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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Inflatable safety devices...
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...Braille typewriters...
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...And carbon-fiber cellos.
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They're designed
To keep your head above water.
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Inflatable safety devices
Activate in seconds
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00:00:59,206 --> 00:01:02,344
To buoy you up and keep you
Afloat until help arrives.
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You'll find these survival
Devices on airplanes and boats.
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Even when they're not inflated,
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00:01:07,241 --> 00:01:08,724
They provide piece of mind
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00:01:08,724 --> 00:01:11,000
That you'll be safe
While on the water.
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00:01:15,379 --> 00:01:16,793
To make a life vest,
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A computer-controlled knife
Cuts a pattern
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In urethane-coated nylon.
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Heat from the blade makes
Some pieces stick together,
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So a worker peels them apart.
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The shiny side
Is the waterproof coating.
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It'll be on the inside
Of the life vest.
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They place the front of the vest
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On a vacuum table
To hold it down.
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Then they silk-screen
The amount of carbon dioxide
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Needed for inflation
Onto the fabric.
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Next, they pull
An oral inflation tube
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Through a precut hole...
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...And then place the assembly
Under a radio-frequency press.
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It emits energy that heat-seals
The tube to the fabric.
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00:02:04,931 --> 00:02:07,482
They fasten the back
And front vest pieces
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On pegs to align them.
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She slides the table
With the vest pieces
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Under a big
Radio-frequency press.
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Again, electromagnetic energy
Bonds the plastic pieces.
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This vest has been put together
Without a single stitch.
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The cylinder that contains
The carbon dioxide
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Has been installed.
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It holds about one ounce
Of the gas under pressure,
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Which will instantly inflate
The vest with one tug on a tab.
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It also activates automatically
When immersed in water.
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A little tablet inside
Dissolves,
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Triggering a spring
That punctures the cylinder.
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Pull the cord on this pack,
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And you'll have an instant
Lifeboat, complete with a roof.
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00:03:10,827 --> 00:03:13,068
To make one,
The computerized blade
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00:03:13,068 --> 00:03:15,448
Cuts shapes out
Of rubberized fabric,
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While a plastic film
Helps hold it in place.
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They brush on a rubber adhesive
To seal the boat's joints
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And press rubber tape
Over the glue.
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They remove air bubbles.
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It will take several days
For the bonding to be complete.
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They apply
The same rubber adhesive
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To all the inflation valves
And pressure tubes.
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To help activate the glue,
They wipe it with a damp rag,
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Then insert a valve
Through a hole
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In one of the raft's
Air chambers.
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They apply more glue
To the outside around the valve
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And secure it with a ring
Called a doubler.
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It really is the glue that holds
Everything together.
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They apply more rubber adhesive
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Onto the lower inflated chamber.
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Then they stretch a sheet
Of rubber flooring over it.
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They smooth down the edges,
Again, to remove air bubbles.
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They run rubberized tape
Around the rim.
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It will protect it
And also act as a hinge
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Between the floor
And the upper air chamber,
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Which will go on next.
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In preparation for that,
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They measure to align
All the inflation valves.
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Then they pull
The upper air chamber,
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The walls of the raft, on top
Of the floor and lower chamber.
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They line up the valves
But hold off on connecting them.
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Next, they pump regular air
Into the upper chamber
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To test the shape and function.
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A plastic strip has been
Keeping the glued surfaces
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From contacting.
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They pull it out and push down
To initiate contact.
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Before they pack up the raft,
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They take stock
Of the survival kit.
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There's the first-aid package...
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Miniflares...
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Food rations...
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A pocketknife...
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And bags of water.
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There are enough supplies
To keep you safe and fed
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While you wait
For help to arrive.
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Narrator: a braille typewriter
Types raised dots
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Using the braille system.
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It's based on six dots
Arranged in a rectangle,
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Three dots high
By two dots across.
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This is called the braille cell.
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Different configurations of dots
Within this cell
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Represent different letters
Of the alphabet,
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Numbers,
And punctuation marks.
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A braille typewriter
Has a spacebar in the middle
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And six keys, one for each dot
Of the braille cell.
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Pressing a key makes a pointed
Steel rod, called a stylus,
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Type a raised dot.
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To build a braillewriter,
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They first position
The six styli one by one
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In a carriage
With steel spacers in between.
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The spacers ensure
The styli move freely.
