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Narrator:
The origin of facial tissue
May be japanese.
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00:00:56,413 --> 00:00:59,689
A 17th-century historical
Account describes japanese
3
00:00:59,689 --> 00:01:02,448
Blowing their noses
In small, soft papers,
4
00:01:02,448 --> 00:01:04,689
Then throwing them
On the ground.
5
00:01:04,689 --> 00:01:08,241
Modern-day tissues were first
Marketed in the early 1920s
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00:01:08,241 --> 00:01:11,931
As a disposable cloth
For wiping off cold cream.
7
00:01:14,551 --> 00:01:18,206
While some sneezers still prefer
Traditional cloth handkerchiefs,
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00:01:18,206 --> 00:01:21,034
The disposable paper tissue
Is the implement of choice
9
00:01:21,034 --> 00:01:24,413
With the sniffling
And lens-cleaning masses.
10
00:01:24,413 --> 00:01:27,482
This brand is made
Entirely of recycled paper --
11
00:01:27,482 --> 00:01:30,206
Specifically,
Used computer-printer paper
12
00:01:30,206 --> 00:01:34,896
Because its short, flexible
Fibers produce soft tissue.
13
00:01:34,896 --> 00:01:38,689
The ½-ton bales go into a giant
Machine called the pulper.
14
00:01:38,689 --> 00:01:41,068
It breaks up
The paper into fibers
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00:01:41,068 --> 00:01:42,793
And mixes them with water.
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00:01:42,793 --> 00:01:44,551
The result is called pulp.
17
00:01:44,551 --> 00:01:46,965
Next, it injects the pulp
With air.
18
00:01:46,965 --> 00:01:49,827
This causes the ink
To detach from the fibers
19
00:01:49,827 --> 00:01:51,724
And cling to the air bubbles,
20
00:01:51,724 --> 00:01:54,172
Which rise to the top
And drain off.
21
00:01:54,172 --> 00:01:56,793
The machine then feeds
The now-ink-free pulp
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00:01:56,793 --> 00:01:58,275
Through several rollers.
23
00:01:58,275 --> 00:02:00,517
Like an old-fashioned
Ringer washing machine,
24
00:02:00,517 --> 00:02:03,620
The rollers squeeze out
The dirty water.
25
00:02:03,620 --> 00:02:05,965
A screw conveyor
Then breaks up the pulp
26
00:02:05,965 --> 00:02:07,931
And moves it
To the next station,
27
00:02:07,931 --> 00:02:10,275
Which rinses it
With clean water.
28
00:02:10,275 --> 00:02:13,137
Now the pulp is ready
To become tissue.
29
00:02:13,137 --> 00:02:16,517
That transformation begins
In the paper machine.
30
00:02:16,517 --> 00:02:20,206
It injects the pulp evenly
Across the screen conveyor belt.
31
00:02:20,206 --> 00:02:22,517
Then the pulp passes
Through rollers
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00:02:22,517 --> 00:02:24,310
That press out the water.
33
00:02:24,310 --> 00:02:27,275
The extracted water drains
Down through the screen.
34
00:02:27,275 --> 00:02:29,931
The pulp then passes
Through a hot-air dryer
35
00:02:29,931 --> 00:02:34,517
And exits the machine as a thin,
10-foot-wide sheet of paper.
36
00:02:34,517 --> 00:02:36,827
Each jumbo roll
Coming off the machine
37
00:02:36,827 --> 00:02:40,275
Contains
About 37 miles of paper.
38
00:02:43,655 --> 00:02:46,068
The converting machine
Is the giant contraption
39
00:02:46,068 --> 00:02:49,689
That now transforms
This paper into tissues.
40
00:02:49,689 --> 00:02:52,620
The first station unwinds
Two rolls of paper,
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00:02:52,620 --> 00:02:56,034
Applying modest tension
To remove waves and wrinkles.
42
00:02:56,034 --> 00:02:58,586
The next station mates
The two papers,
43
00:02:58,586 --> 00:03:01,862
Producing a two-ply sheet.
44
00:03:01,862 --> 00:03:06,137
The following station holds
The sheets steady with suction
45
00:03:06,137 --> 00:03:10,034
As a knife slices across it
Every 8½ inches.
46
00:03:10,034 --> 00:03:14,551
You can see the cuts
In slow motion.
