How It's Made (2001–…): Season 3, Episode 5 - Horse-drawn Carriages/Artificial Eyes/Dog Food and Cat Food/Mirrors - full transcript
Find out how horse-drawn carriages, artificial eyes, dog and cat food and mirrors are manufactured.
Narrator:
TODAY ON "HOW IT'S MADE"...
...HORSE-DRAWN CARRIAGES...
...ARTIFICIAL EYES...
...DOG AND CAT FOOD...
...AND MIRRORS.
NOTHING TAKES YOU
BACK TO THE PAST
QUITE LIKE A RIDE
IN A HORSE-DRAWN CARRIAGE,
A TIMELESS VEHICLE IN BOTH
APPEARANCE AND CONSTRUCTION.
BUILDING ONE TODAY
STILL REQUIRES THE EXPERTISE
OF SEVERAL
TRADITIONAL CRAFTSPEOPLE,
FROM IRONWORKERS
TO WHEELWRIGHTS.
THE CARRIAGE'S TURNING MECHANISM
IS A FIFTH WHEEL
THAT IS POSITIONED HORIZONTALLY
ABOVE THE TWO FRONT WHEELS.
WORKERS WELD THE FIFTH WHEEL
TO THE CARRIAGE'S STEEL FRAME
THEN WELD THE BOARDING STEPS
TO THE FRAME.
UNTIL NOW THE FRAME
HAS BEEN POSITIONED UPSIDE DOWN.
NOW THEY TURN IT RIGHT SIDE UP
TO INSTALL THE DRIVER'S SEAT.
FIRST THEY MEASURE CAREFULLY
TO ENSURE
IT'S PERFECTLY CENTERED.
THEN THEY WELD IT IN PLACE.
ONCE THE FRAME IS COMPLETE,
IT GOES THROUGH AN ACID WASH
TO REMOVE ANY RESIDUE.
THEN THEY BUFF THE WELDED JOINTS
TO SMOOTH OUT THEIR SURFACE.
THE CARRIAGE HAS DRUM BRAKES.
WORKERS INSTALL THEM
ONTO THE AXLE
THEN ASSEMBLE THE STEEL SPRINGS
THAT MAKE UP THE SUSPENSION
AND BOLT THEM ONTO THE AXLE
AS WELL.
NEXT, THEY CONNECT
THE BRAKE LINE.
THEN THEY INSTALL
THE WHOLE ASSEMBLY
UNDER THE CARRIAGE'S FRAME.
LIKE IN THE OLDEN DAYS,
THEY MAKE THE WHEELS
OUT OF WOOD.
METAL ISN'T FLEXIBLE ENOUGH
TO WITHSTAND BUMPS IN THE ROAD.
THEY USE ASH
BECAUSE IT'S A VERY HARD WOOD
THAT DOESN'T ROT EASILY.
WORKERS POSITION 16 SPOKES
AROUND A STEEL HUB.
THEY CLAMP THE SPOKES IN PLACE,
COMPRESSING THEM
AGAINST THE HUB.
THEN THEY SECURE THEM
WITH NUTS AND BOLTS.
NEXT, THEY MARK THE SPOKES
IN TWO PLACES.
THE FIRST LINE SHOWS
HOW LONG TO CUT EACH SPOKE,
THE SECOND LINE
HOW FAR TO DOWEL THE END.
TO FORM THE DOWEL,
THEY FIRST SHAPE THE END
INTO A CONE.
THEN THE CONE INTO A DOWEL.
THOSE DOWELED SPOKES WILL FIT
INTO CORRESPONDING HOLES
THEY NOW DRILL INTO TWO
SEMICIRCULAR STRIPS OF WOOD.
THE STRIPS FORM
WHAT'S CALLED THE FELLOW,
THE ROUND PART OF THE WHEEL.
WORKERS TIGHTEN THE HUB
THEN PRESS A STEEL BAND CALLED
A CHANNEL AGAINST THE FELLOW.
THEY CUT THE CHANNEL TO SIZE.
THEN WELD THE ENDS TOGETHER.
FINALLY,
THEY BUFF THE JOINT SMOOTH.
NEXT, THEY DRILL EIGHT HOLES
THROUGH THE CHANNEL
THEN, USING A TAPERING TOOL,
THREAD THE HOLES
TO FIT THE BOLTS
THAT BIND THE CHANNEL
TO THE FELLOW.
FINALLY, THEY TIGHTEN THE BOLTS
WITH A SPECIAL GUN.
THE TIRES ARE MADE OF RUBBER.
THEY CONTAIN TWO STEEL WIRES
TO HOLD THEM IN PLACE
OVER THE WHEEL.
WORKERS GREASE THE CHANNEL
OF THE NOW-PAINTED WHEEL
SO THAT THE TIRE
WILL SLIP ON EASILY.
THEN THEY MOUNT THE WHEEL
ON THE AUTOMATED
TIRE-INSTALLATION MACHINE,
WHICH PULLS ON THE WIRES,
INSTALLING THE TIRE
TIGHTLY OVER THE WHEEL.
THEY SOLDER THE WIRE ENDS
TOGETHER
USING BRONZE SOLDER
FOR A STRONGER JOINT.
THEN -- HERE COMES
THE HIGH-TECH PART --
THEY BANG THE WHEEL ON
THE GROUND FOUR OR FIVE TIMES
UNTIL THE DISTANCE
BETWEEN THE TIRE ENDS CLOSES,
COVERING THE SOLDERED WIRES
INSIDE.
A TAP OF THE HAMMER
FOLLOWED BY A FINAL BANG
ENSURES THE TIRE JOINT
IS SECURE.
NOW THEY CAN MOUNT THE WHEELS
ONTO THE AXLES
AND INSTALL THE AXLES
UNDER THE BODY OF THE CARRIAGE.
AFTER TESTING THE FIFTH WHEEL
AND THE BRAKES...
...IT'S TIME TO APPLY
THE FINISHING ARTISTIC TOUCHES.
