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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
Despite the name "Lead,"
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The core of a pencil
Isn't actually made of lead.
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00:00:57,793 --> 00:00:59,862
It's made primarily of graphite,
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00:00:59,965 --> 00:01:03,655
A form of carbon that's very
Abundant in the earth's crust.
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00:01:03,758 --> 00:01:05,275
To produce pencil leads,
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00:01:05,379 --> 00:01:08,344
They combine graphite powder
With water and clay.
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00:01:08,448 --> 00:01:12,103
The higher the ratio of clay,
The harder the lead.
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00:01:17,586 --> 00:01:20,551
Quality graphite pencil leads
Don't break easily
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00:01:20,655 --> 00:01:23,344
And glide smoothly on the page.
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00:01:31,931 --> 00:01:35,620
Graphite is mined from both
Open-pit mines and shaft mines,
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00:01:35,724 --> 00:01:37,689
Like this one in germany.
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00:01:43,758 --> 00:01:47,862
Miners use hammer drills
To bore holes for explosives.
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00:01:52,965 --> 00:01:56,275
The chunks of ore must contain
At least 30% graphite
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00:01:56,379 --> 00:01:59,827
To make the area
Financially viable for mining.
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00:02:03,103 --> 00:02:08,137
At the surface, a crusher breaks
The ore into small pieces.
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00:02:08,241 --> 00:02:10,000
Then, adding water and oil,
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00:02:10,103 --> 00:02:12,551
They pulverize it
In a rotating mill.
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00:02:12,655 --> 00:02:15,965
This ore soup
Then flows into a system
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00:02:16,068 --> 00:02:18,620
That separates the graphite
From the impurities.
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00:02:18,724 --> 00:02:21,517
The graphite particles
Cling to the air bubbles
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00:02:21,620 --> 00:02:23,379
And float to the surface.
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00:02:23,482 --> 00:02:26,413
Skimmers send
This layer of graphite foam
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00:02:26,517 --> 00:02:28,310
Back into the mill.
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00:02:28,413 --> 00:02:33,862
5 cycles later, the graphite
Concentration is 96%.
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00:02:35,551 --> 00:02:40,103
However, it's soaking wet,
So it has to go into a dryer.
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00:02:42,517 --> 00:02:46,137
After spinning around
At 572 degrees fahrenheit
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00:02:46,241 --> 00:02:48,000
For about 30 seconds,
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00:02:48,103 --> 00:02:51,620
The graphite becomes
A completely dry, fine powder.
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00:02:54,000 --> 00:02:55,827
Mined and processed,
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00:02:55,931 --> 00:02:58,862
It's ready to be shipped
To the pencil factory.
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00:03:06,379 --> 00:03:08,068
To make pencil leads,
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00:03:08,172 --> 00:03:12,758
The factory combines graphite
Powder with clay and water.
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00:03:12,862 --> 00:03:15,068
During the 35-minute
Mixing cycle,
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00:03:15,172 --> 00:03:17,931
It's critical to control
The blending speed,
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00:03:18,034 --> 00:03:21,758
Pressure, temperature,
And moisture level.
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00:03:21,862 --> 00:03:24,896
This produces
Homogenous granules --
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00:03:25,000 --> 00:03:26,655
The key to ensuring
That all the leads
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00:03:26,758 --> 00:03:28,965
Will be uniform in quality.
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00:03:33,206 --> 00:03:35,620
The granules go into
A hydraulic press,
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00:03:35,724 --> 00:03:38,827
Which shapes them
Into a cylindrical block.
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00:03:43,586 --> 00:03:47,517
Workers then wrap the block
In film to prevent drying out
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00:03:47,620 --> 00:03:50,379
And set it aside for a week
To cure.
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00:04:00,379 --> 00:04:03,724
They load each cured block
Into a hydraulic press,
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00:04:03,827 --> 00:04:05,758
Which pushes it through
A forming die,
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00:04:05,862 --> 00:04:08,758
Producing one long,
Continuous lead.
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00:04:14,896 --> 00:04:19,275
Different dies
Give different-sized leads.
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00:04:19,379 --> 00:04:21,793
The next machine then cuts
The continuous lead
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00:04:21,896 --> 00:04:24,448
Into pencil lengths.