47
00:03:14,551 --> 00:03:17,379
At the next station,
These two-ply sheets meet up
48
00:03:17,379 --> 00:03:20,482
With two-ply sheets coming
From the opposite direction.
49
00:03:20,482 --> 00:03:24,172
Here's what that looks like
In slow motion....
50
00:03:24,172 --> 00:03:28,344
And at full speed.
51
00:03:28,344 --> 00:03:31,655
The sheets enter a mechanism
That folds them in half
52
00:03:31,655 --> 00:03:33,379
In an interlocking fashion.
53
00:03:33,379 --> 00:03:36,517
In slow motion, you can see
How they interlock --
54
00:03:36,517 --> 00:03:39,068
Each sheet folded in half,
55
00:03:39,068 --> 00:03:42,758
One side inserted
Into the fold of the next sheet.
56
00:03:45,517 --> 00:03:51,551
This happens at a speed
Of 16 folds per second.
57
00:03:51,551 --> 00:03:56,827
This produces a huge stack
Of folded tissue 5 feet wide.
58
00:04:01,344 --> 00:04:05,172
The next station separates
The big stack into small ones
59
00:04:05,172 --> 00:04:07,827
In preparation
For the final cutting.
60
00:04:07,827 --> 00:04:09,517
Each smaller stack contains
61
00:04:09,517 --> 00:04:13,034
The precise number of tissues
The tissue box will contain,
62
00:04:13,034 --> 00:04:18,724
From 80 to 250 sheets, depending
On the format they're packaging.
63
00:04:26,448 --> 00:04:29,448
The smaller stacks now travel
To the next station,
64
00:04:29,448 --> 00:04:32,551
Where an automated circular saw
Cuts every 8 inches,
65
00:04:32,551 --> 00:04:34,758
Producing the final tissue size.
66
00:04:42,620 --> 00:04:44,241
The interlocking folds ensure
67
00:04:44,241 --> 00:04:46,275
That when you pull out
One tissue,
68
00:04:46,275 --> 00:04:49,965
It draws the next
Out of the box, ready to use.
69
00:04:49,965 --> 00:04:51,896
To produce three-ply tissues,
70
00:04:51,896 --> 00:04:54,344
The converting machine
Processes six rolls
71
00:04:54,344 --> 00:04:56,482
Into two sheets
Of three plies each,
72
00:04:56,482 --> 00:04:59,241
Then folds them in the same
Interlocking fashion.
73
00:05:04,551 --> 00:05:07,206
The finished tissues travel
By conveyor belt
74
00:05:07,206 --> 00:05:09,931
To the automated packaging line.
75
00:05:16,482 --> 00:05:19,241
A robot with multiple
Suction-cupped arms
76
00:05:19,241 --> 00:05:23,275
Grabs flattened boxes
One at a time, opens them,
77
00:05:23,275 --> 00:05:25,241
And lines them up
On another conveyor belt
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00:05:25,241 --> 00:05:28,413
Running alongside
The tissue belt.
79
00:05:28,413 --> 00:05:31,793
An automated arm
Compresses the tissues
80
00:05:31,793 --> 00:05:34,965
And slides them into the box.
81
00:05:34,965 --> 00:05:38,896
The next station glues
The flaps closed.
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00:05:38,896 --> 00:05:41,827
The top of the box
Has a removable tab
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00:05:41,827 --> 00:05:44,448
With clear plastic film
Underneath.
84
00:05:44,448 --> 00:05:45,965
A tight slot in the film
85
00:05:45,965 --> 00:05:50,241
Makes grabbing a single tissue
A nonissue.
86
00:06:01,137 --> 00:06:03,310
Narrator:
Hitching a travel trailer
To your vehicle
87
00:06:03,310 --> 00:06:06,517
Is the ideal solution
If you yearn to travel freely
88
00:06:06,517 --> 00:06:08,379
With all
The conveniences of home
89
00:06:08,379 --> 00:06:09,586
Or love camping
90
00:06:09,586 --> 00:06:12,344
But want far more comfort
Than a tent has to offer.
91
00:06:12,344 --> 00:06:14,034
Today's trailers come equipped
92
00:06:14,034 --> 00:06:19,586
With beds, mini kitchen,
Dinette, toilet, and shower.
93
00:06:22,275 --> 00:06:24,137
This 16-foot-long travel trailer
94
00:06:24,137 --> 00:06:26,862
Is made of aluminum
And composite materials.
