an efficient gizmo responsible for a lot of projects coming together.", "An augur bit starts as a solid steel rod.", "They heat it to a blistering 1,600 degrees fahrenheit.", "When the rod is white-hot, it's supple enough to be shaped.", "He moves one end of the hot steel rod under a long, pulsating hammer.", "The anvils below allow the energy of the hammer to be transferred to the rod and flatten it.", "He angles the flattened end sideways to shape the edges.", "He then tweaks the profile a bit more by moving the rod from anvil to anvil.", "The anvils are set at various heights for impacts of different force.", "When he's done, the once circular steel rod looks like a long putty knife, but this is just temporary.", "Next, it's back into that super-hot furnace to reheat the forged end to a malleable state once again.", "He clamps the white-hot rod in a machine that twists the flattened end to a specific configuration.", "In this hot and supple state, the steel is as easy to twist as a piece of stiff ribbon.", "As the steel cools, it becomes more rigid, so it's back into the furnace to make it pliable once again.", "He then places it between the jaws of a toothed vice.", "He closes the jaws repeatedly as he pulls the augur along.", "This crimps the augur's spirals to a precise configuration.", "Each spiral ends up exactly the same.", "It's a critical step.", "Without it, the augur wouldn't operate smoothly and could even get stuck as it drills through wood.", "Now he slams a drop hammer onto the tip of the augur repeatedly, forcing it into a dye.", "As the hot steel fills the dye cavity, it takes its shape, giving it the rudimentary profile of the drilling head.", "It's now tapered like a cone, but there's a lot of surplus material surrounding it.", "This surplus steel is a bit of spillover.", "He trims off that hardened spillover with a clip press, and this further defines the drilling head.", "He presses the augur tip against a ridged grinding wheel to carve a screw thread into it.", "The screw thread will give the augur bit extra bite as it drills through wood.", "The focus now turns to the other end of the augur, the shank.", "As it spins in a lathe, cutting tools slim the shank and shorten it to precise specifications.", "Now they toughen up the steel by first heating it and then dipping it in cool oil.", "The shock caused by the abrupt temperature change makes the steel harder.", "Then the augur spins between two wheels.", "One wheel rolls it.", "The other grinds the outer diameter of the twist to specification.", "A worker grinds the valleys in the augur twist by hand in order to reach every spot.", "This smoothes the surface so wood shavings will flow upward as the augur bores deep into the wood.", "He changes the belt to a finer abrasive and preps it with a small stone.", "He spins the belt and polishes the augur until it shines.", "And the result is a glossy sheen.", "It looks good and will further smooth the way for the extraction of wood shavings through the twists.", "Now with a different and much smaller grinder, he carves wings and sharp edges below the augur's cutting head.", "From a simple steel cylinder to a useful wood-drilling bit, this has truly been a story with many twists and turns.", "And with the work of the factory now done, these augurs are ready for any job.", "They come in a range of diameters and lengths for tasks of any size.", "With so many options, all those projects should come together bit by bit." ]

{ "things": [ "Ambulances", "Dining Room Tables", "Diatonic Accordians", "Acrylic Awards" ] }

[ "Today on \"how it's made\"...", "Ambulances...", "Dining room tables...", "Diatonic accordions...", "And acrylic awards.", "Historians believe the notion of ambulance service grew out of the 11th-century crusades, when the knights of st.", "John transported wounded soldiers to treatment tents.", "Today's ambulance technicians and paramedics carry on that tradition in state-of-the-art ambulances equipped to provide lifesaving care en route to a hospital.", "There are three types of vehicles commonly transformed into ambulances-- minivans, trucks with a closed driver's cab, and trucks with an opening between the driver's cab and the back storage area, like this model.", "The most important structural addition is a stabilization bar to diminish rocking when the vehicle is racing at high speed.", "Otherwise, it's mostly a question of retrofitting a regular vehicle to give it the features an ambulance needs.", "Workers begin by cutting a hole in the roof.", "This allows them to install a raised, aerodynamic roof.", "The angle of the new roof lessens air resistance, enabling the ambulance to run more efficiently with more control.", "Inside, meanwhile, they install fiberglass insulation panels with a fireproof metal surface.", "This insulation keeps the medical area warm in the winter and cool in the summer.", "Workers affix the raised roof with adhesive caulking.", "The roof has integrated lights.", "Protruding lights would ruin the streamline.", "Workers measure carefully to ensure they center the roof perfectly.", "Now they spray glue on the back of sheet vinyl.", "This highly durable antibacterial flooring goes on top of a plywood subfloor they've installed on top of the truck's aluminum floor.", "Now for the electrical system.", "They start by replacing the truck's original grill with an ambulance grill that incorporates lights, a siren, and loudspeakers.", "The truck comes equipped from the automotive plant with certain options designed for conversion to an ambulance.", "For instance, instead of two regular batteries, the truck takes four batteries-- two to power the truck accessories, the other two to power the equipment in the back.", "Now they assemble the front console-- an array of buttons and switches that control all the nonmedical equipment, such as the emergency lights, the siren, and the headlights.", "There's also a battery-life indicator and other system gauges.", "Once assembled, the console goes into the dash, and workers test everything out.", "The heating and air-conditioning systems in the original truck aren't strong enough, so the ambulance factory adds an extra system of each to work in tandem with the existing systems.", "The frame of the medical cabinet is made of aluminum-- a metal that's lightweight and, therefore, won't weigh down the vehicle.", "The cabinet shelving is made of either plastic or fiberglass.", "It's molded to the contour of the vehicle, maximizing storage space.", "After installing the suction and oxygen systems, electricians run the wires for the cabinet lighting.", "Once the main electrical panel is in place, they can mount the cabinet and hook up the oxygen equipment, the suction machine, and the lighting.", "A divider between the cab and the back gives the patient privacy.", "Vinyl-covered foam padding on the ceiling protects ambulance workers' heads when the vehicle jerks.", "This ambulance model has rotating lights.", "The red cover, called the lens, is made of virtually unbreakable plastic so that it doesn't crack from the air pressure when the ambulance is speeding.", "The medical area has a swivel chair positioned where the patient's head will be.", "Within reach of the chair is the suction machine.", "The factory thoroughly tests it, along with all other medical equipment.", "A safety net by the three-seater squad bench protects the crew should the ambulance come to a sudden stop.", "This mechanism holds the stretcher in place while the ambulance is moving.", "The