ALL THEY NEED NOW
IS A LITTLE HORSEPOWER.
Narrator:
THE ANCIENT ROMANS AND EGYPTIANS
FASHIONED ARTIFICIAL EYES
OUT OF PAINTED CLAY.
BY THE 1500s,
EUROPEANS STARTED MAKING THEM
OUT OF ENAMELED GOLD
AND SOON OUT OF GLASS,
WHICH REMAINED THE NORM
FOR HUNDREDS OF YEARS.
TODAY MOST ARTIFICIAL EYES
ARE MADE OF ACRYLIC.
IF YOU'VE LOST AN EYE
IN AN ACCIDENT OR TO A DISEASE,
A SPECIALIST
KNOWN AS AN OCULARIST
CAN FIT YOU
WITH AN ARTIFICIAL EYE.
YOU CAN GET A READY-MADE MODEL
OR A CUSTOM-MADE PROSTHESIS,
LIKE THE ONE FOR WHICH
THIS PATIENT IS BEING FITTED.
NO TWO PEOPLE'S EYE SOCKETS
ARE THE SAME,
SO THE FIRST STEP
IS TO TAKE AN IMPRESSION.
AFTER INSERTING
AN IMPRESSION TRAY,
THEY INJECT A MATERIAL
CALLED ALGINATE,
FILLING THE ENTIRE
SOCKET CAVITY.
AFTER 90 SECONDS,
THE ALGINATE SETS,
AND THEY CAN REMOVE
THE HARDENED IMPRESSION.
THEY PLACE THE IMPRESSION
IN A MOLD.
AND POUR IN A TYPE OF PLASTER.
WHEN THE PLASTER HAS HARDENED,
THEY REMOVE THE IMPRESSION TRAY
AND THEN THE IMPRESSION ITSELF.
WHAT'S LEFT IN THE MOLD IS
A PLASTER REPLICA OF THE SOCKET.
NOW THEY PUT A WAD OF ACRYLIC
PLASTIC DOUGH INTO THE MOLD...
...LOCK THE MOLD INTO A PRESS,
AND SUBMERGE IT
IN A HIGH-PRESSURE CURING UNIT
FOR 25 MINUTES.
THEN THEY COOL THE MOLD
IN COLD WATER.
HERE'S THE ORIGINAL IMPRESSION
COMPARED TO THE ACRYLIC MODEL
THEY'VE JUST CAST.
THIS MODEL IS CALLED
THE FITTING SHAPE
BECAUSE THEY USE IT
TO FIT AND MARK THE POSITIONING
OF THE FAKE IRIS.
THEY ACCENTUATE THE MARKINGS,
THEN ATTACH A PEG
WITH A DROP OF WAX.
THE PEG INDICATES
THE NATURAL ANGLE OF THE IRIS
WHEN THE PATIENT
IS LOOKING FORWARD.
NEXT, THEY ADD WAX
AROUND THE PERIMETER
TO ENLARGE THE FITTING SHAPE.
THIS EXCESS
WILL GIVE THE OCULARIST
SOME ROOM TO WORK WITH
FOR THE FINAL SIZING.
NOW THEY TAKE THIS MARKED
AND ENLARGED FITTING SHAPE
AND MAKE A PLASTER MOLD.
THEY WILL LATER USE THAT MOLD
TO CAST
THE ACTUAL ARTIFICIAL EYE.
BUT FIRST THEY HAVE TO MAKE
THE IRIS.
THEY TAKE A CURVED,
BLACK ACRYLIC DISC
AND PAINT IT
AS REALISTICALLY AS POSSIBLE
WITH HIGH-QUALITY ARTIST OILS.
THE PATIENT HAS TO BE PRESENT
SO THEY CAN MATCH THE REAL EYE.
NEXT, THEY GLUE
AN ACRYLIC CORNEA
WITH AN APPROPRIATE-SIZED PUPIL
ONTO THE PAINTED IRIS.
AT THIS POINT,
THE ARTIFICIAL IRIS
IS HALF AN INCH IN DIAMETER.
IF THE PATIENT'S REAL IRIS
IS SMALLER,
THEY TRIM DOWN THE REPLICA
TO MATCH.
THE IRIS THEN GOES
INTO THE PLASTER MOLD
COVERED WITH
WHITE ACRYLIC DOUGH.
AFTER THE SAME HIGH-PRESSURE
CURING PROCESS AS BEFORE,
OUT COMES THE ARTIFICIAL EYE
COVERED WITH
EXCESS WHITE ACRYLIC.
THEY TRIM OFF THAT EXCESS
AND THE PEG
USING A GRINDING TOOL
AND A CUTTER.
THIS REFINES THE SHAPE
AND EXPOSES THE IRIS
BURIED UNDERNEATH.
THEY SMOOTH THE SURFACE
AGAINST A GRINDING STONE
AND VERIFY THE MEASUREMENTS.
THEN,
USING HARD COLORING PENCILS,
THEY ADD FINISHING TOUCHES
TO THE IRIS
AND DRAW BLOOD VESSELS.
THEY LABEL THE EYE
WITH THE PATIENT'S INITIALS
AND THEN APPLY
AN ACRYLIC COATING
TO SEAL THE PENCIL MARKS.
TO CREATE VEINS
WITH SOME DIMENSION,
THEY USE
THE SAME ACRYLIC COATING
TO STICK ON
SOME DELICATE SILK THREADS.
ONCE THEY'RE SATISFIED
THE ARTIFICIAL EYE
IS A PERFECT MATCH,
THEY SEAL THE ARTWORK
WITH ANOTHER ACRYLIC COATING.
ONCE THAT CURES,
THEY POLISH THE EYE TO A SHINE
WITH A COTTON WHEEL.
THE SHAPES AND COLORS
OF ARTIFICIAL EYES ARE ENDLESS
BECAUSE PATIENTS' EYE SOCKETS
AND IRISES VARY GREATLY,
AS DO THEIR SCLERAS,
THE WHITE OF THE EYE.