95
00:06:26,862 --> 00:06:29,275
Unlike traditional
Fiberglass trailers,
96
00:06:29,275 --> 00:06:31,896
There's no steel or wood
In the structure,
97
00:06:31,896 --> 00:06:36,000
So it's resistant
To both rock and corrosion.
98
00:06:36,000 --> 00:06:40,000
It's ultra lightweight and has
A pop-up roof with windows.
99
00:06:40,000 --> 00:06:43,931
The trailer's a-shaped chassis
Is made entirely of aluminum.
100
00:06:43,931 --> 00:06:46,103
The only steel components
Are the tongue
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00:06:46,103 --> 00:06:48,551
That attaches the trailer
To the vehicle's hitch
102
00:06:48,551 --> 00:06:50,068
And the axle.
103
00:06:50,068 --> 00:06:53,551
Workers insulate both
With duct tape.
104
00:06:53,551 --> 00:06:57,275
They bolt the axle, with brakes
Installed, to the chassis,
105
00:06:57,275 --> 00:07:00,448
Then line the chassis
With styrofoam insulation.
106
00:07:00,448 --> 00:07:04,068
This prevents the copper propane
Line from touching the aluminum.
107
00:07:04,068 --> 00:07:07,241
Contact between the two metals
Can trigger corrosion.
108
00:07:07,241 --> 00:07:08,551
Next, they mount
109
00:07:08,551 --> 00:07:11,793
The trailer's plastic freshwater
And waste-water tanks,
110
00:07:11,793 --> 00:07:14,586
Then glue the aluminum floor
To the chassis.
111
00:07:14,586 --> 00:07:17,241
Other workers construct
The trailer's two side walls
112
00:07:17,241 --> 00:07:18,758
As a single piece.
113
00:07:18,758 --> 00:07:20,379
On a large vacuum press,
114
00:07:20,379 --> 00:07:23,103
They spread glue
Onto an aluminum sheet.
115
00:07:23,103 --> 00:07:25,586
Then they lay down
The wall's core,
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00:07:25,586 --> 00:07:29,103
A honeycomb-shaped sheet
Of polypropylene.
117
00:07:33,379 --> 00:07:37,310
They coat it with glue,
118
00:07:37,310 --> 00:07:39,103
Then top it
With another sheet of aluminum.
119
00:07:43,379 --> 00:07:45,827
The honeycomb core makes
The wall rigid
120
00:07:45,827 --> 00:07:47,758
While adding minimal weight.
121
00:07:47,758 --> 00:07:51,482
They cover this sandwich
With a protective fabric sheet,
122
00:07:51,482 --> 00:07:54,241
Then with an airtight cover.
123
00:07:54,241 --> 00:07:56,068
After sealing the perimeter,
124
00:07:56,068 --> 00:07:59,689
They vacuum out the air
For about four hours.
125
00:07:59,689 --> 00:08:02,827
This pulls everything tight,
Compressing the glued layers
126
00:08:02,827 --> 00:08:06,000
So that they fully adhere
To each other.
127
00:08:10,413 --> 00:08:12,344
When the wall comes
Out of the press,
128
00:08:12,344 --> 00:08:13,965
They lay down templates
129
00:08:13,965 --> 00:08:18,206
And, with a router,
Cut it into two side walls.
130
00:08:18,206 --> 00:08:20,724
They also make openings
For windows...
131
00:08:27,172 --> 00:08:30,000
...And holes for trailer lights.
132
00:08:35,241 --> 00:08:37,965
After inserting a rubber seal
In each hole,
133
00:08:37,965 --> 00:08:40,103
They install the lights.
134
00:08:42,413 --> 00:08:46,000
Next, a porthole-style
Tinted upper window.
135
00:08:46,000 --> 00:08:47,586
They glue it
Into the round opening
136
00:08:47,586 --> 00:08:50,310
Just like a car windshield.
137
00:08:50,310 --> 00:08:52,517
The side walls are now ready.
138
00:08:52,517 --> 00:08:54,689
Workers affix them to the floor
139
00:08:54,689 --> 00:08:57,000
With an l-shaped
Aluminum bracket.
140
00:09:05,344 --> 00:09:09,206
Once the walls are up,
Workers saw out a door opening,
141
00:09:09,206 --> 00:09:13,103
Then install the door,
Sliding windows, toilet cabinet,
142
00:09:13,103 --> 00:09:16,448
King-size bed, dining table,
And kitchen unit,
143
00:09:16,448 --> 00:09:21,310
Which has
A sink and propane stove.