stretcher simply locks in, keeping the patient safely immobile until the ambulance reaches the hospital.", "There was a time when the dining room was for formal dining only, and the style of dining-room furniture reflected that.", "Not anymore.", "Today's dining-room sets come in both elegant and casual styles, and there's something to suit every decor, from contemporary to country, from traditional to ultramodern.", "This factory makes casual dining-room furniture.", "It uses only durable hardwoods, such as birch and beech.", "It buys the parts premade from a supplier.", "The workers here assemble the pieces and finish the furniture to the customers' specifications.", "We're going to see how they make tables.", "The parts arrive already sanded, but they still go through a machine that gives them an additional fine sanding.", "This prepares the wood for staining.", "Workers sand the solid-wood parts for the apron by hand.", "The apron will go just under the tabletop.", "Workers closely inspect all the components under fluorescent light.", "They look for any flaws in the wood that they might have missed during sanding.", "It's critical that every imperfection be sanded down.", "Otherwise, it will show up as a glaring defect once they stain the wood.", "After all the parts pass inspection, assembly can begin.", "First, they remove the tabletop's extension piece, called the leaf.", "They make sure the two main sections fit together perfectly.", "Then, using a template to ensure the exact positioning, they screw on the runners-- the sliding mechanism for extending the table.", "Then they mount support pieces called stretchers.", "After marking the position of the apron, workers screw in steel braces to level and align the three sections of the table.", "This table will have a pedestal base rather than four legs.", "After installing a part called the assembly plate, they lay down a series of metal templates.", "These ensure that they mount the apron precisely.", "Now that they've finished assembling the tabletop, they check its stability and test the mechanics.", "If everything is up to par, the tabletop moves on to the finishing department.", "The factory buys wood stain from a supplier.", "To ensure that the colors are consistent from table to table, the factory tests the stain before using it, comparing it to a color sample.", "The staining operation takes place in the part of the factory known as the paint kitchen.", "Each tank has a mixer inside to keep the stain well-blended so that the pigments don't settle to the bottom of the tank.", "This ensures the color will be consistent.", "There is a separate spray gun for each stain color.", "After spraying the stain onto the tabletop, a team of workers quickly wipes off the excess.", "They have just 30 to 90 seconds.", "Otherwise, the shade will be off.", "Another inspection under fluorescent light.", "Any flaw in the wood they missed before would definitely show up now, thanks to the stain.", "Every imperfection will be sanded down.", "Now they spray the table with sealant.", "This protects against variations in humidity, which would make the wood expand and contract and eventually split.", "Then they sand the sealant to prepare for a coat of clear lacquer.", "The lacquer plays two roles-- one functional, protecting the wood from scratches, one decorative, giving it a mild sheen.", "To cure the lacquer, all the table components go into an oven at 300 degrees fahrenheit.", "This also strengthens the finish.", "This factory specializes in personalization.", "You can choose your stain color or two colors for a two-tone effect.", "You can also select the shape of your tabletop, the type of edge and apron, and, of course, the style of table legs.", "A diatonic accordion is much smaller than a piano accordion and is structurally different.", "It has 10 buttons, each of which produces two notes-- one when you push the bellows in, the other when you pull the bellows out.", "The diatonic accordion, also called a squeeze-box, is a staple of cajun music.", "the accordion maker crafts the right-hand keyboard from maple-- a hardwood.", "He saws 10 slots, then drills 10 holes.", "The keyboard has no keys, actually.", "It has 10 buttons.", "They produce the treble notes.", "Now he turns the keyboard over and hollows out the wood with a router.", "This creates space for components to move.", "Each slot in the keyboard will house a rocker-- a piece that links each button to its corresponding air valve.", "Now he builds the wind-chest-- the box that houses the steel reeds that produce the accordion's sound.", "Moving the bellows in and out forces air through holes in the wind-chest.", "The buttons you push determine which reeds get this air, producing notes.", "The longer and thicker the reed, the slower it vibrates, and the lower the pitch of the note.", "The shorter and thinner the reed, the faster the vibration, and the higher the note.", "There are eight reeds per button.", "Pushing the bellows in activates four.", "Pulling the bellows out, the other four.", "Using a hot iron, the accordion maker seals the reed frames with beeswax.", "This prevents air from escaping.", "Now back to the keyboard.", "The accordion maker installs 10 valves made of maple wood.", "Each one has a plastic rocker on the end.", "A spring ensures the rocker has just the right tension to open and close the valve properly when the musician presses the button.", "After staining and varnishing the wood, he glues a button into each hole onto the rocker inside.", "Pressing a button triggers the rocker underneath to lift the valve and uncover the air hole, letting air hit the designated reeds.", "The accordion maker now screws the fully assembled keyboard to the wind-chest.", "Now he constructs the left-hand keyboard.", "He sets the reeds into the left wind-chest, using a hot iron and beeswax, just like before.", "The valves in this keyboard are made of pine, a more flexible wood, making them easier to install in this enclosed space.", "On the outside, a decorative wood inlay-- a strip of ebony and some rosewood detailing.", "The left-hand keyboard has two buttons corresponding to three reeds each.", "It produces two bass notes and two chords.", "After staining and varnishing the keyboard, he hooks a spring between each valve and the button that operates it.", "He adjusts the spring tension and checks the air seal.", "Then he stamps the company name inside.", "Now he screws the finished keyboard to the finished wind-chest.", "Meanwhile, another worker prepares the bellows, which force air through the reeds.", "The factory buys pre-folded cardboard, then cuts and assembles it.", "These diamond-shaped pieces of leather seal the openings, preventing air from escaping.", "Now she glues fabric strips inside the folds of the cardboard.", "This is purely for decoration.", "These stainless-steel covers reinforce the cardboard corners so that they won't perforate from repeated movement.", "Now she glues fabric strips onto the edges of the folds.", "This both decorates and strengthens the cardboard.", "Now for the final assembly.", "The accordion maker nails the bellows to the left-hand keyboard.", "Why nails rather than screws?", "Tradition.", "The left-hand keyboard has a hand strap.", "The right-hand keyboard, a thumb strap.", "After nailing the right-hand keyboard to the rest, this $2,500 diatonic accordion is ready for a musical test-drive.", "there was a time when you'd be presented with a gold watch in recognition of years of loyal service to