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Today on "how it's made,"
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belts...
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...3-d metal printers...
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...Detectable warning panels...
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...And model stirling engines.
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belts have been worn with
different types of garments
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since the invention of clothes.
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Made to cinch your waistline,
this accessory is worn with
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pants, shirts, robes,
or dresses,
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making a fashionable addition
to any outfit.
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Durable and flexible, leather
is the classic material
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used for belt making.
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This production facility
manufactures stylish,
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high quality belts
at top speed.
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A designer creates
a belt pattern on her computer
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and sends the design
electronically
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to the in-house
laser etching machine.
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A craftsman places
a cowhide on a large table.
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He examines the hide
for any flaws
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and carefully marks each one.
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The cowhides are made from
meat industry byproducts,
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and most are sourced
from Italy.
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A device scans
the shape of the hide
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and the craftsman digitally
marks the location of the flaws.
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A specialized cutting machine
uses the marked information
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to create an efficient
series of cuts.
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This process results
in a high quality product
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with minimal waste.
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Another technician sorts
the various belt lengths
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into containers,
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preparing them for
the next step.
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The cutting machine
is capable of slicing
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up to 2,400 belts per day.
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The cutting machine creates
straight, sharp-edged strips.
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The technician feeds the belts
into a machine
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that bevels the edges at
the rate of 6,000 per day.
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At the next station, a series
of small suction devices
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quickly lift and place each
belt on a conveyor system.
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A stamping machine
accurately cuts the shape
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of the belt tip
and the holes for the prong.
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The craftsman stacks a group
of belts and packs them
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tightly together,
then he dyes the edges with ink
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and sands them down.
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These steps complement
the edge dyeing machine process,
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which can add color
to the belt edges.
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Then the belts are transferred
to a drying machine.
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The edges must be completely dry
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before they move
to the next step.
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Powered by world war ii
jeep engines,
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a rotating wooden drum tumbles
the belts,
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while simultaneously
burnishing the leather.
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This type of machinery
comes from
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Italy's famous
leather working region.
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This imported machine,
from milan,
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rapidly punches out
the pattern of perforations,
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which make up the belt's
signature design elements.
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Since the machine's die is less
than 20 inches long,
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the complex pattern along the
belt can't be stamped at once.
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Instead, the machine punches out
a section at a time
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resulting in a production rate
of 1,400 belts per day.
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A laser etching machine
burns a second pattern
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into the leather surface.
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This pattern was created
by the designer
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prior to production.
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At the next station,
a craftswoman fills the holes
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of a specially crafted
two-part metal die
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with nail heads.
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The nail heads are made of
zinc with a brass finish.
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Using a press,
an operator places the die
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in a waiting repository.
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She removes the top half,
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ensuring that all of the holes
are filled with nail heads.
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Then she turns the belt around
and places it over the die
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before sliding the belt
inside the press.
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The press affixes the nail heads
to the leather.
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00:05:01,802 --> 00:05:03,535
Before attaching the buckle,
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the belts go through
a process called skiving.
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This device shaves off
a section of the leather
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so that when it's folded over,
it won't be too thick.
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A loop is attached
on to the end of the belt,
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followed by a buckle.
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The craftswoman uses the loop to
temporarily hold
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the buckle and tag in place.
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The tag contains the belt's
size, price,
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and brand information.
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Another craftswoman sews the
belt buckle and tag in place,
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using 69 weight thread
and a bar tacking stitch.
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This facility manufactures
nearly 10,000 belts per day.
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This intricate
leather fashion accessory
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might be a cinch to wear,
but not to make.
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3-d printers generate metal parts for spacecraft,
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cars, and medical devices,
to name a few.
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3-d printing technology allows
for the production
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of complex design structures
which can't be achieved
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using traditional
manufacturing methods.
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The 3-d metal printer could
truly break the mold.
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Thanks to advancements in
technology,
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it's now possible
to print metal parts.
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This 3-d printer melts
and layers metal powder
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and a part materializes.
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This part will become
a rocket nozzle heat exchanger.
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At the core of the 3-d metal
printer is the deposition head,
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which feeds and melts the
the metal powder.