144
00:09:21,310 --> 00:09:23,344
They install
A rubber-sealed trapdoor
145
00:09:23,344 --> 00:09:25,172
Into an opening in one wall.
146
00:09:25,172 --> 00:09:28,068
This gives outside access
To a storage area
147
00:09:28,068 --> 00:09:31,758
About the size
Of a large suitcase.
148
00:09:31,758 --> 00:09:33,034
Upholstered cushions hide
149
00:09:33,034 --> 00:09:34,896
Under-the-seat
Storage compartments
150
00:09:34,896 --> 00:09:37,379
In the dining area.
151
00:09:37,379 --> 00:09:40,379
They construct the roof
The same way as the walls,
152
00:09:40,379 --> 00:09:42,827
Only in a teardrop-shaped
Vacuum press.
153
00:09:42,827 --> 00:09:47,034
This aerodynamic shape creates
75% less drag
154
00:09:47,034 --> 00:09:49,896
Than a traditional box-shaped
Trailer roof.
155
00:09:49,896 --> 00:09:51,724
When the trailer is parked,
156
00:09:51,724 --> 00:09:55,620
You can raise the roof to reveal
Fixed windows on both sides.
157
00:09:55,620 --> 00:09:57,793
Workers glue
This tinted, tempered glass
158
00:09:57,793 --> 00:10:01,689
To each aluminum window frame,
Glue the frames to the roof,
159
00:10:01,689 --> 00:10:05,655
Then install taillights,
Roof vents, and solar panels
160
00:10:05,655 --> 00:10:07,586
To recharge the battery powering
161
00:10:07,586 --> 00:10:09,862
The lights,
Vent, and water pump.
162
00:10:09,862 --> 00:10:14,689
They install the roof,
Then mount a hinged back wall.
163
00:10:14,689 --> 00:10:17,310
With assembly finally complete,
164
00:10:17,310 --> 00:10:22,000
Workers apply decals and test
All appliances and systems.
165
00:10:25,206 --> 00:10:28,137
Cables connect the roof
To the back wall,
166
00:10:28,137 --> 00:10:29,413
So when the roof lifts,
167
00:10:29,413 --> 00:10:31,689
It pulls up
The otherwise-collapsed wall.
168
00:10:37,000 --> 00:10:39,896
The trailer's interior layout
Is versatile.
169
00:10:39,896 --> 00:10:42,551
The king-size bed converts
Into two twin beds,
170
00:10:42,551 --> 00:10:44,586
And the dining table
Can be moved
171
00:10:44,586 --> 00:10:47,172
To create
Two distinct dining areas,
172
00:10:47,172 --> 00:10:50,689
A two-seat
And a five-seat dinette --
173
00:10:50,689 --> 00:10:55,137
All the comforts and amenities
Of home on wheels.
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00:11:08,931 --> 00:11:11,068
Narrator: there's nothing
Like a pair of slippers
175
00:11:11,068 --> 00:11:14,965
To soothe your tired tootsies
Or warm your frigid feet.
176
00:11:14,965 --> 00:11:17,241
Designed strictly
For indoor use,
177
00:11:17,241 --> 00:11:20,379
Slippers typically have
A soft sole and looser fit
178
00:11:20,379 --> 00:11:23,241
And are made of supple,
Often cushy materials
179
00:11:23,241 --> 00:11:25,310
So that feet feel
Comfortable and cozy.
180
00:11:29,862 --> 00:11:32,655
This style of slipper
Is known as charentaise,
181
00:11:32,655 --> 00:11:36,000
Named after the region of
Charente in southwestern france
182
00:11:36,000 --> 00:11:39,689
Where they originated
In the 17th century.
183
00:11:39,689 --> 00:11:41,931
The slippers are made
Primarily of felt,
184
00:11:41,931 --> 00:11:45,793
Which is made from layers
Of compressed wool fibers.
185
00:11:45,793 --> 00:11:47,586
This french slipper factory uses
186
00:11:47,586 --> 00:11:50,137
A particularly thick and durable
Type of felt
187
00:11:50,137 --> 00:11:53,965
Composed
Of five wool-fiber layers.
188
00:11:53,965 --> 00:11:55,586
To cut the soles,
189
00:11:55,586 --> 00:11:58,034
Workers position
A cookie-cutter-type die
190
00:11:58,034 --> 00:12:00,448
For the specific shoe size
In production.