your employer.", "Today, you're more likely to get a personalized memento cast in acrylic.", "Companies and organizations often choose to hand out custom-made acrylic awards to recognize milestones or special achievements.", "These aren't your run-of-the-mill plaques and trophies, but more like artistic sculptures.", "They're custom-designed and cast in high-grade acrylic.", "In the casting department, workers make acrylic by mixing monomer, a clear, liquid chemical, with polymer, a resin powder.", "Once cured, this thick, white mixture will be crystal clear.", "To make colored acrylic, they add colorants.", "By creatively combining shades, they can even produce special effects, such as a marble or granite look.", "To cast simple shapes with straight lines, they use disposable molds made of thick cardboard.", "This design calls for a blue base, so they pour blue acrylic to the first fill line.", "In two to three hours, the acrylic hardens to a gelatin-like state.", "That's solid enough to bear the weight of the next layer-- a clear one, which they pour to the next fill line.", "Now another two- or three-hour wait until the acrylic can support a decorative object-- in this case, a globe.", "Once they ensure it's properly centered, they pour acrylic to the next fill line and wait two to three hours again.", "Now they apply the client's name and logo printed on acetate and pour the final layer.", "Once that hardens, it's off to the curing department.", "There, workers load the pieces into a pressurized oven called an autoclave.", "It works somewhat like a pressure cooker, forcing out the trapped air bubbles and curing the acrylic until it's rock-hard and transparent.", "This takes 12 to 15 hours.", "Curved designs are cast and cured in reusable metal molds like this.", "The factory always casts a piece slightly larger than its final dimensions to allow for shrinkage during the curing process and some loss through sanding.", "Workers sand each piece three times with progressively finer sandpaper to perfect the shape.", "Then to remove the marks that sanding leaves behind, they buff the piece on a cloth-covered wheel.", "Then they polish the piece with an even softer wheel.", "This shines the acrylic to a high-gloss finish.", "When it's not viable to make a mold for a particular shape, they cast a starting shape, then machine it to the final shape.", "To make a sphere, for example, they first cast a cube.", "They transform the cube into a cylinder, then, working one side at a time, into a perfect sphere.", "The automated tooling equipment is all computer-guided for ultimate precision.", "Some designs call for additional artistic features.", "For example, the factory can print artwork on paper, acetate, or a metal plate, then embed it into the acrylic.", "Another option is to create an opaque image on the surface.", "As we see here, once they finish machining the sphere, they apply tape that's been laser-cut into the shape of a world map.", "They sandblast the exposed areas, transforming the sphere into a globe.", "They can also engrave the surface of a piece or, using a special laser beam, etch letters or a design right inside the acrylic.", "The creative possibilities are endless.", "The infinite combinations of shapes, colors, embedded objects, and artistic features make these acrylic awards highly customized and clearly unique." ]

{ "things": [ "Oil Lamps", "Chocolate Mints", "Underfloor Heating", "Pillows" ] }

[ "Before the invention of electricity, humans relied on fire for light.", "Candles dripped and could be messy.", "Oil lamps were a cleaner alternative.", "Initially, oil lamps were dishes of animal fat with floating wicks.", "But they evolved and became a source of both beauty and light.", "In the 18th century, a swiss chemist invented an oil lamp with a cylindrical wick and chimney.", "The updated design increased air flow to create a flame that was both smokeless and brighter.", "In colonial america, pewter versions became popular.", "And today, a fifth generation pewtersmith keeps this handcrafted tradition alive.", "He starts with the maker's mark and stamps it into the pewter base of the lamp's oil reservoir.", "He clamps another pewter disc in a lathe against an aluminum template for the reservoir body.", "As the disc spins, he shapes it to the template with a tool called a spinner's finger.", "This takes skill.", "If he works too fast or applies too much pressure, the pewter will break.", "His first spin produces the basic shape.", "In the next spin, he trims the edges.", "He also rounds the lower half of the reservoir using the spinner's finger.", "He works freestyle to match the contours of the lower half to the upper half.", "He trims the bottom one more time.", "During the third spin, he fine-tunes the shape, and cuts a hole in the top.", "Then, he sizes the hole for the burner collar.", "This metal is transformed from a basic dome to a well-rounded lid.", "The oil lamp reservoir is now ready for the burner.", "He presses the collar into the hole.", "Then, he brushes a glycerin-based flux onto the collar in the neck of the lamp.", "The flux prevents oxidation and helps solder flow easily as he secures the burner collar to the neck.", "Next, he tack solders the base to the bottom of the oil lap reservoir.", "He applies more flux and solders the seam all the way around.", "The tin-bismuth solder melts at a slightly lower temperature than the pewter does.", "This is delicate work.", "If the torch gets too hot, he'll melt the entire piece.", "With the soldering complete, he trims the excess from the base of the lamp.", "He files the seam until it's smooth.", "Then he sands the rest of the oil lamp reservoir to a satin sheen.", "Another member of the team sands the base up to the maker's mark.", "Next, the pewtersmith rolls a beaded motif into the metal.", "It's a design option that makes the lamp look more elaborate.", "Or for a different look, he gently creates a hammered texture around the lamp.", "Using an engraving pen, the pewtersmith etches his signature onto the base of the lamp.", "With the burner and wick installed, the lamp is ready for packing.", "Plenty of tissue paper is needed to protect both the glass chimney and the nickel burner from damage.", "She includes operation and maintenance instructions.", "Unlike silver, pewter doesn't tarnish, but will develop a richer veneer over time.", "A few scratches or handling marks are normal, but they'll only add authenticity to this traditional light source.", "Like pewter oil lamps of another time, these replicas are a shining example of handcraftsmanship.", "Chocolates and mints are enjoyed by many people.", "Then, someone discovered putting the two together makes for a delicious experience.", "The cool zestiness of the mint offsets the rich creaminess of the chocolate.", "It is one of the sweetest matches in candy history.", "Chocolate or mint?", "With the chocolate mint, the decision is easy because the two flavors are wrapped into one.", "To make chocolate mints, they pump liquid sugar into a heated mixer, and add granular sugar.", "The mixer blends it into simmering syrup exiting through strainers.", "Then, it's moved into a vacuum-sealed cooker.", "It sucks out moisture and the syrup thickens to a jelly-like consistency.", "A worker transfers it to a second mixer and adds the mint flavoring.", "Thorough mixing thickens it and lightens the color substantially.", "He transfers the mint flavored candy to a work table.", "Powerful mechanical arms massage the slab to