THIS ARTIFICIAL EYE,
OR OCULAR PROSTHESIS, IS READY.
THE FINAL STEP IS TO ENSURE
THAT THE FIT IS PERFECT.
THE PATIENT'S OCULAR MUSCLES
ATTACH TO THE IMPLANT,
ENABLING HIS ARTIFICIAL EYE
TO MOVE IN UNISON
WITH HIS REAL EYE.
Narrator: SO MUCH FOR FEEDING
FIDO SCRAPS FROM THE TABLE.
TODAY'S PET FOOD
IS THE STUFF OF SOPHISTICATED
NUTRITIONAL SCIENCE.
IT'S ABOUT PROTEIN,
CARBOHYDRATES,
VITAMINS, MINERALS --
A WELL-BALANCED DIET.
WANT TO BET SOME DOGS AND CATS
EAT HEALTHIER THAN THEIR OWNERS?
THE FORMULAS
FOR DOG AND CAT FOOD DIFFER
BECAUSE DOGS AND CATS
HAVE DIFFERENT
NUTRITIONAL REQUIREMENTS.
CATS, FOR INSTANCE,
NEED MORE FAT AND PROTEIN
IN THEIR DIET THAN DOGS DO.
BUT THE BASIC INGREDIENTS
THAT FACTORIES GRIND UP
TO MAKE DOG AND CAT FOOD
ARE SIMILAR.
FIRST, CORN KERNELS.
THEN CEREALS, SUCH AS BARLEY...
WHEAT...
AND RICE.
WORKERS WEIGH THE INGREDIENTS,
GRIND THEM IN A MILL,
THEN COMBINE EVERYTHING
IN A MIXER
UNTIL THEY HAVE AN EVEN
AND WELL-BLENDED POWDER.
A MACHINE CALLED THE EXTRUDER
TRANSFORMS THAT POWDER
INTO BITE-SIZED PIECES
OF PET FOOD.
IT STEAM-COATS THE MIXTURE,
THEN FORCES IT THROUGH DIES
AT HIGH PRESSURE.
THE DIES SHAPE IT,
THE WAY THE TIP OF A PASTRY BAG
SHAPES ICING INTO SWIRLS
OR ROSES.
CHECK OUT THIS DOG-BONE DIE.
AS THE CONTINUOUS STREAM
OF SHAPED MIXTURE EXITS THE DIE,
A SPINNING KNIFE
CUTS IT INTO PIECES.
THE COMPANY HAS DIFFERENT DIES
TO PRODUCE DIFFERENT SHAPES.
THIS IS A BATCH OF ROUND PIECES.
NEXT STOP, A HOT-AIR DRYER
FOR 25 MINUTES.
IT HEATS THE PIECES
TO 300 DEGREES FAHRENHEIT
TO DRAW OUT THE MOISTURE,
THEN COOLS THEM
AT ROOM TEMPERATURE.
ONCE THE PIECES EXIT THE DRYER,
THEY ENTER A REVOLVING DRUM,
WHERE THEY'RE SPRAYED WITH FAT
AND FLAVORING.
THE FAT IS DESIGNED
TO ADD FOOD ENERGY
WHILE THE FLAVORING
GIVES THE BLAND PIECES
AN APPETIZING ODOR AND TASTE --
APPETIZING FOR PETS, THAT IS.
THE ROTATION ENSURES THE PIECES
GET COATED EVENLY.
FROM HERE, THE PIECES GO
INTO STORAGE SILOS.
WHEN THEY LEAVE THE SILOS
FOR BAGGING,
THE MACHINERY SCREENS OUT
ANY CRUMBS.
THE PET-FOOD INDUSTRY HAS MADE
SOME INTERESTING OBSERVATIONS
ABOUT THE LIKES AND DISLIKES
OF ITS FOUR-LEGGED CLIENTELE.
APPARENTLY, CATS AND DOGS
AREN'T CRAZY ABOUT FOOD
THAT'S TOO DRY,
TOO HARD TO CHEW, OR TOO MUSHY.
IF THE PIECES ARE TOO SMALL,
THEY'LL SWALLOW THEM WHOLE
WITHOUT CHEWING
AND NOT DIGEST THEM PROPERLY.
BUT IF THE PIECES ARE TOO BIG,
THEY'LL GAG AND GET TURNED OFF
TO THE FOOD ALTOGETHER.
IN THE PACKAGING DEPARTMENT,
AUTOMATED SCALES WEIGH
THE EXACT QUANTITY PER PACKAGE.
THIS BATCH IS DESTINED FOR BAGS
WEIGHING ABOUT 6 1/2 POUNDS.
THE PACKAGE SIZES RANGE
FROM JUST UNDER ONE POUND
ALL THE WAY UP TO 44 POUNDS.
SHELF LIFE IS FROM 12
TO 16 MONTHS,
DEPENDING ON THE FORMULA.
PET-FOOD EXPERTS SAY
DOGS AND CATS PREFER FOOD
WITH A FATTIER CONTENT
AND A COMBINED
MEAT-AND-CEREAL FORMULA
OVER JUST CEREAL ALONE,
BUT TOO MUCH MEAT FLAVORING
CAN TURN THEM OFF.
CATS, AS A RULE,
ARE MORE PARTICULAR.
THEY FAVOR MORE ACIDIC FOOD,
WHILE DOGS TEND TO HAVE
A SWEETER TOOTH.
AND YOU THOUGHT KIDS
WERE FUSSY EATERS.
Narrator: NO BATHROOM
IS COMPLETE WITHOUT ONE.
AND ANY PARENT WILL TELL YOU
THAT NO TEENAGER
CAN SURVIVE WITHOUT ONE.
MIRROR, MIRROR ON THE WALL,
HOW DO THEY MAKE YOU, AFTER ALL?
WELL, "HOW IT'S MADE"
IS ABOUT TO SHOW YOU.
BUT FIRST, LET'S REFLECT
ON THE HISTORY OF MIRRORS.