191
00:12:00,448 --> 00:12:05,482
Then a 5-ton press forces it
Through the thick felt.
192
00:12:05,482 --> 00:12:07,620
After cutting
One sole of the pair,
193
00:12:07,620 --> 00:12:10,103
They turn the die
In the opposite direction
194
00:12:10,103 --> 00:12:11,448
To cut the second sole.
195
00:12:15,827 --> 00:12:17,896
Once the batch of soles is cut,
196
00:12:17,896 --> 00:12:21,172
They mark the size in ink
With a rubber stamp.
197
00:12:28,000 --> 00:12:30,344
For the rest of the slipper,
Called the upper,
198
00:12:30,344 --> 00:12:32,620
They use fabric
That's felt on the outside,
199
00:12:32,620 --> 00:12:35,206
Velvet on the inside.
200
00:12:35,206 --> 00:12:38,620
The cutting process
Is the same as for the sole,
201
00:12:38,620 --> 00:12:42,344
With the die corresponding
To the size in production.
202
00:12:50,827 --> 00:12:52,448
Once the uppers are cut,
203
00:12:52,448 --> 00:12:56,172
Workers lay a stencil of the
Embroidery pattern on each one
204
00:12:56,172 --> 00:12:58,724
And lightly mark
The design in pencil.
205
00:13:04,896 --> 00:13:07,275
Seamstresses embroider
Each slipper individually
206
00:13:07,275 --> 00:13:09,275
By a machine.
207
00:13:09,275 --> 00:13:12,379
The yarn is made of hemp.
208
00:13:12,379 --> 00:13:17,724
For this model, the design
Is applied in a chain stitch.
209
00:13:25,000 --> 00:13:30,965
Felt flowers give the design
Three-dimensional features.
210
00:13:35,724 --> 00:13:37,137
With the design complete,
211
00:13:37,137 --> 00:13:40,310
It's time to stitch
The back of the upper closed.
212
00:13:42,896 --> 00:13:46,620
Next, they cushion the opening
At the top with velvet binding,
213
00:13:46,620 --> 00:13:49,896
Bending the wide velvet ribbon
Over the edge of the felt
214
00:13:49,896 --> 00:13:51,724
So that the binding runs along
215
00:13:51,724 --> 00:13:55,103
Both the inside and outside
Of the slipper.
216
00:14:09,862 --> 00:14:12,000
They cover the back seam
With a backstrap,
217
00:14:12,000 --> 00:14:13,862
A felt strip
With a loop at the top
218
00:14:13,862 --> 00:14:15,793
Through which you can
Put your finger
219
00:14:15,793 --> 00:14:19,034
To easily pull the slipper
Onto your foot.
220
00:14:22,620 --> 00:14:25,034
Next, they turn
The back of the upper inside out
221
00:14:25,034 --> 00:14:27,586
In order to attach the sole.
222
00:14:27,586 --> 00:14:31,241
They position the sole 3/10
Of an inch from the bottom edge,
223
00:14:31,241 --> 00:14:32,655
Then, with hemp thread,
224
00:14:32,655 --> 00:14:35,931
Straight-stitch along the entire
Perimeter of the upper.
225
00:14:46,172 --> 00:14:48,448
They cut the slipper's insole
From a fabric
226
00:14:48,448 --> 00:14:52,793
That's felt on one side
And velvet on the other.
227
00:14:52,793 --> 00:14:55,379
They position the felt side
Against the felt sole,
228
00:14:55,379 --> 00:14:57,620
Then sew them together
Along the perimeter
229
00:14:57,620 --> 00:14:59,655
With a particular
Cross-shaped stitch
230
00:14:59,655 --> 00:15:03,172
Traditionally used
For the charentaise.
231
00:15:03,172 --> 00:15:04,793
The inside felt's underside
232
00:15:04,793 --> 00:15:07,103
Gives the slipper
Additional rigidity,
233
00:15:07,103 --> 00:15:08,379
While the soft velvet surface
234
00:15:08,379 --> 00:15:11,206
Cushions
The bottom of your foot.
235
00:15:15,793 --> 00:15:18,275
The slipper
Is now fully constructed.
236
00:15:18,275 --> 00:15:20,206
However, it's inside out.
237
00:15:20,206 --> 00:15:23,172
So the next step is to
Turn the slipper right side out
238
00:15:23,172 --> 00:15:25,517
Using this piece of equipment
Called a goat,
239
00:15:25,517 --> 00:15:31,241
Perhaps because its shape
Resembles goat horns.