cool and harden the candy.", "Next, a hopper funnels the candy into pressurized rollers that squeeze it into a long sheet.", "The sheet rides an inclining conveyor.", "Once it reaches the top, an employee wraps the end around a long steel tube.", "The tube revolves and twists the mint candy around it.", "The long candy sheet takes the shape of the tube.", "They melt and mix chunks of pure chocolate with cocoa, powdered milk, and icing sugar.", "They add coconut oil and lecithin to bind the ingredients.", "Once mixed, the employee transfers it to a hopper next to the big mint candy tube.", "From here, the chocolate is injected into the hollow of the mint candy tube.", "The tube rolls off the forming cylinder and passes by rollers that squeeze the diameter down to a rope size.", "A compactor then mashes the candy rope to give the filling a honeycomb texture.", "Pullers now stretch a second slab of mint candy until it thickens and turns a lighter color.", "The worker cuts it into chunks that fit into the next rolling machine.", "It presses the candy into a sheet which then lands on top of the mint chocolate.", "The two layers now enter the next forming machine.", "This one wraps the outer layer around the chocolate infused one, creating a chocolate filled mint tube.", "Rollers reduce the diameter to half an inch in size.", "Next, the chocolate mint rope enters a die cutter.", "It shapes and cuts the rope into mints.", "The mints spill into a spreader which distributes them evenly across a perforated conveyor.", "Fans blow air through the holes in the conveyor to cool and solidify the candies.", "Once the candies have hardened, they head to the wrapping station.", "Here, they ride a rotating circular platform and fall into candy-size slots.", "Glossy metalized film wrap unwinds.", "Mechanical arms collect the chocolate mints as they fall out of the slots.", "They hold the candies for wrapping while devices twist the ends.", "It takes only a fraction of a second to wrap a candy.", "Then it's on to a weigh station.", "Scales release the individually wrapped chocolate mints in increments.", "They fall into bags ready for retail.", "Approximately 2,400 chocolate mints are made every minute at this factory.", "Two flavors in one candy-- they're quite a treat.", "Heating a room using a water circulation system under the floor is more efficient than using a radiator.", "Radiators can only be at one end of a room, while a circulation system distributes heat evenly throughout.", "Warm water pipes are installed under the floor beneath the plaster leveling layer in the grooves of a plastic guide mat laid on the subfloor.", "Each pipe begins and ends at a distribution manifold.", "The pipes connect to the manifold and each other with various types of brass fittings.", "This computer guided equipment makes the simpler straight ones.", "It first cuts a piece from a long brass bar, progressively shapes it, bores through it, and cuts threads on it.", "This machine makes the nuts that connect the fittings to the manifold.", "The machine cuts a piece from a six-sided brass bar and shapes it into a nut.", "Curved or t-shaped fittings require forging prior to machining.", "The factory cuts the bars into ingots.", "A conveyor then feeds the ingot into an oven.", "The high temperature softens the brass to a malleable state.", "After the ingots exit the oven, they are pressed into a mold by a 400-ton press.", "When the press releases, the forged fitting heads to a collection bin.", "Workers then place it on a die and trim off the excess brass with a punch press.", "The fitting now has its basic shape.", "The next step is to sandblast it.", "This cleans the surface in preparation for machining.", "A vibrating tray now feeds the sandblasted fittings to a robot.", "A camera records the orientation of each piece, guiding the robot to load it in the correct position.", "Guided by a computer, the transfer machine finalizes the shape of the fitting.", "This complex machining process, seen here in super slow motion, takes just a few seconds.", "The transfer machine also makes the manifold from a larger brass bar.", "This manifold has 10 connections.", "So if each room of the home is heated by one circuit, this manifold could control 10 rooms.", "The transfer machine can perform up to 20 different operations on a single fitting.", "The under floor heating pipes have five layers.", "To produce the innermost one, an extruder melts granules of polyethylene-- a strong non-porous type of plastic.", "It is pushed through a circular die, and then cooled rapidly to a solid state.", "Polyethylene pipe enters a second extruder that applies a layer of glue over the poly.", "The glue adheres the third layer-- aluminum.", "The pipe moves through a series of forming rollers which gradually wrap an aluminum strip around it.", "This aluminum layer makes the polyethylene pipe strong.", "Once the pipe is fully encased, a welding machine fuses the strip's overlapping edges.", "The pipe now receives another layer of glue.", "Then, the outer surface of polyethylene is applied.", "The factory makes pipes ranging from 1/2 an inch to 3 1/2 inches in diameter.", "A steel sleeve is pressed over the end, connecting the pipe to the fitting.", "To set up the heating system, the installers lay a plastic guide mat on the subfloor and snap the pipe into the mat's grooves.", "They lay plaster leveling tiles on top of the mat to level the surface then install the flooring.", "They connect one end of the pipe to an inlet manifold, and the other to an outlet manifold.", "The inlet sends warm water through the pipe.", "The outlet receives the returning cold water and sends it to the boiler to be reheated.", "You regulate water flow and temperature either manually or with a thermostat.", "Hard, soft, puffy or flat, the type of pillow you sleep on is a matter of personal preference.", "Your pillow can be stuffed with natural fillings like feathers and wool, or synthetic materials such as foam or polyester fiber.", "These pillows come in two styles-- garnet pillows filled with a roll of synthetic fiber, and blown pillows made of loose synthetic fibers.", "The fiber arrives at the factory in huge, densely packed bales weighing almost 600 pounds.", "This polyester fiber is made from polyethylene and other types of plastics.", "The fibers are all stuck together.", "They need to be pulled apart and smoothed out.", "This process is called \"opening the fibers\".", "The first machine-- the preopener-- combs the fibers with a large steel-spiked roller.", "This separates them considerably but not completely.", "The fibers exit the machine straighter and smoother.", "However, several are still crimped.", "The preopener's four outputs drop the fibers onto a conveyor belt which takes them to the next opening machine.", "Along the way, nozzles spray a special solution to reduce static electricity.", "To make garnet pillows, fans push the fibers to another opening machine called the garnet hopper.", "It feeds the fibers onto a spiked conveyor belt which combs them out further.", "This removes many of the remaining crimps.", "After the garnet hopper, the fibers look like the ones on the right-- fluffier, straighter, and smoother.", "The fibers now travel to the next machine.", "It has several metal rollers with sharp ridges that stretch the fiber straight, removing the remaining crimps.", "The fibers then enter another machine, passing over one of two rollers to form a flat, fluffy sheet called a \"web\".", "The two webs merge as