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00:04:27,551 --> 00:04:30,000
The leads are
The right thickness and length,
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00:04:30,103 --> 00:04:31,586
But they're soft and pliable
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Because they still contain water
From the mixing process.
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00:04:38,448 --> 00:04:40,655
Workers load the leads
Into a rotary dryer
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00:04:40,758 --> 00:04:43,551
At 320 degrees fahrenheit.
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12 hours later, the leads
Exit the dryer straight,
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00:04:48,517 --> 00:04:51,379
But not quite strong enough,
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00:04:51,482 --> 00:04:54,137
So next they go into a kiln
For 10 hours
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00:04:54,241 --> 00:04:56,620
At more than
1,800 degrees fahrenheit.
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00:04:56,724 --> 00:05:01,068
This firing transforms the clay
That's mixed with the graphite,
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00:05:01,172 --> 00:05:04,448
Strengthening the leads
To their final hardness.
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00:05:07,724 --> 00:05:13,206
Finally, a 12-hour bath in
A mixture of high-quality waxes.
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00:05:13,310 --> 00:05:15,655
The waxes fill the pores
In the leads,
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Leaving them with a surface that
Glides smoothly across paper.
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00:05:20,586 --> 00:05:22,724
Throughout
The production process,
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00:05:22,827 --> 00:05:25,896
The factory puts samples
Through quality-control testing
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00:05:26,000 --> 00:05:29,241
To check hardness,
Break resistance, diameter,
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00:05:29,344 --> 00:05:32,068
And, of course, writing quality.
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00:05:34,965 --> 00:05:37,655
This company produces
Three different qualities
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00:05:37,758 --> 00:05:42,241
Of graphite leads
In 16 different hardness levels,
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Plus a full array
Of colored leads made similarly,
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But with pigment powders
And waxes rather than graphite.
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00:06:02,586 --> 00:06:05,310
Narrator: when the clarinetist
Blows into the instrument,
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00:06:05,413 --> 00:06:09,034
A reed in the mouthpiece
Vibrates, creating sound.
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00:06:09,137 --> 00:06:11,827
To turn that basic sound
Into different notes,
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00:06:11,931 --> 00:06:14,275
The player manipulates
The length of the air column
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Inside the instrument
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By opening and closing
Different tone holes.
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00:06:28,965 --> 00:06:33,034
The standard clarinet
Has 24 tone holes.
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The musician covers
Some with his fingers,
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The rest by pressing keys.
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Those keys are made of nickel
Silver or, sometimes, brass.
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00:06:44,827 --> 00:06:49,310
They inject hot wax into a
Plaster mold of a specific key.
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Then, using hot wax,
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They attach several models
Of the same key onto a stem.
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00:07:06,206 --> 00:07:09,310
They put this tree,
As it's called, into a cylinder,
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00:07:09,413 --> 00:07:12,482
Then into a mold-making machine,
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00:07:12,586 --> 00:07:14,793
Which fills the space
Around the tree
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With a silica-based
Ceramic material.
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00:07:18,931 --> 00:07:20,310
When the ceramic hardens,
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00:07:20,413 --> 00:07:23,586
They melt out the way through
An exit hole at the bottom,
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Leaving behind
A tree-shaped cavity.
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00:07:28,172 --> 00:07:31,482
Now they transfer the mold
To a casting machine
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00:07:31,586 --> 00:07:34,586
And load nickel silver
Into a miniature furnace.
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00:07:34,689 --> 00:07:37,965
The metal melts
And fills the entire cavity.
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00:07:41,137 --> 00:07:44,000
To cool and solidify
The casting,
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They submerge the mold
In lukewarm water.
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00:07:46,862 --> 00:07:49,655
The metal contracts
As its temperature drops,
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Loosening from the mold.
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00:07:54,344 --> 00:07:57,896
They extract the tree
And remove the keys.
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00:08:00,517 --> 00:08:04,344
Then they grind off the little
Stub left on each key.
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00:08:10,172 --> 00:08:14,655
Next the keys go into a tumbler
Filled with synthetic stones.
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The stones polish the keys,
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00:08:16,931 --> 00:08:19,448
Preparing their surface
For silver plating.