240
00:15:31,241 --> 00:15:34,241
All that manipulation
Can slightly deform
241
00:15:34,241 --> 00:15:35,827
And crease the upper,
242
00:15:35,827 --> 00:15:37,827
So they put the slipper
In a steam box
243
00:15:37,827 --> 00:15:40,758
For three minutes
To soften the fibers,
244
00:15:40,758 --> 00:15:43,206
Then on a foot-shaped
Aluminum press
245
00:15:43,206 --> 00:15:45,827
Heated
To 158 degrees fahrenheit.
246
00:15:45,827 --> 00:15:48,965
The press irons out
Any remaining wrinkles
247
00:15:48,965 --> 00:15:51,586
And resets the shape.
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This factory's
Charentaise-style slippers
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Range from conservative
To funky.
250
00:15:56,275 --> 00:15:58,758
All are designed
To be comfortable, cozy,
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And as the term "Slippers"
Implies, easy to slip on or off.
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Narrator: the development
Of the motorcycle helmet
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Happened by accident.
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00:16:19,896 --> 00:16:24,482
In 1935, the british war hero
Known as lawrence of arabia
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00:16:24,482 --> 00:16:27,344
Died from a head injury
In a motorcycle crash.
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00:16:27,344 --> 00:16:29,034
He wasn't wearing a helmet.
257
00:16:29,034 --> 00:16:31,241
That tragedy moved
One of his doctors
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00:16:31,241 --> 00:16:35,275
To research the safety potential
Of motorcycle helmets.
259
00:16:38,551 --> 00:16:41,172
The motorcycle helmet
Is the most important part
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00:16:41,172 --> 00:16:43,137
Of the motorcyclist's
Safety gear.
261
00:16:43,137 --> 00:16:45,206
Today, wearing one
Is a rule of the road
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00:16:45,206 --> 00:16:48,655
In many places around the world.
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00:16:48,655 --> 00:16:51,068
Modern helmets
Are entirely synthetic.
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They design them on a computer.
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00:16:55,689 --> 00:16:57,758
The software guides
Milling tools
266
00:16:57,758 --> 00:17:00,482
To produce a prototype
From polyurethane foam.
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00:17:00,482 --> 00:17:02,758
The prototype gives them
A good look
268
00:17:02,758 --> 00:17:04,586
At the helmet's shape and style.
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00:17:06,586 --> 00:17:08,103
Once they're satisfied with it,
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00:17:08,103 --> 00:17:11,655
They build a metal mold
For mass production.
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00:17:14,931 --> 00:17:18,172
The molding material is
A pile of polycarbonate pellets.
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00:17:18,172 --> 00:17:22,586
It's the same thing used to make
Astronaut bubble helmets.
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00:17:22,586 --> 00:17:25,310
An injection molding machine
Melts the pellets
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00:17:25,310 --> 00:17:30,689
And injects them
Into the two-part helmet mold.
275
00:17:30,689 --> 00:17:32,137
The polycarbonate cools
276
00:17:32,137 --> 00:17:34,793
And solidifies
Into the shape of the mold.
277
00:17:34,793 --> 00:17:37,206
The result is
The outer shell of the helmet,
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00:17:37,206 --> 00:17:41,344
Complete with holes
For vents and other parts.
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00:17:44,551 --> 00:17:46,793
Next, a robot grips
The helmet's shell
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00:17:46,793 --> 00:17:48,862
And moves it
Against a sanding belt
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00:17:48,862 --> 00:17:52,103
To smooth the seam
Left by the mold.
282
00:17:52,103 --> 00:17:55,517
The robot also gives the shell
An overall polish.
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00:17:55,517 --> 00:17:57,172
It then goes for a spin
284
00:17:57,172 --> 00:17:59,000
As sprayers coat it
With black paint.
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00:18:04,000 --> 00:18:07,655
A factory employee pulls
A sheet of decals through water
286
00:18:07,655 --> 00:18:12,655
To lift them from the backing.
287
00:18:12,655 --> 00:18:17,137
She applies the decals
To a white, unpainted helmet.
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00:18:17,137 --> 00:18:21,758
It's a flashier look
Than basic black.
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00:18:21,758 --> 00:18:24,827
It takes practice to be able
To apply the decals correctly
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00:18:24,827 --> 00:18:29,655
Because the helmet surface
Is complex and curvy.