they exit the machine, forming a thicker web.", "Then, the next machine laps the web back and forth over itself.", "The width of the lapping determines the width of the pillow.", "The machine cuts the continuous web into pieces and rolls each one into what is called a \"bat\".", "The length of the piece determines the characteristics of the pillow.", "The longer the rolled piece, the higher and firmer the pillow.", "An automated machine makes the cotton or cotton-blended pillowcases.", "Workers mount two identical rolls of fabric onto the machine's cradles and feed the ends through a series of tension rollers.", "The two sheets must be taut as they pass through the machine's different stations.", "First, blades trim the fabric to the correct pillow size-- standard, queen, or king.", "Then, a slitter runs across each sheet, cutting a series of rectangular pieces.", "The machine then stitches two rectangles together on three sides.", "Finally, the product information label is sewn on.", "The machine uses an extremely strong overlock stitch.", "The pillow filling is flattened before it enters the waiting case, which is already covered in retail packaging.", "Sewers close the open end of the pillow and trim off the excess fiber.", "Then the finished pillow is placed in a shipping box.", "For blown pillows, an operator holds the open end of the case over a nozzle.", "Then a machine blows in a pre-set quantity of loose fibers.", "He weighs the pillow then sends it to the sewing department to be stitched closed.", "A blown pillow conforms to your head when you lie down and rebounds when you get up.", "A garnet pillow has less rebound.", "Not sure what to choose?", "Sleep on it." ]

{ "things": [ "Electrical Panels", "Kites", "Eyeglass Frames", "Toothbrushes" ] }

[ "Today on \"how it's made,\" electrical panels...", "Kites...", "Eyeglass frames...", "And toothbrushes.", "The technical name for it is a residential load center, but people usually call it an electrical panel or circuit breaker box.", "This enclosed metal panel is usually built into an interior wall and contains the circuit breakers that distribute, protect, and control the home's lighting and power.", "This load center consists of up to 40 circuits.", "Each one has one or two breakers.", "Each breaker powers several outlets in the home.", "First, a powerful press pounds a sheet of steel into what's called a u-channel.", "At nearly 3 feet long, 18 inches wide, and 4 inches deep, it's part of what's called the tub-- the load center's main casing.", "A worker then attaches steel components made earlier called tub ends.", "A spot welding machine fuses them to close off both ends of the tub.", "Workers feed an aluminum strip that's 330 feet long and 6 inches wide into a stamping press.", "The press cuts the strip into 20-inch-long segments called bus bars.", "It bends each bus bar 10 times, creating two-inch segments called stabs.", "The breakers will later snap onto these stabs.", "Next, a worker inserts each bus bar into a plastic component called a base pan.", "The base pan insulates the bus bar.", "This prevents us from getting electrocuted.", "Another press then inserts a plastic rivet, securing the bus bar to the base pan.", "The worker installs two components, called neutral bars, in the base pan.", "The neutral bars conduct electricity between the circuit and the wall socket.", "Next comes the main breaker.", "Its maximum capacity is 200 amps.", "Amps are the units of measurement for electrical current.", "If demand exceeds maximum capacity, it'll trip, meaning it'll turn off all power in the home.", "She makes sure it's sufficiently tight so that vibrations caused by street traffic won't loosen it.", "She also encloses labels to mark the breaker's pathways and an envelope with installation screws.", "Next, the worker puts the base pan assembly into the tub and secures the neutral bar with a copper bonding strap to ground it and prevent electrocution.", "She adds another component-- one of two grounding bars.", "These ground each circuit.", "The breakers simply snap onto the stabs, making them easy to remove and replace if needed.", "Inside the breaker, several components interact to enable the flow of electricity.", "One is the load terminal-- the entry point for the live current.", "A circular machine, called robot \"a,\" assembles it and other breaker parts along its 16 workstations.", "Another breaker component is the bimetal assembly.", "It's an alloy of two metals and a magnet.", "It trips the breaker when there's an overload or a short circuit.", "Next, robot \"a\" welds a strip of silver, which is conductive, to what's called the contact arm.", "Robot \"a\" then positions the arm for welding with two-inch-long segments of braided copper wire-- copper because it's conductive as well as pliable.", "The robot fuses the copper wire to the contact arm in the bimetal assembly.", "The wire will flex with the arm to touch what's called the line terminal.", "This contact permits the electrical current to flow.", "Next, robot \"a\" deposits the welded parts into the breaker casings, called bases.", "This automated production line functions 24 hours a day, five days a week, and it produces a breaker every three seconds.", "Another machine, called robot \"b,\" stamps the number of amps on each breaker handle.", "Then it connects a spring to link the contact arm to another part, called the cradle.", "When there's an overload, the bimetal assembly causes the cradle to pivot and trip the breaker.", "Robot \"b\" deposits the spring and cradle into the base, then closes the base with a cover.", "This demonstration shows how moving the breaker handle triggers the mechanism that will enable the flow of electricity.", "If power demand exceeds the breaker's maximum capacity by 35%, the bimetal assembly trips the breaker and cuts the power.", "They cap off the load center with a metal cover called a trim.", "The warning label on it provides safety information and instructions.", "The load center is now ready for installation by a certified electrician.", "The earliest written record of a kite tells the story of a chinese general in 206 b.c. who flew a kite over a wicked emperor's palace.", "He marked the line to measure the distance, then reeled it in.", "His small army then dug a tunnel into the palace courtyard, launching a surprise attack that conquered the emperor.", "Today's two-line kite, as the name implies, has two lines to pilot it.", "It can fly nearly 130 feet high.", "This kite is made mainly of a lightweight nylon fabric that is waterproof and fade-resistant.", "It's less than a few hundredths of an inch thick, so it's reinforced with nylon mesh to reduce ripping.", "The kite's other components include nylon and elastic cords and straps; fittings made of leather, rubber, aluminum, and plastic; and carbon rods.", "The kite maker starts with a pattern made out of pressed wood.", "She marks out a piece of the fabric and, with a few bricks to hold the fabric in place, cuts diagonally.", "In sewing terms, that's called cutting on the bias.", "This will stretch the fabric and help it fly.", "Next, she cuts more pieces of fabric, this time in a different color.", "This kite has eight fabric parts that fit together like a puzzle to create an eight-foot wingspan.", "The kite's left and right sides are mirror images, so there are only four different shapes to cut.", "They range in length from 9 inches to 4 feet.", "From start to finish, it takes one worker about two hours to make this