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A cover plate seals
The back of the carriage,
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And what's called a stripper
Plate closes the top.
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The plate has six holes
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In the configuration
Of the braille cell.
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When you press a key,
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The corresponding stylus
Protrudes
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And strikes the paper
Against a dot-shaped eye,
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Creating a raised dot.
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They screw the die
To the carriage top
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But don't install it
In the machine just yet.
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This is how the carriage and die
Will meet once it's in place.
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They start connecting
The components
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Which move the various styli.
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The first part
Is a steel cam rod.
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One end of it has a little
Eyelet called a lug.
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They put a pin in it,
Then slip that pin through holes
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In the prongs of a metal strip
Called a link.
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Later, they'll connect
The other end of the link
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To a lever attached to a key.
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The braillewriter's
Other components
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Are made of cast aluminum.
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The left end plate covers
The left side of the machine.
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To that, they connect
The carriage tube,
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00:08:08,586 --> 00:08:10,689
The cylinder
On which the carriage rides,
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And the feed roller,
The mechanism you turn
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To feed a sheet of paper
Into the typewriter,
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Then what they call
The rear support,
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00:08:18,551 --> 00:08:22,724
An assembly
Of cam rods and links.
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They slide the carriage
Onto the carriage tube.
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00:08:28,965 --> 00:08:31,310
Next, they install the drum.
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The feed tube transfers
The paper to the drum.
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The drum winds it
Into the machine,
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Positioning it for typing.
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Then the rack bar.
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Each tooth in it
Is the width of a braille cell,
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Ensuring the carriage advances
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The correct distance
Between letters.
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Next, they install
The chain assembly,
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Which advances the carriage.
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They close off
The other side of the machine
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With the right end plate.
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Now they can finish the process
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Of connecting the parts
That move the styli.
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So far, each cam rod
Connects to a link.
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00:09:12,931 --> 00:09:15,241
Now they connect each link
To a cam lever,
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Then each lever to a key.
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Here's how it all works.
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You press a key...
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It triggers the cam lever
To turn the cam rod...
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00:09:32,413 --> 00:09:34,793
And push up on the stylus.
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The stylus strikes the paper
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Against the die
Yet to be installed,
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Producing a raised dot.
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00:09:49,965 --> 00:09:52,206
There's still one more
Paper-feed component
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To install --
The pressure roller.
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00:09:54,862 --> 00:09:59,068
It holds the sheet of paper
Against the feed tube.
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00:09:59,068 --> 00:10:01,965
Now they screw the die
To the carriage top
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00:10:01,965 --> 00:10:03,827
And install that
On a support beam.
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00:10:03,827 --> 00:10:06,137
Then they position this assembly
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Over the stripper plate
At the top of the carriage.
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00:10:08,482 --> 00:10:12,241
They check and adjust
The paper hold tension.
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The back plate has slots
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For the two levers
That adjust the margins.
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The apron goes below the keys,
The front plate above them.
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00:10:25,310 --> 00:10:28,344
Then the last component,
The carriage lever.
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When you type
To the end of a line,
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You push this lever to the left
To return to the left margin.
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00:10:34,034 --> 00:10:36,310
You also push a key
On the far left
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To advance the paper
To the next line.
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Typing on a braillewriter
Is an embossing process,
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So you have to use thick paper.
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You push single keys
And combinations of keys
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00:10:49,827 --> 00:10:52,241
To produce different
Configurations of dots,
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Each signifying different
Letters of the alphabet.
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Narrator: this cello is
Made of carbon fibers
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Instead of traditional wood.
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Enthusiasts believe
This newer carbon version
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Has a more powerful sound
Than the wooden instrument.
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00:11:17,172 --> 00:11:19,344
It still has
That characteristic sweetness,
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00:11:19,344 --> 00:11:22,000
But it's more likely to be heard
In the orchestral din.
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And, after all, every musician
Wants to be heard.
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The carbon cello was the idea
Of a boston symphony cellist
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Who noticed waves
Resonate loudly
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00:11:48,413 --> 00:11:50,241
Against carbon-fiber boats.
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They cut the top piece
Of the cello out of fabric
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00:11:52,448 --> 00:11:54,896
That's woven
With carbon strands.
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00:11:54,896 --> 00:11:57,068
This material is
Stronger than steel,
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00:11:57,068 --> 00:11:59,862
Yet electric shears
Easily cut through it.