291
00:18:29,655 --> 00:18:32,034
She smoothes out air bubbles
In preparation
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00:18:32,034 --> 00:18:36,241
For the application
Of a protective clear coat.
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00:18:36,241 --> 00:18:38,482
The next assembler installs
A pivot mechanism
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00:18:38,482 --> 00:18:42,551
On each side of the helmet.
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00:18:42,551 --> 00:18:44,689
They'll enable
The face shield and visor
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00:18:44,689 --> 00:18:48,413
To be raised and lowered.
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00:18:48,413 --> 00:18:51,620
The hardware fits perfectly
Into the molded niches.
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00:18:51,620 --> 00:18:53,172
There's just enough room
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00:18:53,172 --> 00:18:56,241
For the mechanism
To operate smoothly.
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00:19:01,517 --> 00:19:03,931
She attaches
The velour-lined chin strap
301
00:19:03,931 --> 00:19:07,620
With its quick-release mechanism
To the outer shell.
302
00:19:12,793 --> 00:19:16,103
Then these foam polystyrene
Pellets are transformed
303
00:19:16,103 --> 00:19:19,620
Into the helmet's
Cushioning inner shell.
304
00:19:19,620 --> 00:19:25,448
The pellets flow into another
Injection molding system.
305
00:19:25,448 --> 00:19:29,137
A nozzle injects the melted
Polystyrene into the mold,
306
00:19:29,137 --> 00:19:35,517
And it takes the shape of
Shock-absorbing helmet liners.
307
00:19:35,517 --> 00:19:36,862
The foam solidifies,
308
00:19:36,862 --> 00:19:40,655
And the machine ejects
The completed liners.
309
00:19:40,655 --> 00:19:43,172
The density
Of the polystyrene foam varies
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00:19:43,172 --> 00:19:46,172
Throughout the helmet
For strategic shock resistance,
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00:19:46,172 --> 00:19:47,344
Enabling it to meet
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00:19:47,344 --> 00:19:51,827
International
Safety requirements.
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00:19:51,827 --> 00:19:54,000
Padding in the crown
And around the chin area
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00:19:54,000 --> 00:19:57,206
Makes it
More comfortable to wear.
315
00:19:57,206 --> 00:20:01,655
They now join the helmet's
Inner shell to the outer one.
316
00:20:01,655 --> 00:20:05,655
After a liberal application
Of glue,
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00:20:05,655 --> 00:20:07,482
She pushes the liner
Into the shell.
318
00:20:07,482 --> 00:20:08,862
It's a snug fit,
319
00:20:08,862 --> 00:20:12,241
And it takes a bit of
Maneuvering to get it in there.
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00:20:14,689 --> 00:20:17,862
She attaches a robust chin guard
To the helmet.
321
00:20:17,862 --> 00:20:20,862
This molded polycarbonate part
Is designed
322
00:20:20,862 --> 00:20:25,827
To protect the lower half
Of the rider's face.
323
00:20:25,827 --> 00:20:28,103
The assembler screws it
To the helmet on both sides.
324
00:20:34,275 --> 00:20:36,413
With this part in place,
325
00:20:36,413 --> 00:20:41,517
The rider should be able to take
It on the chin if necessary.
326
00:20:44,620 --> 00:20:46,724
A transparent
Polycarbonate face shield
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00:20:46,724 --> 00:20:49,551
Completes
This motorcycle helmet.
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00:20:51,586 --> 00:20:53,206
And now a test.
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00:20:53,206 --> 00:20:55,517
They drop a helmet
From a height of 10 feet
330
00:20:55,517 --> 00:20:58,206
To confirm it can take a fall
Without falling apart.
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00:21:00,758 --> 00:21:05,413
It survives, and the entire
Production batch is approved.
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00:21:05,413 --> 00:21:08,482
Designed for impact
And made to specification,
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00:21:08,482 --> 00:21:12,379
This helmet could
Just save your skull.
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00:21:21,655 --> 00:21:24,000
If you have any comments
About the show
335
00:21:24,000 --> 00:21:26,068
Or if you'd like to suggest
Topics for future shows,
336
00:21:26,068 --> 00:21:28,517
Drop up a line at...
337
00:21:30,896 --> 00:21:33,896
--captions by vitac--
Www.Vitac.Com
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00:21:33,896 --> 00:21:36,862
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