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So far the designing process
has taken hundreds of hours.
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Tools guided by
the design software transform
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a brass cylinder
into the nozzle cone.
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00:07:02,189 --> 00:07:05,056
The profile of the nozzle cone
can vary slightly,
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depending on the parts
the 3-d metal printer
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will be used to produce.
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Next the powder inlet component
is added.
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Metal powder will
flow through this part
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to a mixing chamber and,
eventually, the nozzle cone.
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Computerized tools
cut angled channels,
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delivering different
metal powders
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to the mixing chamber
with an angular velocity,
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creating a vortex to
help blend the powders.
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The part has been nickel plated
and fasteners are installed.
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The technician aligns
the laser delivery channel
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to the powder inlet part,
and screws them together.
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The laser will melt
the metal powder
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as it flows through the inlet.
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00:07:53,073 --> 00:07:56,541
She installs latches on the rim
of the powder inlet part
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00:07:56,543 --> 00:07:59,678
and tightly torques the screws
that hold them in place.
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Using the latches, she locks
the mixing chamber to the inlet.
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00:08:06,553 --> 00:08:09,821
The latches will help make
further assembly and disassembly
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00:08:09,823 --> 00:08:12,123
of the 3-d metal printer head
a snap.
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00:08:17,231 --> 00:08:19,965
next, a laser nozzle is screwed
onto the mixing chamber.
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00:08:22,035 --> 00:08:24,936
Then, the technician places
the main nozzle cone
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00:08:24,938 --> 00:08:26,838
over the laser nozzle
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00:08:26,840 --> 00:08:30,141
and connects the threaded rim
to the mixing chamber.
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The deposition head
is now complete.
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Next, another the technician
mounts the laser system
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to a vertical axis
in the printer housing.
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He runs coolant lines
for the laser
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and attaches
the deposition head,
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screwing it in place with
a threaded brass collar.
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The laser system and deposition
head are now integrated.
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First, the powder feeder
is assembled with
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00:09:02,676 --> 00:09:07,145
a substantial base to
accommodate a feed drive system.
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00:09:07,147 --> 00:09:09,347
The technician installs
the feeder shaft
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00:09:09,349 --> 00:09:11,049
in the upper half of the base.
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00:09:12,419 --> 00:09:15,320
Then, he screws a disc
to the shaft.
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The disc will spin to
move the metal powder
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into the printer head system.
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00:09:20,427 --> 00:09:22,527
He slides a spring
on to the shaft
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which helps maintain its
position.
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00:09:25,499 --> 00:09:28,767
Then, he connects the upper half
of the base to the bottom half.
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00:09:29,570 --> 00:09:32,103
He installs an inlet
for carrier gas
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that will be used to move
the powder through tubing
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to the printer head.
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He assembles windows to a lid.
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They'll provide a view
of the metal powder
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swirling in the feeder disc,
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so that any problems
can be identified.
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He press fits the hopper cone
into a ridged hole in the lid.
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00:09:58,932 --> 00:10:01,433
he attaches the hopper
to the cone.
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00:10:03,670 --> 00:10:07,405
He clamps the feeder motor to
the hopper using long screws,
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00:10:07,407 --> 00:10:12,110
which seals the hopper and turns
it into a pressure vessel.
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00:10:12,112 --> 00:10:14,846
The resulting pressure
will help force the powder
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00:10:14,848 --> 00:10:17,015
through tubing to
the deposition head.
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00:10:18,719 --> 00:10:21,820
He installs the lid and hopper
assembly on the base.
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00:10:23,991 --> 00:10:25,957
Once assembly is complete,
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the technician sets
the base on a mount,
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00:10:28,629 --> 00:10:32,998
sliding protruding pins into
corresponding holes in the lid.
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This completes
the powder feeder.
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00:10:37,337 --> 00:10:40,839
The powder feeder now ready
to supply the raw material
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for 3-d printing.
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00:10:43,343 --> 00:10:46,544
An operator connects
it to the printer
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00:10:46,546 --> 00:10:48,947
and pours metal powder
into the hopper.
