Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated:
1
00:00:01,793 --> 00:00:04,793
--captions by vitac--
Www.Vitac.Com
2
00:00:04,793 --> 00:00:07,620
Captions paid for by
Discovery communications, inc.
3
00:00:23,000 --> 00:00:25,931
Narrator:
Today on "How it's made"...
4
00:00:25,931 --> 00:00:28,137
Conga drums...
5
00:00:32,448 --> 00:00:34,103
...Metal plating...
6
00:00:38,344 --> 00:00:40,896
...And buttons.
7
00:00:52,482 --> 00:00:56,413
The conga drum may be a staple
Of latin-american music,
8
00:00:56,413 --> 00:00:59,620
But it was developed
From an ancient african drum
9
00:00:59,620 --> 00:01:01,344
Made from an animal skin
10
00:01:01,344 --> 00:01:03,586
Stretched over
A hollow tree trunk.
11
00:01:03,586 --> 00:01:05,310
Today, they stretch the hide
12
00:01:05,310 --> 00:01:07,793
Over a wood
Or fiberglass cylinder.
13
00:01:07,793 --> 00:01:09,448
As you're about to see,
14
00:01:09,448 --> 00:01:12,379
Making congas takes plenty
Of hands-on skill.
15
00:01:18,448 --> 00:01:20,620
These congas are made of ash,
16
00:01:20,620 --> 00:01:22,965
A wood that has good acoustics.
17
00:01:22,965 --> 00:01:25,793
That means
Sound resonates off of it
18
00:01:25,793 --> 00:01:28,931
Rather than being absorbed
Into it.
19
00:01:28,931 --> 00:01:32,034
First, the drum maker
Cuts the curved slats
20
00:01:32,034 --> 00:01:34,931
That will form the drum's body,
Called the shell.
21
00:01:34,931 --> 00:01:38,103
He traces a slat-shaped template
22
00:01:38,103 --> 00:01:41,344
On a rectangular piece of wood.
23
00:01:41,344 --> 00:01:44,724
Then, using a band saw,
He cuts along the trace line,
24
00:01:44,724 --> 00:01:49,586
Creating a curve on the outside
And inside surfaces.
25
00:01:55,793 --> 00:01:58,103
Then he moves to a bench saw,
26
00:01:58,103 --> 00:02:02,206
A saw whose blade can be
Adjusted to different angles.
27
00:02:02,206 --> 00:02:06,310
He clamps the piece
Onto a template
28
00:02:06,310 --> 00:02:09,000
And angles the edge.
29
00:02:20,000 --> 00:02:22,310
He flips the piece over...
30
00:02:25,137 --> 00:02:27,655
...And angles the other edge.
31
00:02:38,034 --> 00:02:42,068
The drum maker applies
Carpenter's glue to both edges
32
00:02:42,068 --> 00:02:45,068
And clamps the slats
Together in a circle
33
00:02:45,068 --> 00:02:48,137
On a specially designed form.
34
00:02:48,137 --> 00:02:50,758
The number of slats
Per drum varies,
35
00:02:50,758 --> 00:02:53,862
Depending on the diameter
Of the shell.
36
00:02:53,862 --> 00:02:58,137
The larger the diameter,
The lower the conga's sound.
37
00:02:58,137 --> 00:03:01,034
The glue dries in 24 hours.
38
00:03:01,034 --> 00:03:02,965
It comes off the form
39
00:03:02,965 --> 00:03:07,344
Looking like this bongo shell,
But taller.
40
00:03:07,344 --> 00:03:11,896
The drum maker now mounts
The dried shell on a wood lathe.
41
00:03:11,896 --> 00:03:15,103
Using a tool called
A wood gouge,
42
00:03:15,103 --> 00:03:17,724
He shears off
About .2 of an inch,
43
00:03:17,724 --> 00:03:22,034
Rounding the outside
Of the shell.
44
00:03:22,034 --> 00:03:25,241
Then he uses a series
Of woodworking tools
45
00:03:25,241 --> 00:03:27,172
To add decorative detailing.
46
00:03:27,172 --> 00:03:30,724
Once that's done,
He smoothes the shell's surface,
47
00:03:30,724 --> 00:03:34,448
Using three progressively
Finer grains of sandpaper.
48
00:03:34,448 --> 00:03:40,379
Then he either leaves the wood
Its natural color or stains it.