model, called the dragonfly.", "First, the kite maker sews the longest part, called the belly, to the other parts.", "She double stitches with heavy-duty nylon thread to help the kite withstand winds up to 23 miles per hour.", "She makes tiny incisions along the belly's curved edge so she can fold it and sew in what's called the tension line.", "Tension line is a type of nylon cord she'll sew into all the seams of the kite's lower sections.", "It'll give the kite some structure and help keep it rigid while airborne.", "The kite maker secures each line with a knot which can later be loosened or tightened to adjust the kite's overall tension.", "The kite maker uses straps made of very durable, yet flexible, plastic to line the middle and the edges of the wings.", "The straps strengthen the kite, enabling it to survive crashes into trees and rocks.", "After all, what goes up must come down.", "Next, the kite maker sews a piece of leather, called a fitting, onto the plastic strap.", "It's made of leather to protect the kite's structural joints, such as the nose of the kite.", "It gets a leather patch, as well.", "The kite maker uses a serrated saw to cut the 10 carbon rods to size.", "They're a quarter-inch in diameter and range in length from 7 to 32 inches.", "They form the kite's skeleton and, like bones, they're the most likely part of the kite to break in an accident.", "But if they do break, it's easy to replace them.", "A variety of molded plastic, rubber, and aluminum fittings serve a dual purpose.", "They join the rods together and keep them from falling out of their sleeves.", "Now the kite maker attaches a nylon cord, called a bridle, to the fitting that joins the rods on the wing's leading edge.", "The bridle is the kite's rudder, steering the kite to the left or right.", "The bridle comes off easily if you need to replace the rods.", "The kite maker now attaches tension lines to two plastic components called arrows.", "They're located at the kite's wing tips.", "She ties elastic bungee cords through the arrows to hold the tension lines in place.", "This makes all the fabric parts taut enough to fly.", "Next, she attaches the bridle to the center rod, the spine of the kite.", "She inserts the rod into its protective leather pouch at the nose.", "She inserts other rods into both sides of the wing.", "These give the wing its curved, aerodynamic shape and help the kite stay aloft.", "Finally, additional rods under the wing provide more structure and support.", "These rods spread the kite and help keep it open.", "In the mood for a sky-high experience?", "For $250, you can buy a handmade model like this one and go fly a kite.", "Eyeglasses don't merely correct vision.", "They're also a fashion statement-- so much so that many of today's top clothing designers produce a line of eyeglass frames.", "Whether you prefer plastic frames or metal ones, they come in so many different colors, sizes, and shapes that you're guaranteed to find a pair that suits you.", "Metal frames comes in a multitude of shapes, from ordinary to extraordinary.", "It all starts with a computerized system called a three-axis eye winding machine.", "A set of rollers pulls metal wire from a big spool.", "Then, with software-driven precision, the machine bends the wire into the shape of the frame, then cuts the end free.", "The lenses will fit into precut grooves on the inside.", "A small part, called the insert, connects the two ends of the eye frame, holding them closed around the lens.", "To attach the insert, they put it in a clamp, then position the eye frame just above it.", "They apply a cleaning agent, called flux, then filler wire.", "An electric current heats the wire, metal frame, and insert until they all melt and fuse together.", "Now they do the same to what's called the screw hinge-- the piece that attaches the arm to the eye frame.", "Again, electrically generated heat fuses the hinge to the insert.", "This process, similar to soldering, is called brazing.", "Now for the bridge-- the piece over the nose that joins the two eye frames.", "A small press bends a piece of metal into the shape of the bridge.", "Then a worker aligns it with the eye frames in an assembly jig.", "This ensures the frames are perfectly straight.", "Brazing again melds everything together.", "Next comes the piece above the bridge, called the brow bar.", "An automated machine cuts metal wire to pieces the right length, then carves grooves on the ends to enable the brow bar to fit snugly onto the top of the frames.", "It then bends each piece to the right shape.", "The brow bar now goes into position.", "A little flux to remove any dust or dirt that might prevent the metal from fusing properly.", "Then they braze the brow bar to the frame.", "Now come little hooks called pad arms.", "They hold small pads under the bridge that cushion your nose.", "A worker fuses the pad arms to the frames using the same brazing process as before.", "Now for the arms that attach to the eye frames on one end and sit on your ears on the other.", "The industry calls these arms temples because they're at the level of your temples when you wear the glasses.", "After stamping the size and company name on the inside, they fuse a hinge to each one and press a plastic sleeve on the other end.", "They set the arms momentarily aside while they position the lenses in the groove of the eye frame.", "A screw keeps everything tight and intact.", "Now they screw an arm onto each hinge.", "The arms on most models have curled ends that hook over the ears for a more secure and comfortable fit.", "A special machine, called a mechanical cam, applies pressure to bend the plastic sleeves to a 45-degree angle.", "These metal-frame glasses are functional and fashionable.", "The chinese invented the first toothbrush around 1600, but it wasn't till about 1780 in england that it became a mass-produced item.", "Like those that followed, its bristles came from the necks and shoulders of pigs.", "In the late 1930s, synthetic materials replaced natural swine bristles.", "These toothbrushes should make you want to flash your pearly whites in appreciation if you consider that, thousands of years ago, people used twigs to clean their teeth.", "Today's toothbrush begins as little plastic pellets.", "A vacuum sucks them up into an injection mold machine.", "The machine melts the pellets into a kind of plastic dough, then injects it into a stainless-steel mold, forming 10 toothbrush handles at once.", "The head of each handle has up to 56 holes for bristles.", "This machine generates 10 handles every 35 seconds.", "That works out to 27,000 handles in 24 hours.", "Now they melt blue rubber pellets.", "They pipe the liquid rubber into the mold with the white toothbrush handles, then press the rubber onto the handles to form a grip.", "So now you'll have a toothbrush you can really hang on to.", "No dropping this one in the sink.", "They use a semiclear plastic to produce another type of grip, one that's softer and more pliable.", "It's called the gummy brush, because the grip really does feel a bit like one of those gummy candies.", "These nylon fibers will form the bristles.", "A robotic arm pats them down so that they sit very evenly.", "Then, faster than you can blink an eye, the machine feeds the bristles into the holes in the head of the toothbrush handle.", "This machine works at a blurring speed, filling 900 holes per minute.", "And it operates with incredible precision.", "Here's the bristle-selection process in slow motion.", "The machine