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00:10:49,583 --> 00:10:51,950
The system delivers the powder
to the printer head.
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00:10:53,420 --> 00:10:56,087
The dispensing and melting
of the metal powder,
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as well as the layering,
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are all controlled by
a computer generated program.
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This 3-d printer can manufacture
a part in a few hours,
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00:11:06,600 --> 00:11:10,135
so you can sit back
and watch it materialize.
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narrator:
Detectable warning panels
are cautionary signals
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00:11:26,319 --> 00:11:28,219
for the visually impaired.
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00:11:28,221 --> 00:11:30,422
Their specific
pattern of domed bumps
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00:11:30,424 --> 00:11:34,092
are detectable by touch or with
walking aid equipment.
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00:11:34,094 --> 00:11:35,960
They also serve as
warning systems
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00:11:35,962 --> 00:11:39,064
at intersections
or on transit platforms,
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alerting all people
to proceed with caution.
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00:11:44,271 --> 00:11:45,970
For the visually impaired,
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these little bumps
on the road aren't a problem.
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00:11:48,575 --> 00:11:50,208
They're a solution.
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00:11:50,210 --> 00:11:52,477
Embedded in surfaces
at intersections,
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00:11:52,479 --> 00:11:55,280
detectable warning panels
help people
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00:11:55,282 --> 00:11:57,182
find their way through touch.
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Making a fiberglass polymer
version of the panels
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starts with a carefully
calculated formula.
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Technicians add pigment
to resin paste
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keeping a close eye
on the scale
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to confirm the amounts
are correct.
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00:12:11,498 --> 00:12:13,932
Next, a chemical thickener
is added,
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00:12:13,934 --> 00:12:16,568
this ingredient will increase
the viscosity
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00:12:16,570 --> 00:12:19,904
to a syrupy consistency.
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00:12:19,906 --> 00:12:22,707
Then the ingredients
are blended together.
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00:12:22,709 --> 00:12:26,578
The agitation from the blender
causes the mixture to heat,
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00:12:26,580 --> 00:12:28,379
starting a chemical reaction
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00:12:28,381 --> 00:12:31,116
which will eventually
cause solidification.
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00:12:32,319 --> 00:12:35,787
As the mixture thickens,
it turns a vivid color
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00:12:35,789 --> 00:12:39,357
that people with compromised
vision can still perceive.
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00:12:40,961 --> 00:12:42,961
The technician gauges
the temperature
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00:12:42,963 --> 00:12:47,098
to confirm that the chemical
reaction isn't too advanced.
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00:12:47,100 --> 00:12:48,967
Then,
the mix is set aside,
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00:12:48,969 --> 00:12:52,137
so technicians can
prepare other ingredients.
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00:12:52,139 --> 00:12:55,740
Rams punch the bag of mineral
fillers to break up any clumps
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00:12:55,742 --> 00:12:58,376
as they flow into a hopper.
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00:12:58,378 --> 00:13:01,212
Stearic acid is added to
cut the thickening.
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00:13:02,282 --> 00:13:05,550
A computer dispenses
the mineral filler and resin
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00:13:05,552 --> 00:13:07,218
into a large mixing tank.
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00:13:12,626 --> 00:13:14,492
an operator adds an inhibitor
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00:13:14,494 --> 00:13:17,796
to delay the chemical reaction
as the mixing blade
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00:13:17,798 --> 00:13:20,498
blends the ingredients
into a paste.
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00:13:21,101 --> 00:13:23,568
Zinc stearate is added to
the mixture,
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00:13:23,570 --> 00:13:25,403
which will allow the completed
panel to release from the mold.
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00:13:28,441 --> 00:13:31,910
Glass bundles, known as
rovings, then unwind.
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00:13:32,312 --> 00:13:35,680
A blade chops them into
toothpick sized pieces.
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00:13:36,917 --> 00:13:38,149
The pigment mixture,
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00:13:38,151 --> 00:13:40,552
which has been blended
into the resin paste,
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00:13:40,554 --> 00:13:42,821
flows on to a plastic liner.