49
00:03:40,379 --> 00:03:43,344
A thick coat of oil-based
Lacquer protects the wood
50
00:03:43,344 --> 00:03:47,241
From both dryness and humidity.
51
00:03:51,172 --> 00:03:53,862
Now for the essential hardware.
52
00:03:53,862 --> 00:03:57,034
First, side plates
Made of chrome-plated steel.
53
00:03:57,034 --> 00:04:02,137
Their job is to anchor
The drum's animal-skin head.
54
00:04:02,137 --> 00:04:04,655
They're bolted to the shell.
55
00:04:06,862 --> 00:04:09,827
Next, the drum maker
Feeds a steel strip
56
00:04:09,827 --> 00:04:12,034
Through a bending machine.
57
00:04:12,034 --> 00:04:14,655
Its high-pressure rollers
Curve the strip,
58
00:04:14,655 --> 00:04:16,586
Forming the drum's rim.
59
00:04:16,586 --> 00:04:21,482
Then he rivets v-shaped
Steel pieces onto the rim.
60
00:04:24,344 --> 00:04:26,413
Elsewhere in the workshop,
61
00:04:26,413 --> 00:04:29,965
They prepare the cowhide that
Will become the drum's head.
62
00:04:33,103 --> 00:04:34,793
First they soak it
63
00:04:34,793 --> 00:04:38,379
In a corrosive bath
Of cold water and lime.
64
00:04:38,379 --> 00:04:41,931
This literally burns the hair
Off the hide.
65
00:04:46,620 --> 00:04:48,482
After two or three days,
66
00:04:48,482 --> 00:04:52,758
They remove the skin and scrape
Off any stubborn hairs.
67
00:04:56,793 --> 00:04:59,379
Then they stretch it
Over a circular frame,
68
00:04:59,379 --> 00:05:01,896
Leaving it to dry
At room temperature
69
00:05:01,896 --> 00:05:03,931
For a couple of days.
70
00:05:06,103 --> 00:05:08,344
After chrome-plating the rim,
71
00:05:08,344 --> 00:05:10,448
It's time
For the final assembly.
72
00:05:10,448 --> 00:05:12,965
They stretch the head
Over the shell
73
00:05:12,965 --> 00:05:14,793
And clasp it in place
With the rim.
74
00:05:14,793 --> 00:05:17,241
They hook the v's
To the side plates,
75
00:05:17,241 --> 00:05:21,000
Then adjust the tension
To tune the instrument.
76
00:05:21,000 --> 00:05:24,862
The last step is to trim off
The excess skin.
77
00:05:24,862 --> 00:05:28,310
Now the musical handiwork
Can begin.
78
00:05:49,827 --> 00:05:52,827
Narrator: plating is a layer
Of metal coating an object
79
00:05:52,827 --> 00:05:54,793
Made of a different type
Of metal.
80
00:05:54,793 --> 00:05:57,551
The purpose can be decorative,
As in silver plating,
81
00:05:57,551 --> 00:05:59,206
Or practical.
82
00:05:59,206 --> 00:06:01,482
With industrial parts,
For instance,
83
00:06:01,482 --> 00:06:03,241
Zinc or cadmium plating
84
00:06:03,241 --> 00:06:05,689
Prevents the underlying metal
From rusting,
85
00:06:05,689 --> 00:06:09,172
While nickel or chrome plating
Protects against wear.
86
00:06:15,275 --> 00:06:18,172
You can plate
Almost any type of metal.
87
00:06:18,172 --> 00:06:20,655
Let's follow some
Steel aerospace parts
88
00:06:20,655 --> 00:06:23,241
As they're about to be plated
With cadmium
89
00:06:23,241 --> 00:06:26,448
To make them
Corrosion-resistant.
90
00:06:26,448 --> 00:06:29,275
For the plating metal
To bond properly,
91
00:06:29,275 --> 00:06:31,862
The steel surface must be free
Of contaminants
92
00:06:31,862 --> 00:06:34,275
Such as oil and grease.
93
00:06:34,275 --> 00:06:36,344
Workers suspend the parts
94
00:06:36,344 --> 00:06:39,689
Over a vat of boiling
Chemical solvents.
95
00:06:39,689 --> 00:06:43,206
As the hot vapor comes in
Contact with the colder metal,
96
00:06:43,206 --> 00:06:45,862
It condenses,
Dripping down into the vat
97
00:06:45,862 --> 00:06:49,724
And taking any contaminants
Along with it.