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00:08:21,103 --> 00:08:23,793
Silver doesn't adhere directly
To nickel silver,
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00:08:23,896 --> 00:08:26,827
So they plate the keys
In copper first.
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00:08:26,931 --> 00:08:31,896
For each layer, they submerge
The keys in a chemical solution,
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00:08:32,000 --> 00:08:34,862
Then apply
A negative electric charge
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00:08:34,965 --> 00:08:38,517
While running a positive charge
To pieces of the plating metal.
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Like a magnet, this draws
Particles of the plating metal
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Onto the keys,
Forming a thin overall coat.
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00:08:47,724 --> 00:08:50,896
A clarinet's two-part body
Is typically made of wood
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Or, like these, plastic resin.
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00:08:53,793 --> 00:08:57,517
A computer-guided drill
Bores 24 tone holes
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And 40 smaller holes
For the posts,
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Which support
The key mechanisms.
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A sonic welding machine
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Presses each post
Into its respective hole
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00:09:08,172 --> 00:09:10,793
While zapping it with
A high-frequency sound wave
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00:09:10,896 --> 00:09:13,275
To melt the plastic
Around the base.
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00:09:13,379 --> 00:09:17,206
This anchors the post securely.
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00:09:17,310 --> 00:09:20,551
The next machine reams a hole
Through the head of each post
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00:09:20,655 --> 00:09:23,034
For the rods
That operate the keys.
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00:09:25,310 --> 00:09:28,793
They wrap natural cork around
The connecting ends of the body,
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00:09:28,896 --> 00:09:33,413
Then illuminate the interior for
A quality-control inspection.
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00:09:35,965 --> 00:09:38,758
It's time for
The final assembly.
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00:09:38,862 --> 00:09:41,448
They lubricate
All the moving parts,
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00:09:41,551 --> 00:09:45,241
Then install the 17 keys
Onto their mechanisms.
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00:09:59,586 --> 00:10:01,965
Each key has a foam pad
To prevent air
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00:10:02,068 --> 00:10:05,000
From leaking out
When the hole's covered.
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00:10:05,103 --> 00:10:06,793
They use a strip of foil
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00:10:06,896 --> 00:10:10,000
To test whether the seal
Is tight enough.
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00:10:10,103 --> 00:10:13,793
With both body sections
Of the instrument finished,
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00:10:13,896 --> 00:10:15,758
A musician assembles them
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00:10:15,862 --> 00:10:19,206
And checks that each
And every key moves fluidly.
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00:10:19,310 --> 00:10:22,965
Then, after attaching the bell
And the mouthpiece,
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00:10:23,068 --> 00:10:25,724
She conducts
A sound-quality test,
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00:10:25,827 --> 00:10:28,620
Performing a set
Of musical exercises.
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00:10:30,448 --> 00:10:33,172
The clarinet now goes
To the packing department
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00:10:33,275 --> 00:10:35,793
Where the packager
Gently removes fingerprints,
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00:10:35,896 --> 00:10:39,034
Lint, and lubricant residue,
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00:10:39,137 --> 00:10:42,344
Then lays the instrument parts
In a velvet-lined case.
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00:10:42,448 --> 00:10:45,551
It's a fitting finale
To the making of an instrument
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00:10:45,655 --> 00:10:48,275
That looks as good as it sounds.
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00:11:10,793 --> 00:11:13,068
Narrator: special effects
In animated films
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00:11:13,172 --> 00:11:15,275
Breathe life
Into characters and scenes
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00:11:15,379 --> 00:11:17,379
That are completely imaginary.
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00:11:17,482 --> 00:11:19,862
It usually takes a mix
Of different effects
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00:11:19,965 --> 00:11:22,586
To give the fantasy
A realistic texture.
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00:11:22,689 --> 00:11:26,241
From miniature-scale models
To computer-generated imagery,
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00:11:26,344 --> 00:11:29,000
It's all about the big picture.
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00:11:33,896 --> 00:11:36,310
3-d animation
And photographic tricks
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00:11:36,413 --> 00:11:41,103
Make this miniature village
Loom large on the big screen.