222
00:13:44,491 --> 00:13:48,393
Shards of glass fall down
on to the yellow resin mixture.
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00:13:50,497 --> 00:13:53,131
As the machine pulls
the mixture forward,
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00:13:53,133 --> 00:13:55,567
the liner takes
the glass-encrusted resin
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00:13:55,569 --> 00:13:57,735
to the next stage.
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00:13:59,005 --> 00:14:01,306
More resin and a top plastic
liner,
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00:14:01,308 --> 00:14:06,077
create an encasing with
the glass in the middle.
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00:14:06,079 --> 00:14:08,713
Rollers squeeze
the encasing together,
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00:14:08,715 --> 00:14:12,383
forcing the resin to flow
around the glass shards.
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00:14:12,385 --> 00:14:15,820
The material is compacted
to the desired thickness.
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00:14:15,822 --> 00:14:18,089
Then, the glass
and resin material
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00:14:18,091 --> 00:14:20,491
cures for 24 hours.
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00:14:20,493 --> 00:14:22,760
This allows
the materials to thicken,
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00:14:22,762 --> 00:14:25,263
so it can be cut into panels.
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00:14:25,265 --> 00:14:29,000
A circular cutting wheel moves
on a carriage across the mat
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00:14:29,002 --> 00:14:30,635
slicing it to length.
237
00:14:32,639 --> 00:14:36,274
The mats are retrieved from the
machine and stacked.
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00:14:36,276 --> 00:14:39,878
The plastic liners on both
sides are still intact.
239
00:14:42,616 --> 00:14:47,318
Next, the material is weighed
to confirm the specified amount.
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00:14:47,320 --> 00:14:48,586
If more is needed,
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00:14:48,588 --> 00:14:50,855
a technician will adjust
accordingly.
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00:14:52,392 --> 00:14:54,225
He then peels off the liners.
243
00:14:57,330 --> 00:15:01,499
The glass and resin material are
transferred to a heated mold.
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00:15:01,501 --> 00:15:05,303
The mold applies 500 tons
of hot pressure.
245
00:15:05,305 --> 00:15:09,040
The material liquefies and flows
into the crevasses of the mold,
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00:15:09,042 --> 00:15:11,576
forcing air out.
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00:15:11,578 --> 00:15:13,811
As the bumpy panels take shape,
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00:15:13,813 --> 00:15:17,448
a chemical reaction causes
the material to solidify.
249
00:15:19,953 --> 00:15:22,520
A worker trims
the freshly molded panels
250
00:15:22,522 --> 00:15:24,689
to give them a cleaner line.
251
00:15:26,359 --> 00:15:28,192
And sands the edges smooth.
252
00:15:32,565 --> 00:15:35,500
He clamps the panel to
a fixture at both ends.
253
00:15:37,938 --> 00:15:40,505
The clamps keep
the panel in position
254
00:15:40,507 --> 00:15:42,307
and prevent it from bending.
255
00:15:42,309 --> 00:15:45,143
As mounting holes are drilled
into the panel.
256
00:15:50,884 --> 00:15:52,917
the technician
uses an air gun to
257
00:15:52,919 --> 00:15:54,886
blow off drilling residue
and dust.
258
00:15:58,692 --> 00:16:02,894
This detectable warning panel
is now ready for installation.
259
00:16:02,896 --> 00:16:05,396
Two craftsmen pipe adhesive
into channels
260
00:16:05,398 --> 00:16:07,265
at the back of the panel.
261
00:16:07,467 --> 00:16:10,935
The panel is installed in
a recessed part of the curb
262
00:16:10,937 --> 00:16:13,571
and screwed into anchors
in the concrete.
263
00:16:17,577 --> 00:16:19,143
For people with limited vision
264
00:16:19,145 --> 00:16:21,312
trying to navigate
their way around,
265
00:16:21,314 --> 00:16:25,149
these tactile panels will make
a difference they can feel.
266
00:16:40,967 --> 00:16:42,967
A stirling engine produces power
267
00:16:42,969 --> 00:16:46,504
by circulating hot and cold air,
or other types of gas,
268
00:16:46,506 --> 00:16:48,373
at different temperatures.