98
00:06:49,724 --> 00:06:52,758
The remaining solvent
Residues evaporate,
99
00:06:52,758 --> 00:06:57,551
Leaving the parts
Squeaky-clean and dry.
100
00:06:57,551 --> 00:07:00,241
Next, a worker
Wearing protective clothing
101
00:07:00,241 --> 00:07:03,551
Sandblasts the parts
With aluminum oxide powder,
102
00:07:03,551 --> 00:07:05,172
A strong abrasive.
103
00:07:05,172 --> 00:07:07,206
This roughens up the surface
104
00:07:07,206 --> 00:07:10,068
So that the plating metal
Will adhere better.
105
00:07:15,793 --> 00:07:18,206
The most common plating metals
For industrial purposes
106
00:07:18,206 --> 00:07:21,517
Are zinc, chrome, and nickel.
107
00:07:21,517 --> 00:07:24,310
Think motorcycle parts
Or sink faucets.
108
00:07:24,310 --> 00:07:26,896
Decorative items,
On the other hand,
109
00:07:26,896 --> 00:07:31,620
Are most likely to be plated
In tin, brass, gold, or silver.
110
00:07:31,620 --> 00:07:33,965
Traditional tea sets,
For instance,
111
00:07:33,965 --> 00:07:37,172
Are often made of silver-plated
Copper or zinc.
112
00:07:41,103 --> 00:07:43,655
The plating process
Is called electroplating
113
00:07:43,655 --> 00:07:46,862
Because the key is electricity.
114
00:07:46,862 --> 00:07:49,620
They start by tying strands
Of copper wire
115
00:07:49,620 --> 00:07:51,758
To a copper support frame.
116
00:07:51,758 --> 00:07:57,068
Copper is the best metal
For conducting electricity.
117
00:07:57,068 --> 00:08:01,172
Then they attach the steel parts
They'll be plating.
118
00:08:05,206 --> 00:08:08,517
When they hook up the support
To an electric current,
119
00:08:08,517 --> 00:08:12,241
Electricity will run from
The support through these wires
120
00:08:12,241 --> 00:08:14,931
Right to the pieces.
121
00:08:30,034 --> 00:08:32,448
They do the electroplating
In a tank.
122
00:08:32,448 --> 00:08:35,344
After filling it with water,
123
00:08:35,344 --> 00:08:38,758
They add a handful of chemicals
To help conduct electricity,
124
00:08:38,758 --> 00:08:42,551
Because water alone
Won't conduct it sufficiently.
125
00:08:42,551 --> 00:08:46,275
Along the sides of the tank,
In bags, are metal baskets.
126
00:08:46,275 --> 00:08:49,448
They contain bars or balls
Of the plating metal --
127
00:08:49,448 --> 00:08:52,620
In this case, cadmium.
128
00:08:52,620 --> 00:08:55,965
Workers connect the support
Frame with the steel parts
129
00:08:55,965 --> 00:08:58,862
To the negative terminal
Of an electric source --
130
00:08:58,862 --> 00:09:02,379
The baskets of cadmium
To the positive terminal.
131
00:09:02,379 --> 00:09:04,931
Then, they switch on
A steady d.C. Current
132
00:09:04,931 --> 00:09:07,793
No stronger than six volts.
133
00:09:07,793 --> 00:09:10,620
The electricity dissolves
The cadmium,
134
00:09:10,620 --> 00:09:13,655
Placing the particles
With a positive charge.
135
00:09:13,655 --> 00:09:15,655
They travel through the water
136
00:09:15,655 --> 00:09:19,034
And attach themselves to the
Negative-charged steel parts.
137
00:09:19,034 --> 00:09:22,827
This creates a smooth and even
Layer of cadmium.
138
00:09:22,827 --> 00:09:26,034
Thin plating requires
Just a few minutes in the tank.
139
00:09:26,034 --> 00:09:28,862
Thick plating, several hours.
140
00:09:28,862 --> 00:09:32,206
Then workers rinse the parts
In water for about a minute
141
00:09:32,206 --> 00:09:35,586
To remove the chemical residues.
142
00:09:35,586 --> 00:09:38,482
To make the parts
Even more rust-resistant,
143
00:09:38,482 --> 00:09:41,586
Workers immerse them
In a series of compounds.
144
00:09:41,586 --> 00:09:44,517
This triggers a chemical
Reaction in the plating,
145
00:09:44,517 --> 00:09:47,862
Enhancing its ability
To withstand corrosion.