THE EARLIEST MIRRORS WERE CURVED
PIECES OF HIGHLY POLISHED METAL,
SUCH AS BRASS OR BRONZE.
THEY'RE EVEN MENTIONED
IN THE BIBLE.
THEN, IN THE 14th CENTURY,
THE VENETIANS INVENTED
VERY CRUDE GLASS MIRRORS
THAT REFLECTED OFF
A METALLIC BACKING.
THEY LATER PERFECTED
THIS TECHNIQUE
USING AN AMALGAM
OF TIN AND MERCURY.
EVENTUALLY, THE SECRET
OF MIRROR-MAKING SPREAD
TO OTHER CITIES.
BY 1835,
A GERMAN CHEMIST DEVELOPED
THE SILVER-BACKED MIRROR
THAT WE KNOW TODAY.
A MIRROR STARTS OUT
AS CLEAR GLASS.
A ROBOT LAYS EACH PANEL
HORIZONTALLY ON A CONVEYOR BELT,
WHICH TRANSPORTS IT
TO THE WASHING STATION.
THERE, SPRAYERS BLAST THE GLASS
WITH WATER AND CERIUM OXIDE,
A POWDER DERIVED
FROM A TYPE OF SOIL.
ROTATING BRUSHES SCRUB
AND POLISH
BOTH THE TOP
AND BOTTOM SURFACES,
REMOVING OILS
AND OTHER CONTAMINANTS.
THIS WASHING PROCESS TAKES
ABOUT A MINUTE PER PANEL.
NEXT, SPRAYERS RINSE THE GLASS
WITH PIPING-HOT
DEMINERALIZED WATER,
DEMINERALIZED BECAUSE
THE MINERALS IN PLAIN TAP WATER
WOULD DAMAGE THE METALS
THEY APPLY NEXT.
THE FIRST METAL
IS LIQUEFIED TIN,
WHICH GOES ON WHAT WILL BE
THE BACK OF THE MIRROR.
IT ALLOWS THE SECOND METAL,
SILVER, TO ADHERE
BECAUSE SILVER WON'T STICK
DIRECTLY TO GLASS.
THE SILVER
IS ALSO IN LIQUID FORM
MIXED WITH A CHEMICAL ACTIVATOR.
WITHIN SECONDS OF INTERACTING
WITH THE TIN, IT HARDENS.
AND AS IT DOES,
YOU BEGIN TO SEE A REFLECTION.
IT'S THIS SILVER BACKING
THAT TRANSFORMS CLEAR GLASS
INTO A MIRROR.
SPRAYERS RINSE OFF
THE EXCESS SILVER,
WHICH GETS RECYCLED
BACK INTO THE SYSTEM.
THE FACTORY WILL SEAL THE SILVER
BACKING WITH TWO COATS OF PAINT.
PAINT BY ITSELF, HOWEVER,
ISN'T ENOUGH TO PROTECT
THE SILVER IN THE LONG TERM.
SO THEY FIRST SPRAY ON
A LAYER OF COPPER.
SPRAYERS RINSE OFF
THE EXCESS COPPER.
THEN THE PANEL PASSES THROUGH
A DRYER
AT ALMOST 160 DEGREES
FAHRENHEIT.
THIS EVAPORATES THE MOISTURE
ON THE SURFACE
IN JUST 75 SECONDS.
NOW THE PANEL PASSES,
COPPER SIDE UP,
THROUGH WHAT IS CALLED
THE CURTAIN COATER,
A MACHINE THAT RUNS
A CONTINUOUS CURTAIN OF PAINT
ACROSS THE CONVEYOR BELT.
WITH ITS FRESH COAT OF PAINT,
THE MIRROR THEN PASSES THROUGH
AN OVEN
HEATED TO 210 DEGREES
FAHRENHEIT.
AFTER A MINUTE AND 45 SECONDS,
THE PAINT IS CURED.
NOW THE SECOND COAT OF PAINT.
THERE'S NO REASON
FOR THE DIFFERENT COLOR
OTHER THAN TO DIFFERENTIATE
THE COATS.
THIS TIME, THE CURING PERIOD
IS TWICE AS LONG
AND AT A HIGHER TEMPERATURE,
CLOSE TO 245 DEGREES FAHRENHEIT.
AFTER AN ACID WASH TO REMOVE
ANY METAL RESIDUES,
THEY STAND THE PANEL UPRIGHT
TO INSPECT IT.
IF THEY FIND A FAULT,
SUCH AS A BUBBLE IN THE GLASS,
THEY CUT THAT PORTION OUT.
THE FACTORY NOW CUTS
THESE LARGE PANELS
INTO WHATEVER SIZE AND SHAPE
THE CUSTOMER HAS ORDERED
USING A SPECIAL
MIRROR-CUTTING MACHINE
THAT'S PRECISION-GUIDED
BY COMPUTER SOFTWARE.
IT SCORES THE MIRROR
USING A CARBIDE WHEEL.
CARBIDE IS A STRONG METAL.
TO MAKE ROUND MIRRORS,
THE MACHINE FIRST SCORES
THE PANEL INTO SQUARES.
THEN, IN EACH SQUARE,
IT SCORES A CIRCLE.
USING SPECIAL TOOLS,
WORKERS SEPARATE THE SQUARES,
THEN THE CIRCLES.
TO MAKE BEVELED MIRRORS,
THEY USE WHAT'S CALLED
THE SHAPE-BEVEL MACHINE.
FIRST, IT CARVES OUT THE EDGE.
THEN POLISHES IT TO A SHINE
USING CONCENTRATED CERIUM OXIDE,
A STRONGER VERSION
OF WHAT THEY USED EARLIER
TO CLEAN THE GLASS SURFACE
BEFORE PLATING IT WITH METALS.
MIRROR FACTORIES
ALSO SHIP WHOLE PANELS
TO SHOPS THAT DO THE CUTTING
THEMSELVES,
A FRAGILE FEAT THAT'S CERTAINLY
NOT FOR THE SUPERSTITIOUS.
