All language subtitles for S05E12 - Kitchen Knives; Mannequins; Socks; Hypodermic Needles (576p AMZN WEB-DL x265 Garshasp)_track4_[eng]

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Narrator: 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.

Narrator: 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.

Narrator: 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.

Narrator: 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?

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