146
00:09:47,862 --> 00:09:52,103
This reaction, however,
Changes the color.
147
00:09:52,103 --> 00:09:55,000
A final rinse in hot water,
148
00:09:55,000 --> 00:09:59,413
And this cadmium-plated steel
Aerospace part is finally ready.
149
00:09:59,413 --> 00:10:01,310
From start to finish,
150
00:10:01,310 --> 00:10:04,551
The process has taken
About 90 minutes.
151
00:10:07,103 --> 00:10:08,827
To plate with chrome or gold,
152
00:10:08,827 --> 00:10:11,034
They have to use
A chemical compound
153
00:10:11,034 --> 00:10:13,068
Containing gold or chromium.
154
00:10:13,068 --> 00:10:15,862
That's because electricity
Can't dissolve
155
00:10:15,862 --> 00:10:18,000
Solid chromium well enough,
156
00:10:18,000 --> 00:10:20,931
And it can't dissolve solid gold
At all.
157
00:10:20,931 --> 00:10:23,689
The compound dissolves
In the bath like salt,
158
00:10:23,689 --> 00:10:25,413
But then solidifies
159
00:10:25,413 --> 00:10:28,896
Once it reaches
The object being plated.
160
00:10:28,896 --> 00:10:31,724
Metal plating is very durable,
161
00:10:31,724 --> 00:10:34,482
But if subjected
To a lot of wear and tear,
162
00:10:34,482 --> 00:10:38,551
The object will eventually
Have to be replated.
163
00:10:46,896 --> 00:10:49,172
Narrator: have you ever wondered
Why men's buttons
164
00:10:49,172 --> 00:10:51,310
Are traditionally
On the right side of a garment
165
00:10:51,310 --> 00:10:52,862
And women's on the left?
166
00:10:52,862 --> 00:10:55,241
Legend has it
That this enabled a man
167
00:10:55,241 --> 00:10:57,689
To unbutton his coat
With his left hand
168
00:10:57,689 --> 00:10:59,758
While drawing a sword
With his right.
169
00:10:59,758 --> 00:11:01,206
Wealthy women, meanwhile,
170
00:11:01,206 --> 00:11:03,241
Had their buttons
Sewn on the left side
171
00:11:03,241 --> 00:11:05,482
To make it easier
For their right-handed maids
172
00:11:05,482 --> 00:11:07,000
To dress them.
173
00:11:09,241 --> 00:11:11,275
One way to make plastic buttons
174
00:11:11,275 --> 00:11:15,068
Uses a multilayer sheet
Of synthetic resin --
175
00:11:15,068 --> 00:11:18,137
Hence the industry term,
Sheet buttons.
176
00:11:18,137 --> 00:11:21,344
Workers start by mixing
Liquid polyester resin
177
00:11:21,344 --> 00:11:23,517
With a catalyst to gel it.
178
00:11:23,517 --> 00:11:26,241
They pour the material
Into a revolving drum,
179
00:11:26,241 --> 00:11:29,103
Which disperses it evenly.
180
00:11:29,103 --> 00:11:32,137
They spray a solution containing
An ultraviolet pigment
181
00:11:32,137 --> 00:11:34,413
On this first layer only.
182
00:11:34,413 --> 00:11:36,655
You'll see why later on.
183
00:11:36,655 --> 00:11:38,551
For this particular model,
184
00:11:38,551 --> 00:11:42,068
They make grooves in the resin
While it's still malleable.
185
00:11:42,068 --> 00:11:45,275
This will create a design.
186
00:11:45,275 --> 00:11:46,931
After about five minutes,
187
00:11:46,931 --> 00:11:50,275
The resin gels and they can mix
And add a second layer
188
00:11:50,275 --> 00:11:52,241
In a different color.
189
00:11:52,241 --> 00:11:55,241
Besides building up
The thickness of the sheet,
190
00:11:55,241 --> 00:11:57,862
The resin flows
Into the first layer's grooves,
191
00:11:57,862 --> 00:12:01,448
Creating a design
Of contrasting lines.
192
00:12:03,758 --> 00:12:05,586
Once this second layer gels,
193
00:12:05,586 --> 00:12:09,103
They mix and pour in
A third color.
194
00:12:09,103 --> 00:12:12,000
The drum spins
For another 10 to 15 minutes
195
00:12:12,000 --> 00:12:14,172
Until all layers cure.