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00:11:41,206 --> 00:11:43,482
It all starts
At the drawing board.
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00:11:43,586 --> 00:11:46,137
An artist sketches
The various components
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00:11:46,241 --> 00:11:47,586
Of the fantasy village.
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Once he gets it down on paper,
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00:11:51,413 --> 00:11:54,896
The rest of the crew
Can build it.
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00:11:55,000 --> 00:11:57,413
Using one of the sketches
As a reference,
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00:11:57,517 --> 00:12:00,172
A sculptor carves foam
Into sections of a roof,
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00:12:00,275 --> 00:12:01,931
And he glues the pieces
Together.
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00:12:04,068 --> 00:12:07,793
This foam roof will then be used
To make a mold.
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00:12:12,310 --> 00:12:15,448
The mold maker
Builds a box around the roof,
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00:12:15,551 --> 00:12:17,931
Which is now gray-colored
Due to the application
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Of a nonstick substance.
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00:12:22,241 --> 00:12:26,482
He pours liquid silicon rubber
Onto the foam roof in the box.
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00:12:31,586 --> 00:12:34,551
After 12 hours,
They pull apart the box
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00:12:34,655 --> 00:12:37,862
And remove the foam
To reveal the mold.
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00:12:37,965 --> 00:12:41,896
This mold will be used
To cast multiple roof parts
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00:12:42,000 --> 00:12:44,172
For the mini film set.
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00:12:44,275 --> 00:12:46,931
They mix a two-part
Urethane solution
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00:12:47,034 --> 00:12:49,655
And pour it into the mold.
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00:12:52,758 --> 00:12:55,931
A chemical reaction
Causes the urethane to solidify,
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00:12:56,034 --> 00:12:58,862
And as it does,
It takes the shape of the mold
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00:12:58,965 --> 00:13:01,172
With all the details.
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00:13:06,275 --> 00:13:07,586
After half an hour,
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00:13:07,689 --> 00:13:10,758
He extracts the cured urethane
From the mold.
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00:13:10,862 --> 00:13:14,517
It's a perfect copy
Of the original roof carving.
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00:13:19,827 --> 00:13:23,068
They mold various roofs
For visual interest.
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00:13:23,172 --> 00:13:25,275
The crew then paints
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All the molded parts
Of the mini village set
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In colors that are true to life.
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00:13:30,793 --> 00:13:33,068
The palette
Has been selected beforehand,
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00:13:33,172 --> 00:13:35,413
But if it doesn't look right
To the eye,
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00:13:35,517 --> 00:13:37,620
Adjustments can be made.
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00:13:42,931 --> 00:13:45,241
For larger-scale structures,
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00:13:45,344 --> 00:13:49,344
A technician arranges reflective
Dots in a grid pattern.
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00:13:49,448 --> 00:13:53,206
These dots
Serve as reference points
189
00:13:53,310 --> 00:13:55,793
To laser-scan the image
Of the house into a computer.
190
00:14:02,517 --> 00:14:07,310
The technician transfers
The image a section at a time.
191
00:14:07,413 --> 00:14:11,620
Once the image has been loaded
Into the computer,
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00:14:11,724 --> 00:14:13,827
Animators can really play around
With it.
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00:14:13,931 --> 00:14:15,793
They can insert
Digital characters
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00:14:15,896 --> 00:14:21,551
Or impose a digital image over
A filmed one to cast a shadow.
195
00:14:22,965 --> 00:14:25,551
Meanwhile,
Another member of the crew
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00:14:25,655 --> 00:14:28,413
Plants molded trees
Onto hills of plastic
197
00:14:28,517 --> 00:14:31,620
And shapes the landscape
Of the set.
198
00:14:31,724 --> 00:14:35,517
The trees and vegetation
Are very small-scale
199
00:14:35,620 --> 00:14:38,000
Because the landscape
Will be in the background.
200
00:14:44,137 --> 00:14:47,137
In the world
Of digital animation,
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00:14:47,241 --> 00:14:49,206
Clumps of moss can mimic shrubs,
202
00:14:49,310 --> 00:14:52,620
And a hot-glue gun
Is an indispensable tool.