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS, INC.
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
DROP US A LINE AT...
TODAY ON "HOW IT'S MADE"...
...HORSE-DRAWN CARRIAGES...
...ARTIFICIAL EYES...
...DOG AND CAT FOOD...
...AND MIRRORS.
NOTHING TAKES YOU
BACK TO THE PAST
QUITE LIKE A RIDE
IN A HORSE-DRAWN CARRIAGE,
A TIMELESS VEHICLE IN BOTH
APPEARANCE AND CONSTRUCTION.
BUILDING ONE TODAY
STILL REQUIRES THE EXPERTISE
OF SEVERAL
TRADITIONAL CRAFTSPEOPLE,
FROM IRONWORKERS
TO WHEELWRIGHTS.
THE CARRIAGE'S TURNING MECHANISM
IS A FIFTH WHEEL
THAT IS POSITIONED HORIZONTALLY
ABOVE THE TWO FRONT WHEELS.
WORKERS WELD THE FIFTH WHEEL
TO THE CARRIAGE'S STEEL FRAME
THEN WELD THE BOARDING STEPS
TO THE FRAME.
UNTIL NOW THE FRAME
HAS BEEN POSITIONED UPSIDE DOWN.
NOW THEY TURN IT RIGHT SIDE UP
TO INSTALL THE DRIVER'S SEAT.
FIRST THEY MEASURE CAREFULLY
TO ENSURE
IT'S PERFECTLY CENTERED.
THEN THEY WELD IT IN PLACE.
ONCE THE FRAME IS COMPLETE,
IT GOES THROUGH AN ACID WASH
TO REMOVE ANY RESIDUE.
THEN THEY BUFF THE WELDED JOINTS
TO SMOOTH OUT THEIR SURFACE.
THE CARRIAGE HAS DRUM BRAKES.
WORKERS INSTALL THEM
ONTO THE AXLE
THEN ASSEMBLE THE STEEL SPRINGS
THAT MAKE UP THE SUSPENSION
AND BOLT THEM ONTO THE AXLE
AS WELL.
NEXT, THEY CONNECT
THE BRAKE LINE.
THEN THEY INSTALL
THE WHOLE ASSEMBLY
UNDER THE CARRIAGE'S FRAME.
LIKE IN THE OLDEN DAYS,
THEY MAKE THE WHEELS
OUT OF WOOD.
METAL ISN'T FLEXIBLE ENOUGH
TO WITHSTAND BUMPS IN THE ROAD.
THEY USE ASH
BECAUSE IT'S A VERY HARD WOOD
THAT DOESN'T ROT EASILY.
WORKERS POSITION 16 SPOKES
AROUND A STEEL HUB.
THEY CLAMP THE SPOKES IN PLACE,
COMPRESSING THEM
AGAINST THE HUB.
THEN THEY SECURE THEM
WITH NUTS AND BOLTS.
NEXT, THEY MARK THE SPOKES
IN TWO PLACES.
THE FIRST LINE SHOWS
HOW LONG TO CUT EACH SPOKE,
THE SECOND LINE
HOW FAR TO DOWEL THE END.
TO FORM THE DOWEL,
THEY FIRST SHAPE THE END
INTO A CONE.
THEN THE CONE INTO A DOWEL.
THOSE DOWELED SPOKES WILL FIT
INTO CORRESPONDING HOLES
THEY NOW DRILL INTO TWO
SEMICIRCULAR STRIPS OF WOOD.
THE STRIPS FORM
WHAT'S CALLED THE FELLOW,
THE ROUND PART OF THE WHEEL.
WORKERS TIGHTEN THE HUB
THEN PRESS A STEEL BAND CALLED
A CHANNEL AGAINST THE FELLOW.
THEY CUT THE CHANNEL TO SIZE.
THEN WELD THE ENDS TOGETHER.
FINALLY,
THEY BUFF THE JOINT SMOOTH.
NEXT, THEY DRILL EIGHT HOLES
THROUGH THE CHANNEL
THEN, USING A TAPERING TOOL,
THREAD THE HOLES
TO FIT THE BOLTS
THAT BIND THE CHANNEL
TO THE FELLOW.
FINALLY, THEY TIGHTEN THE BOLTS
WITH A SPECIAL GUN.
THE TIRES ARE MADE OF RUBBER.
THEY CONTAIN TWO STEEL WIRES
TO HOLD THEM IN PLACE
OVER THE WHEEL.
WORKERS GREASE THE CHANNEL
OF THE NOW-PAINTED WHEEL
SO THAT THE TIRE
WILL SLIP ON EASILY.
THEN THEY MOUNT THE WHEEL
ON THE AUTOMATED
TIRE-INSTALLATION MACHINE,
WHICH PULLS ON THE WIRES,
INSTALLING THE TIRE
TIGHTLY OVER THE WHEEL.
THEY SOLDER THE WIRE ENDS
TOGETHER
USING BRONZE SOLDER
FOR A STRONGER JOINT.
THEN -- HERE COMES
THE HIGH-TECH PART --
THEY BANG THE WHEEL ON
THE GROUND FOUR OR FIVE TIMES
UNTIL THE DISTANCE
BETWEEN THE TIRE ENDS CLOSES,
COVERING THE SOLDERED WIRES
INSIDE.
A TAP OF THE HAMMER
FOLLOWED BY A FINAL BANG
ENSURES THE TIRE JOINT
IS SECURE.
NOW THEY CAN MOUNT THE WHEELS
ONTO THE AXLES
AND INSTALL THE AXLES
UNDER THE BODY OF THE CARRIAGE.
AFTER TESTING THE FIFTH WHEEL
AND THE BRAKES...
...IT'S TIME TO APPLY
THE FINISHING ARTISTIC TOUCHES.
ALL THEY NEED NOW
IS A LITTLE HORSEPOWER.