196
00:12:14,172 --> 00:12:16,551
A resin sheet can be comprised
197
00:12:16,551 --> 00:12:21,206
Of up to 4 different
Color layers.
198
00:12:21,206 --> 00:12:24,172
Workers can now
Remove the sheet.
199
00:12:24,172 --> 00:12:27,310
It's hardened enough
To be cut into buttons,
200
00:12:27,310 --> 00:12:30,413
But it's still flexible enough
Not to crack when cut.
201
00:12:37,758 --> 00:12:40,310
They feed each sheet
Into a press
202
00:12:40,310 --> 00:12:41,827
That's outfitted with the die
203
00:12:41,827 --> 00:12:44,068
For that particular
Button model.
204
00:12:44,068 --> 00:12:48,137
The press punches out circles
In the diameter of the button.
205
00:12:51,793 --> 00:12:54,344
These circles are called blanks.
206
00:12:54,344 --> 00:12:57,413
Here, you can see
The different color layers.
207
00:13:00,137 --> 00:13:03,206
The blanks move on
To the machining center,
208
00:13:03,206 --> 00:13:06,000
Where they'll be transformed
Into buttons.
209
00:13:06,000 --> 00:13:08,931
Automated equipment
Loads them onto carousels
210
00:13:08,931 --> 00:13:11,517
With the back of the blank
Facing outward.
211
00:13:11,517 --> 00:13:15,241
How does the loader know
Which side is which?
212
00:13:15,241 --> 00:13:17,137
Remember
That ultraviolet solution
213
00:13:17,137 --> 00:13:20,482
The workers sprayed onto
The first layer of resin?
214
00:13:20,482 --> 00:13:23,655
A u.V. Detector scans each blank
215
00:13:23,655 --> 00:13:26,620
To make sure the first layer
Is facing upward.
216
00:13:26,620 --> 00:13:29,241
If it isn't, the machine
Rejects the blank,
217
00:13:29,241 --> 00:13:31,620
Then flips and reloads it.
218
00:13:36,758 --> 00:13:39,275
The carousels first
Run the back of the blank
219
00:13:39,275 --> 00:13:41,517
Against a series
Of cutting heads.
220
00:13:41,517 --> 00:13:44,827
The heads are changed according
To the model being produced.
221
00:13:44,827 --> 00:13:49,448
For this one, the heads
Gradually carve a curved back.
222
00:13:56,586 --> 00:14:00,689
The equipment then transfers the
Blank onto a second carousel,
223
00:14:00,689 --> 00:14:04,413
Exposing the front side
This time.
224
00:14:04,413 --> 00:14:06,689
Again, a series of cutting heads
225
00:14:06,689 --> 00:14:09,965
Gradually carve
The front of the button.
226
00:14:15,655 --> 00:14:17,965
The shape of this model
227
00:14:17,965 --> 00:14:20,724
Exposes the different
Color layers underneath,
228
00:14:20,724 --> 00:14:23,172
Creating a veined effect.
229
00:14:28,068 --> 00:14:30,620
The last cutting head
Drills the holes.
230
00:14:38,689 --> 00:14:41,068
Here, you can see
The full progression
231
00:14:41,068 --> 00:14:44,000
From blank to button.
232
00:14:44,000 --> 00:14:46,896
Now they polish the buttons
For several hours
233
00:14:46,896 --> 00:14:52,413
In drums containing abrasive
Ceramic stones and pumice.
234
00:14:52,413 --> 00:14:55,103
Then workers flush the drums
With water.
235
00:14:55,103 --> 00:14:57,793
The heavy polishing stones
Sink to the bottom
236
00:14:57,793 --> 00:14:59,689
While the lightweight buttons
237
00:14:59,689 --> 00:15:01,655
Float to the surface
And spill out.
238
00:15:03,862 --> 00:15:07,241
The buttons then go into drums
That contain silicon wax
239
00:15:07,241 --> 00:15:10,034
And thousands
Of tiny wooden pegs.
240
00:15:10,034 --> 00:15:13,586
While the drums spin,
The pegs act as a carrier,
241
00:15:13,586 --> 00:15:17,137
Distributing
An even coat of wax.
242
00:15:17,137 --> 00:15:21,413
As the buttons exit the drums,
The pegs are screened out.
243
00:15:26,413 --> 00:15:29,517
From here, plain buttons
Are often custom-dyed
244
00:15:29,517 --> 00:15:31,275
To match fabric swatches
245
00:15:31,275 --> 00:15:33,862
Provided by clothing
Manufacturers.
