How It's Made (2001–…): Season 5, Episode 13 - Electrical Panels/Kites/Eyeglass Frames/Toothbrushes - full transcript
Discover the intricate beginnings of electrical panels, kites, eyeglass frames, and toothbrushes.
Narrator:
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.
Narrator: 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.
Narrator: 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.
Narrator: 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.
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,"
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.
Narrator: 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.
Narrator: 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.
Narrator: 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.
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DISCOVERY COMMUNICATIONS, INC.
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