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00:12:03,620 --> 00:12:06,620
A worker cuts out
Numerous top cello pieces
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00:12:06,620 --> 00:12:08,172
And then sets them aside
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00:12:08,172 --> 00:12:11,931
While he works on another
Section of the instrument.
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He brushes special resin
Onto a fiberglass mold
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00:12:15,620 --> 00:12:18,000
Of the cello's
Back, ribs, and neck.
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00:12:18,000 --> 00:12:19,310
The mold has been prewaxed
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00:12:19,310 --> 00:12:22,103
To keep the resin
From sticking to it.
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00:12:27,896 --> 00:12:29,793
The idea is to saturate
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00:12:29,793 --> 00:12:32,241
This big piece of carbon fabric
With the resin
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00:12:32,241 --> 00:12:34,965
As he tucks it
Into the curves of the mold.
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00:12:36,931 --> 00:12:39,551
He smoothes it down
To get rid of any bubbles
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00:12:39,551 --> 00:12:42,517
That could affect
The cello's tone.
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00:12:45,689 --> 00:12:49,275
He brushes more resin onto
The other side of the fabric,
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00:12:49,275 --> 00:12:51,793
Making sure
It gets into all the crevices.
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00:12:56,551 --> 00:12:58,655
He sponges away any surplus
205
00:12:58,655 --> 00:13:01,724
And then layers
More fabric and resin
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00:13:01,724 --> 00:13:04,620
As he builds a laminated
Carbon-fiber shape.
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00:13:07,379 --> 00:13:10,379
He covers the layers
With nylon-like material
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00:13:10,379 --> 00:13:13,206
And trims the edges
Of the carbon fabric.
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00:13:13,206 --> 00:13:16,793
Next, he places
Perforated plastic on the nylon
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00:13:16,793 --> 00:13:20,137
And piles absorbent batting
On top of that.
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00:13:20,137 --> 00:13:21,965
He installs a vacuum pump
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00:13:21,965 --> 00:13:25,689
And drapes a big plastic vacuum
Bag over everything...
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00:13:30,206 --> 00:13:34,068
...Then activates the vacuum.
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00:13:34,068 --> 00:13:38,379
It sucks out the air
And any excess resin.
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00:13:38,379 --> 00:13:41,103
The perforated plastic
Controls the amount,
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00:13:41,103 --> 00:13:42,862
And the batting absorbs it.
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00:13:46,517 --> 00:13:48,137
While it's still under vacuum,
218
00:13:48,137 --> 00:13:50,172
They put the whole thing
In an oven
219
00:13:50,172 --> 00:13:52,482
To bake the carbon-fiber
Layers together.
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00:13:54,758 --> 00:13:57,241
After they peel away
The batting and plastic,
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00:13:57,241 --> 00:13:58,896
It comes out looking like this.
222
00:13:58,896 --> 00:14:00,896
The plies have fused together,
223
00:14:00,896 --> 00:14:02,965
And the shell has
A sleek look to it.
224
00:14:12,482 --> 00:14:15,172
They laminate the cello's
Top piece in a mold
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00:14:15,172 --> 00:14:17,275
And bake it
Until it's also hard.
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00:14:19,931 --> 00:14:22,724
Using a band saw,
They trim off the ragged edges
227
00:14:22,724 --> 00:14:24,862
And sand them
For a smooth finish.
228
00:14:32,448 --> 00:14:34,793
Now they clamp
The cello top piece
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00:14:34,793 --> 00:14:37,689
Onto a fixture that has
Stencils on the back.
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00:14:39,448 --> 00:14:42,793
With a router,
They cut out the stencil shape.
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00:14:42,793 --> 00:14:44,620
The sound
Will eventually emanate
232
00:14:44,620 --> 00:14:46,517
From these f-holes,
As they're called.
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00:14:52,655 --> 00:14:54,793
They attach
The company's label with glue
234
00:14:54,793 --> 00:14:57,655
To the inside of the cello's
Back section.
235
00:15:05,827 --> 00:15:09,206
Then they glue around
The top inner rim of the cello.
236
00:15:14,413 --> 00:15:17,758
They tape the back tightly
In place while it hardens.
237
00:15:26,689 --> 00:15:29,655
Next, they glue
The laminated carbon fingerboard
238
00:15:29,655 --> 00:15:31,793
To the neck of the cello.