246
00:15:44,448 --> 00:15:46,793
Narrator: you've seen
How they manufacture
247
00:15:46,793 --> 00:15:48,689
Some types of plastic buttons,
248
00:15:48,689 --> 00:15:53,172
Just a few of the many styles
On the market.
249
00:15:53,172 --> 00:15:54,965
There are several different ways
250
00:15:54,965 --> 00:15:57,517
To produce these handy
Little fasteners.
251
00:15:57,517 --> 00:15:59,862
So, forgive us
If we buttonhole you
252
00:15:59,862 --> 00:16:02,655
To stay tuned
And watch some more.
253
00:16:10,241 --> 00:16:12,827
Archeologists
Have unearthed bone buttons
254
00:16:12,827 --> 00:16:15,448
Dating back
To prehistoric times.
255
00:16:15,448 --> 00:16:18,310
The ancient greeks and romans
Used buttons
256
00:16:18,310 --> 00:16:21,517
To fasten and decorate
Their clothing.
257
00:16:21,517 --> 00:16:24,103
Europeans wore buttons
Strictly for adornment
258
00:16:24,103 --> 00:16:26,068
Until about the 1200s.
259
00:16:26,068 --> 00:16:29,103
That's when fitted garments
Became the trend,
260
00:16:29,103 --> 00:16:32,827
Fastened by a long row
Of buttons down the front.
261
00:16:32,827 --> 00:16:35,896
The rich wore buttons
Made of silver or gold,
262
00:16:35,896 --> 00:16:39,413
Sometimes set
With precious gemstones.
263
00:16:39,413 --> 00:16:44,206
Ordinary people wore buttons
Made of bronze or wood.
264
00:16:51,068 --> 00:16:53,551
This is another way
To make plastic buttons
265
00:16:53,551 --> 00:16:56,655
Using polyester resin.
266
00:16:56,655 --> 00:16:59,655
Only instead of turning it
Into sheets,
267
00:16:59,655 --> 00:17:02,827
They pour the resin
Into long metal tubes.
268
00:17:02,827 --> 00:17:05,344
Here, they're mixing
Two different colors
269
00:17:05,344 --> 00:17:07,827
To create a design
In the plastic.
270
00:17:10,827 --> 00:17:12,448
The tubes go into an oven,
271
00:17:12,448 --> 00:17:16,034
Where they bake at 212 degrees
Fahrenheit for about an hour
272
00:17:16,034 --> 00:17:18,586
Until the liquid resin hardens.
273
00:17:18,586 --> 00:17:21,206
Once the tubes cool off,
274
00:17:21,206 --> 00:17:24,689
Workers remove the contents.
275
00:17:24,689 --> 00:17:27,137
These long resin rods
Will become
276
00:17:27,137 --> 00:17:30,000
What the industry calls
Rod buttons.
277
00:17:37,586 --> 00:17:41,517
The rods go into a machine
Called the slicer.
278
00:17:41,517 --> 00:17:44,448
Its sharp carbide blade
Chops the long rods
279
00:17:44,448 --> 00:17:47,413
Into button-sized blanks.
280
00:17:50,655 --> 00:17:54,241
Here's what that looks like
In slow motion.
281
00:17:54,241 --> 00:17:56,931
It's no use showing you this
At regular speed.
282
00:17:56,931 --> 00:17:59,827
It would be but a blur.
283
00:17:59,827 --> 00:18:03,379
This machine cuts
Up to 700 blanks per minute.
284
00:18:06,448 --> 00:18:07,965
Blanks cut from resin rods
285
00:18:07,965 --> 00:18:10,137
Run through
The same machining center
286
00:18:10,137 --> 00:18:12,965
As those cut from resin sheets.
287
00:18:12,965 --> 00:18:15,000
In the last segment,
288
00:18:15,000 --> 00:18:17,655
We showed you the machining
Steps in slow motion.
289
00:18:17,655 --> 00:18:20,862
Here's what they look like
At actual speed.
290
00:18:23,586 --> 00:18:26,137
Any type of button
Can be engraved
291
00:18:26,137 --> 00:18:27,896
With a company name or logo.
292
00:18:27,896 --> 00:18:29,413
They do this
293
00:18:29,413 --> 00:18:32,379
Using a computer-programmed
Laser machine.
294
00:18:32,379 --> 00:18:35,896
The laser beam burns
The lettering into the plastic.