selects between 22 and 24 bristles for each hole in the brush.", "With 56 holes per toothbrush, that adds up to over 1,300 bristles for each brush.", "This fully automated system works faster than any human ever could.", "And here's another advantage-- a human hand rarely has to touch the bristles, so the process is incredibly hygienic.", "Wondering what holds the bristles in place?", "Wire.", "The machine bends the fibers in half, anchoring them to the brush with wire in the middle.", "Now it's time for a brush cut.", "These blades trim the bristles to about the same length.", "Another set of blades sculpts different types of edges, depending on the toothbrush model in production.", "These may look like spinning tops, but they're rotating disks coated with diamond dust, a mild abrasive.", "They sand the edges of the bristles to produce a particular finish.", "For instance, the bristles can be straight or zigzagged.", "Different finishes have different tooth-cleaning effects.", "You may have noticed that some bristles are white and others are blue or another color.", "This is purely aesthetic-- a nifty color combination to make the toothbrush look smarter.", "And, of course, the machine knows exactly which color goes where, so you end up with a two-tone brush like this one.", "Every so often, the factory pulls a toothbrush off the assembly line for a spot check.", "A robot arm tugs at the bristles to make sure they're secure enough.", "And if the brush passes the test, the rest of the production run is cleared for sale.", "Then a robotic system packages the brushes so that they come right off the line ready for shipping and ready to maintain toothy smiles everywhere." ]

{ "things": [ "Stile and Rail Doors", "Steam Cleaners", "Hand" ] }

[ "Today on \"how it's made\"-- ...", "Stile and rail doors...", "Steam cleaners...", "Hand-held pizzas...", "And power brushes.", "Many doors are made of a single piece of wood.", "But stile and rail doors contain a rectangular frame around one or more central panels.", "The term stile refers to the frame's vertical pieces.", "And rail refers to its horizontal ones.", "Stile and rail doors come in many different shapes and sizes.", "They have several components.", "Some even have sectioned glass panels.", "They use poplar wood for paint-grade doors.", "If the door will be stained, customers can choose from several different wood options, including oak, cherry, maple, and african mahogany.", "They feed the rough lumber through a planer.", "The first two stations simultaneously shave the top and bottom of the wood.", "The third station has multiple saw blades that cut the piece into several strips.", "Workers line up the strips and coat one side with glue.", "Then they transfer the wood strips to a clamping machine.", "They stack one piece of linear-strand lumber in between the glued sides of two solid-wood strips.", "Linear-strand lumber, called lsl for short, is a piece of lumber made from glued wood fibers.", "The robot holds the assembly in place for an hour until the glue dries.", "Then they put this engineered lumber through a glue spreader.", "It coats the top and bottom surfaces with heat-activated glue.", "They sandwich the lumber between two thin sheets of wood called veneer.", "For a paint-grade door, they use ultra-thin mdf, medium-density fiberboard, instead.", "Mdf is a man-made material with a smooth, paint-friendly surface.", "They place the pieces into a hot press for two minutes.", "The heat activates the glue, while the pressure flattens the veneer against the lumber.", "These pieces will become the door's stiles and rails.", "The panels inside the stiles and rails are made of mdf.", "For a stained door, workers apply the veneer before they contour the pieces.", "Workers carve the pieces using a shaper machine.", "They change the machine heads in order to cut different designs.", "The workers used a different shaper machine to carve the inside edge of the stiles.", "They also drilled holes for the dowels of the adjoining rails.", "They apply glue, then attach the matching bottom rail to the first stile.", "They insert the panel into a groove in the rail and stile.", "They are assembling a two-panel door.", "So next, they fit a middle rail and another panel.", "They install a top rail and then the second stile.", "They place the newly-assembled door in a large clamping machine.", "It applies pressure on the door for an hour while the glue dries.", "The machine transfers the door to a cutting table.", "Then a computer-guided saw trims the top and bottom of the door.", "The machine switches to a different tool that bevels the edge of the door.", "It switches tools again and drills holes for the door's hardware.", "The stile and rail door is now ready for finishing.", "Workers sand the surface to prepare it for either staining or painting.", "Then the stained doors receive a coat of sealer and two coats of clear lacquer.", "This protects the wood's surface.", "The panels used in stile and rail doors are never glued in place.", "They sit inside the frame.", "This leaves space for the wood and mdf to naturally expand without warping or cracking the door.", "In the 1960s, italian boilermakers figured out how to harness steam to clean.", "Steam cleaning is much safer than traditional methods because dirt and bacteria can be eliminated without the use of harmful chemicals.", "High-pressure, low-moisture steam is enough to vaporize most germs.", "The water in a steam cleaner is heated to over 200 degrees fahrenheit.", "It's safe to use on both hard and soft surfaces.", "Steam cleaners start out as a computer design.", "This is a commercial model that will be used to clean hotels, restaurants, offices, and schools.", "They make the components using polycarbonate plastic pellets.", "A molding machine heats the plastic, then injects it into molds.", "The plastic hardens into the shape of parts.", "This one is the cover for the steam cleaner's boiler.", "A robot with vacuum-suction grippers extracts the cover from the mold.", "They mold other parts, including the base, extension tubes, handles, and hooks the same way.", "A worker installs a water-level probe on the steel boiler.", "He also screws on a fitting for the fill hose.", "He adds two solenoid valves.", "They turn the steam on and off and control its intensity.", "Then he places the boiler in a test device.", "The device verifies that the electrical parts are insulated properly.", "He tightens the solenoid valves to complete the installation.", "After the hoses are attached to the boiler, they place it in the base of the steam cleaner.", "A worker plugs in the electrical contacts.", "They will power the steam hose's controls.", "Then he connects the steam hose to a fitting next to the contacts.", "He tightens a metal clip around it to reinforce the connection.", "He links the main electronic board to temperature sensors that have been installed on the boiler.", "The worker also wires the steam-pressure sensors.", "He covers the top of the boiler with melamine insulation.", "Then he slides a heat-resistant plastic cover over the boiler.", "He attaches the fill hose to the fitting on the top of the boiler.", "He connects the other end to the water tank.", "The worker equips the tank with two water-level sensors.", "He hooks up a gauge for the steam pressure.", "Then he fills the tank with water and tests the steam cleaner.", "He uses a small mirror to check for leaks.", "Another worker assembles the steam gun.", "He attaches a plastic joint to the