269
00:16:48,375 --> 00:16:52,210
Heating expands the gas,
while cooling contracts it.
270
00:16:52,212 --> 00:16:56,180
These alternating reactions move
up to four pistons at a time,
271
00:16:56,182 --> 00:16:59,250
driving the machine and the
pulleys attached to the engine.
272
00:17:02,989 --> 00:17:06,491
This german company manufactures
model stirling engines
273
00:17:06,493 --> 00:17:10,561
and accessories,
like this marble tower.
274
00:17:10,563 --> 00:17:13,631
The engine parts move by
a closed loop of air
275
00:17:13,633 --> 00:17:15,933
that circulates
inside the engine,
276
00:17:15,935 --> 00:17:21,372
expanding and contracting as
it repeatedly heats and cools.
277
00:17:21,374 --> 00:17:23,608
A specialist designs the engines
278
00:17:23,610 --> 00:17:27,678
and produces digital renderings
for each component.
279
00:17:27,680 --> 00:17:29,347
The dimensions must be accurate
280
00:17:29,349 --> 00:17:32,917
within 1/1,000
of a millimeter.
281
00:17:32,919 --> 00:17:36,154
A computer guided turret machine
shapes the engine's
282
00:17:36,156 --> 00:17:40,691
cooling cylinder
out of a solid piece of brass.
283
00:17:40,693 --> 00:17:44,796
Heat escapes brass quickly,
making it ideal for a component
284
00:17:44,798 --> 00:17:47,231
to rapidly reduce its
hot air temperature.
285
00:17:48,968 --> 00:17:51,969
The cooled air contracts,
producing a vacuum
286
00:17:51,971 --> 00:17:55,173
that draws the engine's
working piston downward.
287
00:17:55,175 --> 00:17:59,310
When reheated, the air expands,
pushing the piston up.
288
00:17:59,312 --> 00:18:02,980
This repetitive motion
drives the crankshaft.
289
00:18:02,982 --> 00:18:06,584
The cooling cylinder has
fins to help diffuse heat,
290
00:18:06,586 --> 00:18:09,020
a hole on top for
the working piston
291
00:18:09,022 --> 00:18:12,123
and another hole on the side
for the displace piston.
292
00:18:13,960 --> 00:18:16,527
After cleaning the cylinder
with compressed air,
293
00:18:16,529 --> 00:18:20,198
a technician performs
a quality control check.
294
00:18:20,200 --> 00:18:23,701
First, he inserts multiple
test pins into the hole
295
00:18:23,703 --> 00:18:27,972
for the working piston
until one is the right fit.
296
00:18:27,974 --> 00:18:30,174
This tells him
the diameter measurement.
297
00:18:31,311 --> 00:18:34,479
Using a digital caliper,
the technician measures a series
298
00:18:34,481 --> 00:18:37,682
of aluminum working pistons
until he finds the one
299
00:18:37,684 --> 00:18:40,585
that's the correct size
for the hole's diameter.
300
00:18:43,223 --> 00:18:45,690
He inserts the piston
into the cylinder,
301
00:18:47,026 --> 00:18:49,861
then holds the cylinder
upside down.
302
00:18:49,863 --> 00:18:53,898
If the piston falls out slowly,
it's the right size.
303
00:18:53,900 --> 00:18:57,301
The fit must be precise to
prevent the circulating air
304
00:18:57,303 --> 00:18:59,237
from leaking out
of the cylinder.
305
00:19:01,141 --> 00:19:02,740
In the assembly area,
306
00:19:02,742 --> 00:19:05,977
another technician superglues
a crankshaft ball bearing
307
00:19:05,979 --> 00:19:09,714
into each of the engine's
stainless steel side frames.
308
00:19:10,550 --> 00:19:14,685
She glues the displace axle
to the displace piston.
309
00:19:14,687 --> 00:19:17,221
The part should fit loosely
in the cooling cylinder
310
00:19:17,223 --> 00:19:19,323
to allow the air
to flow around it,
311
00:19:19,325 --> 00:19:21,359
while moving back and forth
312
00:19:21,361 --> 00:19:24,162
between the engine's
heating and cooling zones.