Narrator:
THE ANCIENT ROMANS AND EGYPTIANS
FASHIONED ARTIFICIAL EYES
OUT OF PAINTED CLAY.
BY THE 1500s,
EUROPEANS STARTED MAKING THEM
OUT OF ENAMELED GOLD
AND SOON OUT OF GLASS,
WHICH REMAINED THE NORM
FOR HUNDREDS OF YEARS.
TODAY MOST ARTIFICIAL EYES
ARE MADE OF ACRYLIC.
IF YOU'VE LOST AN EYE
IN AN ACCIDENT OR TO A DISEASE,
A SPECIALIST
KNOWN AS AN OCULARIST
CAN FIT YOU
WITH AN ARTIFICIAL EYE.
YOU CAN GET A READY-MADE MODEL
OR A CUSTOM-MADE PROSTHESIS,
LIKE THE ONE FOR WHICH
THIS PATIENT IS BEING FITTED.
NO TWO PEOPLE'S EYE SOCKETS
ARE THE SAME,
SO THE FIRST STEP
IS TO TAKE AN IMPRESSION.
AFTER INSERTING
AN IMPRESSION TRAY,
THEY INJECT A MATERIAL
CALLED ALGINATE,
FILLING THE ENTIRE
SOCKET CAVITY.
AFTER 90 SECONDS,
THE ALGINATE SETS,
AND THEY CAN REMOVE
THE HARDENED IMPRESSION.
THEY PLACE THE IMPRESSION
IN A MOLD.
AND POUR IN A TYPE OF PLASTER.
WHEN THE PLASTER HAS HARDENED,
THEY REMOVE THE IMPRESSION TRAY
AND THEN THE IMPRESSION ITSELF.
WHAT'S LEFT IN THE MOLD IS
A PLASTER REPLICA OF THE SOCKET.
NOW THEY PUT A WAD OF ACRYLIC
PLASTIC DOUGH INTO THE MOLD...
...LOCK THE MOLD INTO A PRESS,
AND SUBMERGE IT
IN A HIGH-PRESSURE CURING UNIT
FOR 25 MINUTES.
THEN THEY COOL THE MOLD
IN COLD WATER.
HERE'S THE ORIGINAL IMPRESSION
COMPARED TO THE ACRYLIC MODEL
THEY'VE JUST CAST.
THIS MODEL IS CALLED
THE FITTING SHAPE
BECAUSE THEY USE IT
TO FIT AND MARK THE POSITIONING
OF THE FAKE IRIS.
THEY ACCENTUATE THE MARKINGS,
THEN ATTACH A PEG
WITH A DROP OF WAX.
THE PEG INDICATES
THE NATURAL ANGLE OF THE IRIS
WHEN THE PATIENT
IS LOOKING FORWARD.
NEXT, THEY ADD WAX
AROUND THE PERIMETER
TO ENLARGE THE FITTING SHAPE.
THIS EXCESS
WILL GIVE THE OCULARIST
SOME ROOM TO WORK WITH
FOR THE FINAL SIZING.
NOW THEY TAKE THIS MARKED
AND ENLARGED FITTING SHAPE
AND MAKE A PLASTER MOLD.
THEY WILL LATER USE THAT MOLD
TO CAST
THE ACTUAL ARTIFICIAL EYE.
BUT FIRST THEY HAVE TO MAKE
THE IRIS.
THEY TAKE A CURVED,
BLACK ACRYLIC DISC
AND PAINT IT
AS REALISTICALLY AS POSSIBLE
WITH HIGH-QUALITY ARTIST OILS.
THE PATIENT HAS TO BE PRESENT
SO THEY CAN MATCH THE REAL EYE.
NEXT, THEY GLUE
AN ACRYLIC CORNEA
WITH AN APPROPRIATE-SIZED PUPIL
ONTO THE PAINTED IRIS.
AT THIS POINT,
THE ARTIFICIAL IRIS
IS HALF AN INCH IN DIAMETER.
IF THE PATIENT'S REAL IRIS
IS SMALLER,
THEY TRIM DOWN THE REPLICA
TO MATCH.
THE IRIS THEN GOES
INTO THE PLASTER MOLD
COVERED WITH
WHITE ACRYLIC DOUGH.
AFTER THE SAME HIGH-PRESSURE
CURING PROCESS AS BEFORE,
OUT COMES THE ARTIFICIAL EYE
COVERED WITH
EXCESS WHITE ACRYLIC.
THEY TRIM OFF THAT EXCESS
AND THE PEG
USING A GRINDING TOOL
AND A CUTTER.
THIS REFINES THE SHAPE
AND EXPOSES THE IRIS
BURIED UNDERNEATH.
THEY SMOOTH THE SURFACE
AGAINST A GRINDING STONE
AND VERIFY THE MEASUREMENTS.
THEN,
USING HARD COLORING PENCILS,
THEY ADD FINISHING TOUCHES
TO THE IRIS
AND DRAW BLOOD VESSELS.
THEY LABEL THE EYE
WITH THE PATIENT'S INITIALS
AND THEN APPLY
AN ACRYLIC COATING
TO SEAL THE PENCIL MARKS.
TO CREATE VEINS
WITH SOME DIMENSION,
THEY USE
THE SAME ACRYLIC COATING
TO STICK ON
SOME DELICATE SILK THREADS.
ONCE THEY'RE SATISFIED
THE ARTIFICIAL EYE
IS A PERFECT MATCH,
THEY SEAL THE ARTWORK
WITH ANOTHER ACRYLIC COATING.
ONCE THAT CURES,
THEY POLISH THE EYE TO A SHINE
WITH A COTTON WHEEL.
THE SHAPES AND COLORS
OF ARTIFICIAL EYES ARE ENDLESS
BECAUSE PATIENTS' EYE SOCKETS
AND IRISES VARY GREATLY,
AS DO THEIR SCLERAS,
THE WHITE OF THE EYE.
THIS ARTIFICIAL EYE,
OR OCULAR PROSTHESIS, IS READY.