steam hose, then installs a nozzle on the end.", "He slides the joint forward to surround the spray nozzle and screws a plastic wand to the end of the joint.", "He tucks the hose on one side of the handle's plastic casing and installs a trigger.", "Then he snaps on the cover.", "He screws the handle together.", "He connects the steam gun to the boiler unit.", "He turns it on.", "And the sprayer shoots out a hot, pressurized mist known as dry steam.", "Its moisture content is only 5%, allowing cleaned surfaces to dry quickly.", "The steam cleaner also comes with a vacuum.", "It sucks up residual water and dirt after a steam cleaning.", "He attaches the vacuum motor to the filter.", "He places the motor and filter into the base canister and locks the assembly together with clips at the sides.", "The worker transfers the steam cleaner to a cart.", "Once the vacuum is on board, this duo is ready to eradicate dirt, grease, and pathogens.", "Just aim and pull the trigger.", "The steam will do the rest.", "A slice of pizza isn't always a portable snack.", "The toppings can slide off while you're eating it.", "These hand-held, individual pizzas solve that problem.", "The toppings are safely encased inside the pizza dough.", "Hand-held pizzas are small enough for kids to easily hold.", "They're made without preservatives, and all the ingredients are organic, making them the perfect frozen snack for hungry children.", "One main ingredient is cauliflower.", "It packs a strong nutritional punch without altering the flavor.", "Cauliflower is low in calories but high in vitamins, minerals, and dietary fiber.", "It also helps thicken the filling.", "After removing the stems, the cooks boil the cauliflower heads until tender.", "They remove them from the pot with a slotted spoon to let the water drain away.", "They puree the cauliflower in a food processor.", "The cooks also boil and puree butternut squash, which is full of vitamin a, vitamin c, and many other nutrients.", "The squash puree slightly sweetens the filling and helps thicken it.", "Other ingredients that go into the filling are tomato paste, parmesan and mozzarella cheeses, potato flakes, sea salt, spices, and water.", "After measuring out the required amounts, workers pour the ingredients into a large bowl.", "They manually blend the ingredients with a large whisk to keep the filling's texture coarse.", "The pizza dough is made with wheat flour, unbleached all-purpose flour, and baking soda.", "They also add palm fruit shortening and water to make the dough pliable.", "They combine all the ingredients in a mixer.", "The mixer blends the ingredients thoroughly until the dough reaches the right consistency.", "After mixing, they let the dough rest.", "Next, they transform the blocks of dough into sheets.", "They place an 8-inch block of dough on a machine called the dough sheeter.", "The dough moves back and forth beneath a roller until it's flat.", "They add flour so the dough won't stick to the roller.", "A worker winds the sheet of dough onto a spool and transfers it to the processing line.", "Here, four rotary blades trim the sides and divide the sheet into three strips.", "Spray nozzles lightly mist the dough with water to keep it pliable.", "A machine dispenses the filling at perfectly timed intervals.", "It adds one ounce of filling per pizza to one side of each strip.", "Then the machine folds the other side over.", "A crimping wheel seals the edge to encase the filling.", "They add more flour on top so the crimper and rotary cutters can easily trim off the excess dough.", "A chopping blade separates the filled dough into individual pizzas.", "Then the crimper seals the third edge.", "Workers transfer the pizzas by hand onto baking sheets.", "They're lined with parchment paper to prevent sticking.", "Then they bake the pizzas in an oven.", "As soon as they come out, they're flash-frozen.", "This rapid deep-freeze locks in the nutrients and makes preservatives unnecessary.", "The frozen pizzas go straight to the packaging room.", "It's refrigerated so the pizzas won't begin to thaw.", "The equipment individually wraps the pizzas in plastic then packages them, two per box.", "After 60 seconds in the microwave, these pizzas are ready to eat.", "The thick filling doesn't drip, making them the perfect meal on the go.", "Wire power brushes rotate at high speeds to clean metal without damaging it.", "These industrial tools can scrub off almost anything, including weld splatter, rust, and paint.", "They can also smooth away sharp edges and protrusions known as burrs.", "Wire power brushes come in many different shapes and sizes.", "The bristles are either knotted or crimped.", "There's a wire power brush for every metal-cleaning job.", "Automated tools work with pinpoint accuracy to create a wire brush with knotted bristles.", "A tool inserts 22 wires into each hole of the steel disk.", "The wires are made of high-carbon steel.", "Another tool twists the wire bundle into a knot.", "It makes a special knot designed for maximum strength and durability.", "The system installs 48 knotted wire bundles in each brush.", "An employee transfers the brush to a machine with circular blades.", "The blades trim the wires down and sharpen the ends.", "The next worker sandwiches the brush's center disk between two larger disks.", "A press welder creates three dimples in the metal.", "These dimples tightly hold the brush structure in place.", "A press drives a large nut into the center hole.", "It will be used to securely attach the wire brush to a power tool.", "This completes the knotted wire power brush assembly.", "Next, they make the crimped wire brush.", "First, a device feeds steel wire to a cutting machine in preset increments.", "The machine's cutting wheels slice the wires to the correct length.", "It deposits the wire bundles on a rack, and a worker collects them.", "Then, another worker threads a long wire between two metal flanges and a winding machine.", "She lines up the pins around the flanges.", "Then she tucks freshly-cut wire bundles into those slots.", "She continues until she's stacked the wire bundles all the way around the flanges.", "Then she starts the machine.", "It winds the long wire around the shorter wire bundles.", "This crimps the short wires at the center and holds them in place between the flanges.", "She pulls the end of the wire to the side of the brush segment.", "Then it's ready for the next operation.", "A 100-ton press bends the flanges over the crimped bristles, encasing the longer wire that holds them together.", "Next, a worker spins the ends of the brush between two circular blades.", "This is a preliminary trimming.", "Then a punch enlarges the diameter of the center hole.", "Next, they combine several of the crimped brush segments together.", "An employee piles up the segments.", "He places a tube in the center and spacers in between the brushes.", "Once the brush reaches the right size, he uses a compression tool to curl the tube's top rim against the flange.", "This secures the segments, creating one large crimped wire brush.", "Then he trims the wire bristles to the correct length.", "When attached to a power tool, knotted bristle wire brushes can spin up to 25,000 rotations per minute.", "The brush's high speed allows it to efficiently scrub dirt and grease from an oil-well drill pipe.", "The crimped wire brush is designed for lighter work, like scrubbing rust off a metal pipe.", "These power brushes are bristling with cleaning potential and ready for work." ]