313
00:19:27,000 --> 00:19:29,967
She inserts the displace
piston into the side hole
314
00:19:29,969 --> 00:19:31,335
of the cooling cylinder.
315
00:19:33,406 --> 00:19:37,008
Then the heating cylinder is
mounted over the piston.
316
00:19:37,010 --> 00:19:40,178
The heating cylinder draws heat
generated by the flame
317
00:19:40,180 --> 00:19:41,846
into the engine.
318
00:19:41,848 --> 00:19:46,050
She attaches it to the cooling
cylinder with four screws.
319
00:19:50,456 --> 00:19:53,524
A connecting rod is attached
to the working piston
320
00:19:53,526 --> 00:19:56,294
and the piston is inserted
into the cooling cylinder.
321
00:19:58,164 --> 00:20:00,965
Next, the technician
mounts one of the side frames
322
00:20:00,967 --> 00:20:02,333
to the cylinder,
323
00:20:02,335 --> 00:20:05,102
attaches a rocker arm
to the side frame,
324
00:20:05,104 --> 00:20:07,038
then puts one end
of the crankshaft
325
00:20:07,040 --> 00:20:09,140
through the side frame's
ball bearing.
326
00:20:12,111 --> 00:20:14,545
She attaches
the second side frame,
327
00:20:14,547 --> 00:20:16,614
by inserting the other end
of the crankshaft
328
00:20:16,616 --> 00:20:18,149
through its ball bearing.
329
00:20:22,088 --> 00:20:24,555
She mounts what has been
assembled so far
330
00:20:24,557 --> 00:20:28,159
on to a wooden base plate,
then she connects one end
331
00:20:28,161 --> 00:20:31,495
of the rocker arm to the
working piston's connecting rod.
332
00:20:33,066 --> 00:20:35,166
The other end of the rocker arm
is joined
333
00:20:35,168 --> 00:20:37,301
to the crankshaft
connecting rod,
334
00:20:37,303 --> 00:20:39,770
which is connected at
a 90-degree angle
335
00:20:39,772 --> 00:20:42,273
to both the rocker arm
and the crankshaft.
336
00:20:43,509 --> 00:20:45,543
On each end of the crankshaft,
337
00:20:45,545 --> 00:20:48,346
a heavy brass flywheel
is mounted.
338
00:20:48,348 --> 00:20:51,716
The flywheels increase
the momentum of the engine.
339
00:20:51,718 --> 00:20:54,719
To power an accessory
with the stirling engine,
340
00:20:54,721 --> 00:20:57,555
one end of a drive belt
is run around a pulley
341
00:20:57,557 --> 00:21:00,224
on the accessory,
and the other end of the belt
342
00:21:00,226 --> 00:21:02,426
around a plastic drive wheel.
343
00:21:07,500 --> 00:21:10,001
The finishing touch is
an engraved brass
344
00:21:10,003 --> 00:21:11,669
identification plate.
345
00:21:12,805 --> 00:21:14,872
Here's how this engine works.
346
00:21:14,874 --> 00:21:18,809
First, the burner case is filled
with denatured alcohol
347
00:21:18,811 --> 00:21:20,544
and the wick is attached.
348
00:21:20,546 --> 00:21:23,681
The burner case is placed
under the heating cylinder,
349
00:21:23,683 --> 00:21:26,083
light the wick,
and let the engine preheat
350
00:21:26,085 --> 00:21:28,019
for 10 to 15 seconds,
351
00:21:28,021 --> 00:21:31,022
then turn a flywheel to
kickstart the engine.
352
00:21:31,024 --> 00:21:34,558
The flame heats the air
inside the heating cylinder.
353
00:21:34,560 --> 00:21:37,428
The hot air expands
into the cooling cylinder,
354
00:21:37,430 --> 00:21:40,331
causing the cylinder
to cool and contract.
355
00:21:40,333 --> 00:21:42,833
This moves the working
piston up and down,
356
00:21:42,835 --> 00:21:46,070
turning the engine's crankshaft.
29265
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