295
00:18:38,620 --> 00:18:41,482
Workers visually inspect
The finished buttons
296
00:18:41,482 --> 00:18:44,620
To make sure that none
Have defects.
297
00:18:48,793 --> 00:18:51,172
A third way
To make plastic buttons
298
00:18:51,172 --> 00:18:54,172
Is a method called
Thermoset compression,
299
00:18:54,172 --> 00:18:57,206
A technique that combines
Both heat and pressure
300
00:18:57,206 --> 00:18:59,551
To mold the button's shape.
301
00:19:01,241 --> 00:19:03,586
As we see here in slow motion,
302
00:19:03,586 --> 00:19:06,586
The raw material
Isn't liquid resin,
303
00:19:06,586 --> 00:19:09,275
But rather melamine powder.
304
00:19:09,275 --> 00:19:11,000
A pill-making machine --
305
00:19:11,000 --> 00:19:13,586
The kind pharmaceutical
Companies use --
306
00:19:13,586 --> 00:19:17,379
Compresses the powder
Into pill-shaped blanks.
307
00:19:19,482 --> 00:19:21,931
Here's what that pill-making
Action looks like
308
00:19:21,931 --> 00:19:23,551
At actual speed.
309
00:19:38,068 --> 00:19:40,827
To transform these pills
Into buttons,
310
00:19:40,827 --> 00:19:43,827
Workers load them onto a press.
311
00:19:46,586 --> 00:19:48,517
The press uses high pressure
312
00:19:48,517 --> 00:19:51,172
To force each pill
Into a button mold
313
00:19:51,172 --> 00:19:53,655
For a period
Of 40 to 60 seconds,
314
00:19:53,655 --> 00:19:57,172
Depending on the size
Of the button.
315
00:19:57,172 --> 00:19:58,793
At the same time,
316
00:19:58,793 --> 00:20:03,034
It heats the mold
To 325 degrees fahrenheit.
317
00:20:03,034 --> 00:20:06,482
This bakes the melamine
Into hard plastic.
318
00:20:08,758 --> 00:20:12,448
They cool the molded buttons
In a basin of cold water.
319
00:20:12,448 --> 00:20:15,241
Some specialty buttons
Will be gold-plated,
320
00:20:15,241 --> 00:20:18,413
But not before soaking
In a chemical bath
321
00:20:18,413 --> 00:20:20,103
To clean their surface
322
00:20:20,103 --> 00:20:22,586
So that the plating
Will bond well.
323
00:20:22,586 --> 00:20:25,965
As a rule, only materials
That conduct electricity
324
00:20:25,965 --> 00:20:27,931
Can be metal-plated.
325
00:20:27,931 --> 00:20:30,724
Plastic, of course,
Is nonconductive.
326
00:20:30,724 --> 00:20:33,724
This company has managed
To devise a way
327
00:20:33,724 --> 00:20:35,689
To gold-plate plastic buttons.
328
00:20:35,689 --> 00:20:38,689
Exactly how
Is a closely guarded secret
329
00:20:38,689 --> 00:20:41,827
It's not willing to divulge.
330
00:20:41,827 --> 00:20:45,344
After plating the buttons
In copper, a 12-hour process,
331
00:20:45,344 --> 00:20:47,068
They plate them in nickel,
332
00:20:47,068 --> 00:20:49,620
Which takes
Just a couple of minutes,
333
00:20:49,620 --> 00:20:52,620
And finally, in 24-karat gold,
334
00:20:52,620 --> 00:20:56,000
Which takes just a few seconds.
335
00:20:56,000 --> 00:20:58,413
A mere one ounce of gold
336
00:20:58,413 --> 00:21:03,862
Is enough to plate
180 pounds of buttons.
337
00:21:03,862 --> 00:21:07,413
Thermoset compression buttons
Are a lower-end product
338
00:21:07,413 --> 00:21:09,965
Used primarily for uniforms.
339
00:21:09,965 --> 00:21:13,206
Sheet buttons and rod buttons
Are higher quality,
340
00:21:13,206 --> 00:21:17,413
The standard choice for everyday
And higher-end clothing.
341
00:21:22,310 --> 00:21:24,655
If you have any comments
About the show,
342
00:21:24,655 --> 00:21:27,206
Or if you'd like to suggest
Topics for future shows,
343
00:21:27,206 --> 00:21:29,068
Drop us a line at...
26932
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.