THE FINAL STEP IS TO ENSURE
THAT THE FIT IS PERFECT.
THE PATIENT'S OCULAR MUSCLES
ATTACH TO THE IMPLANT,
ENABLING HIS ARTIFICIAL EYE
TO MOVE IN UNISON
WITH HIS REAL EYE.
Narrator: SO MUCH FOR FEEDING
FIDO SCRAPS FROM THE TABLE.
TODAY'S PET FOOD
IS THE STUFF OF SOPHISTICATED
NUTRITIONAL SCIENCE.
IT'S ABOUT PROTEIN,
CARBOHYDRATES,
VITAMINS, MINERALS --
A WELL-BALANCED DIET.
WANT TO BET SOME DOGS AND CATS
EAT HEALTHIER THAN THEIR OWNERS?
THE FORMULAS
FOR DOG AND CAT FOOD DIFFER
BECAUSE DOGS AND CATS
HAVE DIFFERENT
NUTRITIONAL REQUIREMENTS.
CATS, FOR INSTANCE,
NEED MORE FAT AND PROTEIN
IN THEIR DIET THAN DOGS DO.
BUT THE BASIC INGREDIENTS
THAT FACTORIES GRIND UP
TO MAKE DOG AND CAT FOOD
ARE SIMILAR.
FIRST, CORN KERNELS.
THEN CEREALS, SUCH AS BARLEY...
WHEAT...
AND RICE.
WORKERS WEIGH THE INGREDIENTS,
GRIND THEM IN A MILL,
THEN COMBINE EVERYTHING
IN A MIXER
UNTIL THEY HAVE AN EVEN
AND WELL-BLENDED POWDER.
A MACHINE CALLED THE EXTRUDER
TRANSFORMS THAT POWDER
INTO BITE-SIZED PIECES
OF PET FOOD.
IT STEAM-COATS THE MIXTURE,
THEN FORCES IT THROUGH DIES
AT HIGH PRESSURE.
THE DIES SHAPE IT,
THE WAY THE TIP OF A PASTRY BAG
SHAPES ICING INTO SWIRLS
OR ROSES.
CHECK OUT THIS DOG-BONE DIE.
AS THE CONTINUOUS STREAM
OF SHAPED MIXTURE EXITS THE DIE,
A SPINNING KNIFE
CUTS IT INTO PIECES.
THE COMPANY HAS DIFFERENT DIES
TO PRODUCE DIFFERENT SHAPES.
THIS IS A BATCH OF ROUND PIECES.
NEXT STOP, A HOT-AIR DRYER
FOR 25 MINUTES.
IT HEATS THE PIECES
TO 300 DEGREES FAHRENHEIT
TO DRAW OUT THE MOISTURE,
THEN COOLS THEM
AT ROOM TEMPERATURE.
ONCE THE PIECES EXIT THE DRYER,
THEY ENTER A REVOLVING DRUM,
WHERE THEY'RE SPRAYED WITH FAT
AND FLAVORING.
THE FAT IS DESIGNED
TO ADD FOOD ENERGY
WHILE THE FLAVORING
GIVES THE BLAND PIECES
AN APPETIZING ODOR AND TASTE --
APPETIZING FOR PETS, THAT IS.
THE ROTATION ENSURES THE PIECES
GET COATED EVENLY.
FROM HERE, THE PIECES GO
INTO STORAGE SILOS.
WHEN THEY LEAVE THE SILOS
FOR BAGGING,
THE MACHINERY SCREENS OUT
ANY CRUMBS.
THE PET-FOOD INDUSTRY HAS MADE
SOME INTERESTING OBSERVATIONS
ABOUT THE LIKES AND DISLIKES
OF ITS FOUR-LEGGED CLIENTELE.
APPARENTLY, CATS AND DOGS
AREN'T CRAZY ABOUT FOOD
THAT'S TOO DRY,
TOO HARD TO CHEW, OR TOO MUSHY.
IF THE PIECES ARE TOO SMALL,
THEY'LL SWALLOW THEM WHOLE
WITHOUT CHEWING
AND NOT DIGEST THEM PROPERLY.
BUT IF THE PIECES ARE TOO BIG,
THEY'LL GAG AND GET TURNED OFF
TO THE FOOD ALTOGETHER.
IN THE PACKAGING DEPARTMENT,
AUTOMATED SCALES WEIGH
THE EXACT QUANTITY PER PACKAGE.
THIS BATCH IS DESTINED FOR BAGS
WEIGHING ABOUT 6 1/2 POUNDS.
THE PACKAGE SIZES RANGE
FROM JUST UNDER ONE POUND
ALL THE WAY UP TO 44 POUNDS.
SHELF LIFE IS FROM 12
TO 16 MONTHS,
DEPENDING ON THE FORMULA.
PET-FOOD EXPERTS SAY
DOGS AND CATS PREFER FOOD
WITH A FATTIER CONTENT
AND A COMBINED
MEAT-AND-CEREAL FORMULA
OVER JUST CEREAL ALONE,
BUT TOO MUCH MEAT FLAVORING
CAN TURN THEM OFF.
CATS, AS A RULE,
ARE MORE PARTICULAR.
THEY FAVOR MORE ACIDIC FOOD,
WHILE DOGS TEND TO HAVE
A SWEETER TOOTH.
AND YOU THOUGHT KIDS
WERE FUSSY EATERS.
Narrator: NO BATHROOM
IS COMPLETE WITHOUT ONE.
AND ANY PARENT WILL TELL YOU
THAT NO TEENAGER
CAN SURVIVE WITHOUT ONE.
MIRROR, MIRROR ON THE WALL,
HOW DO THEY MAKE YOU, AFTER ALL?
WELL, "HOW IT'S MADE"
IS ABOUT TO SHOW YOU.
BUT FIRST, LET'S REFLECT
ON THE HISTORY OF MIRRORS.
THE EARLIEST MIRRORS WERE CURVED
PIECES OF HIGHLY POLISHED METAL,
SUCH AS BRASS OR BRONZE.