203
00:14:55,068 --> 00:14:57,793
Once buildings
Have been inserted in the set,
204
00:14:57,896 --> 00:15:01,172
The crew brings up the lights
And checks the effect.
205
00:15:01,275 --> 00:15:04,310
They add props,
And, sometimes, take others away
206
00:15:04,413 --> 00:15:07,310
To improve the look
Of each scene.
207
00:15:10,241 --> 00:15:12,068
Technicians tweak the lighting,
208
00:15:12,172 --> 00:15:15,482
Which can add visual depth
And credibility to any scene,
209
00:15:15,586 --> 00:15:19,000
But it's even more critical
With a small-scale vista.
210
00:15:21,482 --> 00:15:24,758
Little rectangular mirrors
Attached to the lights
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00:15:24,862 --> 00:15:27,482
Allow for minute adjustments.
212
00:15:30,275 --> 00:15:34,000
The director of photography
Operates the camera remotely.
213
00:15:34,103 --> 00:15:37,137
Adjustments to the shot's frame
Or depth of field
214
00:15:37,241 --> 00:15:40,862
Can trick the eye and make
Miniatures seem much larger.
215
00:15:40,965 --> 00:15:44,758
The computer
Records the camera movements
216
00:15:44,862 --> 00:15:48,034
So they can be repeated
At any time.
217
00:15:52,931 --> 00:15:57,379
Later, water will be digitally
Added to this riverbed.
218
00:15:58,448 --> 00:16:01,965
Coming up next, animated
Characters enter the scene
219
00:16:02,068 --> 00:16:05,413
With the help
Of computer-generated tricks.
220
00:16:18,931 --> 00:16:22,655
Narrator: today, virtual beings
Are a hollywood phenomenon.
221
00:16:22,758 --> 00:16:25,793
Computer effects have rocketed
3-d animated characters
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00:16:25,896 --> 00:16:27,310
Into superstardom,
223
00:16:27,413 --> 00:16:30,931
But even for digital creatures,
Fame doesn't come easy.
224
00:16:31,034 --> 00:16:32,241
It takes years of work
225
00:16:32,344 --> 00:16:34,655
And a large crew
Of skilled professionals
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00:16:34,758 --> 00:16:37,620
To make them look good
On the big screen.
227
00:16:41,172 --> 00:16:45,137
It all starts with a good,
Old-fashioned sketch pad.
228
00:16:45,241 --> 00:16:48,068
Once the character
Is defined on paper,
229
00:16:48,172 --> 00:16:50,862
The artist sculpts him
With clay.
230
00:16:58,068 --> 00:17:00,793
Then the high-tech wizardry
Begins
231
00:17:00,896 --> 00:17:04,482
As they laser-scan the
3-d character from all angles
232
00:17:04,586 --> 00:17:06,793
And load the image
Into the computer.
233
00:17:09,482 --> 00:17:10,586
Once he's been captured,
234
00:17:10,689 --> 00:17:12,517
The computer artist
Wraps the character
235
00:17:12,620 --> 00:17:15,000
In a digital wire frame.
236
00:17:15,103 --> 00:17:17,413
He manipulates the wire mesh
237
00:17:17,517 --> 00:17:20,310
To make the character move
And breathe.
238
00:17:21,551 --> 00:17:24,793
After he creates a dozen or more
Facial expressions,
239
00:17:24,896 --> 00:17:28,275
This machine makes hard copies
Of those many faces.
240
00:17:28,379 --> 00:17:31,620
It repeatedly deposits
Layers of plastic
241
00:17:31,724 --> 00:17:34,931
To build up a physical version
Of the image.
242
00:17:41,689 --> 00:17:43,896
They insert eyes in the sockets,
243
00:17:44,000 --> 00:17:47,793
Then give these washed-out
Plastic faces some color.
244
00:17:51,206 --> 00:17:55,137
An artist paints each one of
The faces along the same lines.
245
00:17:55,241 --> 00:17:58,379
Continuity is critical
246
00:17:58,482 --> 00:18:02,034
Because the faces will be filmed
And the images edited together
247
00:18:02,137 --> 00:18:04,517
To create
The illusion of movement.
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It's a traditional animation
Technique called stop-motion,
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And these plastic models
Are called puppets.