239
00:15:42,172 --> 00:15:44,965
They drill holes into the pegbox
240
00:15:44,965 --> 00:15:48,034
And insert the pegs which are
Used to tighten the strings.
241
00:15:51,137 --> 00:15:54,310
Soon, this cello will be
More than just a shell.
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00:15:54,310 --> 00:15:57,000
Coming up, we reveal
Its inner workings.
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00:16:14,517 --> 00:16:17,241
Narrator: the story
Of this cello has many layers.
244
00:16:17,241 --> 00:16:20,068
They're all carbon,
And now the layers have hardened
245
00:16:20,068 --> 00:16:22,310
Into the shape
Of a concert instrument.
246
00:16:22,310 --> 00:16:25,137
At this point, you can't make
Music with it, though,
247
00:16:25,137 --> 00:16:28,034
Because they have yet to
Construct the inner workings,
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00:16:28,034 --> 00:16:30,379
A process that is
Another demonstration
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Of fine craftsmanship.
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The cello frames
Need a bit of bodywork.
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They rough them up
With sandpaper...
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Then spray on
A polyurethane clear coat
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To protect the surface.
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Then it's over to the string
Specialist, called a luthier.
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He sets a roughly cut wooden
Bridge on top of the cello
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And takes measure
Of the position.
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The placement of this bridge
Needs to be exact
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Because its job is
To elevate the strings
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And transfer their vibrations
To the instrument.
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If its position is a bit off,
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The cello's sound
Will also be a bit off.
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Using a grease pencil,
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He maps out the position
Of the bridge
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Between the f-holes,
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Then sets it aside.
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Now he slips the wooden sound
Post into one of the f-holes
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And wedges it between the front
And back of the cello.
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The sound post is crucial.
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It will strengthen the cello
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And couple
The strings' vibrations
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Between the front and back
Of the instrument.
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This is delicate
And highly skilled work.
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He measures to determine if
The sound post is on the mark.
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If it's off by even a fraction
Of an inch,
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He adjusts it a bit more.
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Afterwards, he double-checks
The bridge's positioning.
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Then, with a red grease pencil,
He colors over the spots
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Where the feet of the bridge
Are to sit.
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He presses the bridge's feet
Into the grease marks,
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00:18:38,137 --> 00:18:42,448
And this makes red smears
On the feet.
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00:18:42,448 --> 00:18:45,034
The smears tell him
Where to shave the wood
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So that it will fit perfectly
On the top of the cello.
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The bridge
Doesn't get glued down.
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It's held in place only by
The pressure of the strings.
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Next, he makes pencil marks
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On both tips
Of a measuring stick.
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00:19:12,413 --> 00:19:14,586
He leans the stick
Against the bridge
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00:19:14,586 --> 00:19:17,586
At the same angle as the strings
That will run over it.
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00:19:17,586 --> 00:19:19,620
He then transfers
The pencil marks
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00:19:19,620 --> 00:19:21,931
From the stick
To the top of the bridge.
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00:19:25,344 --> 00:19:29,620
He rounds off the marks by
Penciling around a template.
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00:19:29,620 --> 00:19:32,413
And then he carves the bridge
Down to size.
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00:19:36,689 --> 00:19:39,206
He planes it down
To make it thinner.
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00:19:44,310 --> 00:19:48,000
With a file, he cuts grooves
To cradle the strings.
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00:19:54,137 --> 00:19:56,896
Now he moves to the bottom
Of the instrument
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00:19:56,896 --> 00:20:00,241
And slides a spike called
An end pin into a precut hole.
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The end pin will rest
On the floor,
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Steadying the cello.
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00:20:05,586 --> 00:20:08,206
He lassos the end pin
With plastic rope,
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Which is attached
To the tailpiece,
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And he rests the tailpiece
On the belly of the cello.
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He pulls the steel strings
From the pegs
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And hooks them
Onto the tailpiece.
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Like most classical
String instruments,
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The cello has four strings.
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Now he slides the strings
Into the grooves on the bridge.
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He turns the pegs
To tighten the strings.
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The strings push down
On the bridge,
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Holding it in place.
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00:20:51,793 --> 00:20:54,000
He tunes the cello,
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And now it's ready
For a real performance.
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If you have any comments
About the show,
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00:21:20,103 --> 00:21:22,689
Or if you'd like to suggest
Topics for future shows,
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Drop us a line at...
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