THEY'RE EVEN MENTIONED
IN THE BIBLE.
THEN, IN THE 14th CENTURY,
THE VENETIANS INVENTED
VERY CRUDE GLASS MIRRORS
THAT REFLECTED OFF
A METALLIC BACKING.
THEY LATER PERFECTED
THIS TECHNIQUE
USING AN AMALGAM
OF TIN AND MERCURY.
EVENTUALLY, THE SECRET
OF MIRROR-MAKING SPREAD
TO OTHER CITIES.
BY 1835,
A GERMAN CHEMIST DEVELOPED
THE SILVER-BACKED MIRROR
THAT WE KNOW TODAY.
A MIRROR STARTS OUT
AS CLEAR GLASS.
A ROBOT LAYS EACH PANEL
HORIZONTALLY ON A CONVEYOR BELT,
WHICH TRANSPORTS IT
TO THE WASHING STATION.
THERE, SPRAYERS BLAST THE GLASS
WITH WATER AND CERIUM OXIDE,
A POWDER DERIVED
FROM A TYPE OF SOIL.
ROTATING BRUSHES SCRUB
AND POLISH
BOTH THE TOP
AND BOTTOM SURFACES,
REMOVING OILS
AND OTHER CONTAMINANTS.
THIS WASHING PROCESS TAKES
ABOUT A MINUTE PER PANEL.
NEXT, SPRAYERS RINSE THE GLASS
WITH PIPING-HOT
DEMINERALIZED WATER,
DEMINERALIZED BECAUSE
THE MINERALS IN PLAIN TAP WATER
WOULD DAMAGE THE METALS
THEY APPLY NEXT.
THE FIRST METAL
IS LIQUEFIED TIN,
WHICH GOES ON WHAT WILL BE
THE BACK OF THE MIRROR.
IT ALLOWS THE SECOND METAL,
SILVER, TO ADHERE
BECAUSE SILVER WON'T STICK
DIRECTLY TO GLASS.
THE SILVER
IS ALSO IN LIQUID FORM
MIXED WITH A CHEMICAL ACTIVATOR.
WITHIN SECONDS OF INTERACTING
WITH THE TIN, IT HARDENS.
AND AS IT DOES,
YOU BEGIN TO SEE A REFLECTION.
IT'S THIS SILVER BACKING
THAT TRANSFORMS CLEAR GLASS
INTO A MIRROR.
SPRAYERS RINSE OFF
THE EXCESS SILVER,
WHICH GETS RECYCLED
BACK INTO THE SYSTEM.
THE FACTORY WILL SEAL THE SILVER
BACKING WITH TWO COATS OF PAINT.
PAINT BY ITSELF, HOWEVER,
ISN'T ENOUGH TO PROTECT
THE SILVER IN THE LONG TERM.
SO THEY FIRST SPRAY ON
A LAYER OF COPPER.
SPRAYERS RINSE OFF
THE EXCESS COPPER.
THEN THE PANEL PASSES THROUGH
A DRYER
AT ALMOST 160 DEGREES
FAHRENHEIT.
THIS EVAPORATES THE MOISTURE
ON THE SURFACE
IN JUST 75 SECONDS.
NOW THE PANEL PASSES,
COPPER SIDE UP,
THROUGH WHAT IS CALLED
THE CURTAIN COATER,
A MACHINE THAT RUNS
A CONTINUOUS CURTAIN OF PAINT
ACROSS THE CONVEYOR BELT.
WITH ITS FRESH COAT OF PAINT,
THE MIRROR THEN PASSES THROUGH
AN OVEN
HEATED TO 210 DEGREES
FAHRENHEIT.
AFTER A MINUTE AND 45 SECONDS,
THE PAINT IS CURED.
NOW THE SECOND COAT OF PAINT.
THERE'S NO REASON
FOR THE DIFFERENT COLOR
OTHER THAN TO DIFFERENTIATE
THE COATS.
THIS TIME, THE CURING PERIOD
IS TWICE AS LONG
AND AT A HIGHER TEMPERATURE,
CLOSE TO 245 DEGREES FAHRENHEIT.
AFTER AN ACID WASH TO REMOVE
ANY METAL RESIDUES,
THEY STAND THE PANEL UPRIGHT
TO INSPECT IT.
IF THEY FIND A FAULT,
SUCH AS A BUBBLE IN THE GLASS,
THEY CUT THAT PORTION OUT.
THE FACTORY NOW CUTS
THESE LARGE PANELS
INTO WHATEVER SIZE AND SHAPE
THE CUSTOMER HAS ORDERED
USING A SPECIAL
MIRROR-CUTTING MACHINE
THAT'S PRECISION-GUIDED
BY COMPUTER SOFTWARE.
IT SCORES THE MIRROR
USING A CARBIDE WHEEL.
CARBIDE IS A STRONG METAL.
TO MAKE ROUND MIRRORS,
THE MACHINE FIRST SCORES
THE PANEL INTO SQUARES.
THEN, IN EACH SQUARE,
IT SCORES A CIRCLE.
USING SPECIAL TOOLS,
WORKERS SEPARATE THE SQUARES,
THEN THE CIRCLES.
TO MAKE BEVELED MIRRORS,
THEY USE WHAT'S CALLED
THE SHAPE-BEVEL MACHINE.
FIRST, IT CARVES OUT THE EDGE.
THEN POLISHES IT TO A SHINE
USING CONCENTRATED CERIUM OXIDE,
A STRONGER VERSION
OF WHAT THEY USED EARLIER
TO CLEAN THE GLASS SURFACE
BEFORE PLATING IT WITH METALS.
MIRROR FACTORIES
ALSO SHIP WHOLE PANELS
TO SHOPS THAT DO THE CUTTING
THEMSELVES,
A FRAGILE FEAT THAT'S CERTAINLY
NOT FOR THE SUPERSTITIOUS.
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DISCOVERY COMMUNICATIONS, INC.
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