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Next a seamstress
Builds a suit of clothes
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For one of the puppets.
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00:18:22,517 --> 00:18:24,206
He has to look great
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00:18:24,310 --> 00:18:27,172
Because he'll be used to promote
The character to merchandisers
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00:18:27,275 --> 00:18:29,965
Who might market him as a toy.
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00:18:33,172 --> 00:18:36,137
They scan the fabric and wrap it
Around the digital character
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00:18:36,241 --> 00:18:38,896
To give him the same outfit,
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00:18:39,000 --> 00:18:42,517
Then add creases
For a more realistic texture.
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00:18:45,620 --> 00:18:46,793
The crew lights the mini set
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00:18:46,896 --> 00:18:49,586
For one of the character's
Big scenes
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00:18:49,689 --> 00:18:51,586
And plans the camera moves.
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00:18:51,689 --> 00:18:54,103
It's a kind of dress rehearsal.
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00:18:56,172 --> 00:18:58,000
One of the puppets acts
As a stand-in
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00:18:58,103 --> 00:19:01,655
For the animated character.
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00:19:03,758 --> 00:19:07,206
They move him around in a
Process called rough placement.
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00:19:07,310 --> 00:19:08,551
It's a critical step
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00:19:08,655 --> 00:19:11,241
Which ensures that everyone
Is in sync --
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00:19:11,344 --> 00:19:15,896
Cinematographers,
Lighting artists, and animators.
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00:19:19,827 --> 00:19:21,413
Seeing the puppet in the room
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00:19:21,517 --> 00:19:24,275
Will help animators
Place his digital counterpart
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00:19:24,379 --> 00:19:27,758
In the various visuals.
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00:19:27,862 --> 00:19:29,586
They literally cover
All the angles
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00:19:29,689 --> 00:19:31,827
And leave nothing to chance.
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00:19:35,931 --> 00:19:39,068
Now the physical merges
With the virtual
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00:19:39,172 --> 00:19:42,103
In a special-effects trick
Called human motion capture.
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00:19:42,206 --> 00:19:45,655
A man walks around
In a special suit
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00:19:45,758 --> 00:19:48,689
Covered with reflective dots.
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00:19:48,793 --> 00:19:52,724
The computer recognizes the dots
To transfer the man's movements
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00:19:52,827 --> 00:19:56,517
To a version of the digital
Character instantaneously.
279
00:20:03,517 --> 00:20:06,103
The computer artist
Uses those captured movements
280
00:20:06,206 --> 00:20:10,172
To manipulate the character
And insert him into the scene.
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00:20:10,275 --> 00:20:12,931
The effect is one
Of a digital character
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00:20:13,034 --> 00:20:16,137
Who moves
Just like a human being.
283
00:20:18,448 --> 00:20:21,137
They layer digitized images
Of the set
284
00:20:21,241 --> 00:20:25,517
And blend them seamlessly
Into a single image.
285
00:20:25,620 --> 00:20:28,241
This digital layering
Is called compositing.
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00:20:28,344 --> 00:20:29,517
It allows animators
287
00:20:29,620 --> 00:20:32,793
To accurately place
The character in the scene.
288
00:20:40,413 --> 00:20:42,862
The blend
Of high-tech special effects
289
00:20:42,965 --> 00:20:45,379
With traditional
Animation techniques
290
00:20:45,482 --> 00:20:48,413
Gives the best of both worlds.
291
00:20:48,517 --> 00:20:52,034
Combined, all these
Special-effects tricks
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00:20:52,137 --> 00:20:56,724
Can generate 3-d characters
With star quality.
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00:20:56,827 --> 00:20:58,517
They are virtual puppets,
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00:20:58,620 --> 00:21:01,137
And the animators
Are the puppeteers.
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00:21:01,241 --> 00:21:02,965
And on the big screen,
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00:21:03,068 --> 00:21:06,310
The fantasy
Has never looked so real.
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00:21:23,655 --> 00:21:25,689
If you have any comments
About the show,
298
00:21:25,793 --> 00:21:28,620
Or if you'd like to suggest
Topics for future shows,
299
00:21:28,724 --> 00:21:31,068
Drop us a line at...
24411
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