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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:
TODAY, ON "HOW IT'S MADE"...
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History suggests slate
may have first been mined
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in the Roman Era,
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although the earliest confirmed
records date back to
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the early 1700s.
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Slate tiles were used for
general building construction
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and are still used today
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for practical and aesthetic
purposes.
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These pieces of floor slate
appear to be right
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from the quarry,
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but they're part of an 18 piece puzzle
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that's cut the same way
every time.
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These pieces of wall slate
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are much thinner
and are used for paneling.
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Uncut sheets of slate
in a variety of thicknesses
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come straight from the quarry.
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After the slate sheets
are stacked on a forklift,
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a worker carefully
drives them
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to another part
of the storage yard.
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He sets them down gently.
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Another worker splits the sheets
of slate
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using a pneumatic zip gun.
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It's a delicate process.
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Once he splits the slate sheets,
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the worker inspects the lines
in the pieces of slate
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00:02:07,025 --> 00:02:08,394
and looks for cracks.
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00:02:11,897 --> 00:02:15,234
Then, he carries the sheet
to a gauging machine.
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He checks the thickness
of the sheet
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to make sure it won't cause jams
on the cutting table.
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This multiblade cutting table
slices a sheet of slate
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into a series of strips.
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00:02:33,218 --> 00:02:35,554
It's covered
with recycled water.
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This lubricates
the cutting process,
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cools the slate
and cutting blades,
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and removes unwanted dust
and particles.
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A conveyor slowly moves
the slate sheet forward.
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A total of 18 diamond blades
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slice the sheet of slate
into strips.
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These strips of slate
will be used for wall paneling.
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This cutting table
can cut several sheets of slate
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at the same time.
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Once the cutting process
is complete,
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a worker inspects the strips
of slate and sorts
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them according to thickness
and width.
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Next, he piles some of them
in preparation for splitting.
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00:03:25,937 --> 00:03:29,073
He cracks thicker strips
of slate using a stone splitter
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00:03:29,074 --> 00:03:30,842
with a hardened steel blade.
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00:03:33,979 --> 00:03:35,380
He makes sure
they're thin enough
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00:03:35,381 --> 00:03:37,649
to be used for wall paneling.
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Once the pieces of slate
reach their final thickness,
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a worker places them in boxes,
ready for installation.
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00:03:50,163 --> 00:03:51,962
A worker inspects a sheet
of slate
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that will be used for flooring.
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The thickness of slate flooring
must be constant.
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He places a sheet on a conveyor.
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00:04:03,308 --> 00:04:05,744
It takes the slate
through a gauging machine,
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where its surface
will be made perfectly even.
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Using two diamond grinding
wheels, the gauging machine
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shaves off any pieces of stone
that exceed a preset thickness.
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After several minutes
of shaving,
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the slate sheet emerges
from the gauging machine.
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00:04:27,733 --> 00:04:31,669
An employee checks the sheet
to make sure it's smooth.
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First, he checks the underside
of the eventual floor tiles.
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00:04:36,875 --> 00:04:38,842
Then, he checks the top side,
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the stone face
that will be displayed.
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The worker places the smooth,
flat piece of slate
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on a cutting frame.
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00:04:48,588 --> 00:04:50,256
The computerized cutting machine
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cuts 18 pieces of slate
according to a preset pattern.
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A high velocity water jet
cuts the stone at three times
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the speed of sound.
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00:05:00,600 --> 00:05:04,201
The water is pure,
filtered several times.
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00:05:04,202 --> 00:05:06,938
The first time the slabs
move through the machine,
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it cuts pieces 1 to 9,
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and the second time through,
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it cuts pieces 10 to 18.
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The worker snaps off excess trim
and stacks
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the cut pieces of slate
according to their numbers.
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All the number ones
are identical to each other,
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as are each of the other numbers
in the 18 piece pattern.
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Repeated on a floor,
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the 18 piece pattern
appears natural.
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This nonporous slate comes in
different textures and colors,
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and can also be used
in bathrooms or roofing.
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Narrator:
The first hot dog carts
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were rolled out in New York City
in the mid 19th century.
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They were simple push carts
with small charcoal stoves
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and served sausages on buns.
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Those sandwiches became known
as hot dogs.
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A modern hot dog cart
is a kitchen on wheels.
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Equipped with a water tank
and sink,
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a steamer and grill,
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and a cooler,
it's made to serve the public.
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And they're sometimes designed
to stand out in a crowd.
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To make this hot dog cart,
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they start with molds
for the hot dog shaped body.
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A worker brushes a nonstick
coating into the first mold.
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It will allow the completed part
to be easily removed.
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He places fiberglass one sheet
at time in the mold.
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He brushes a generous amount
of epoxy resin onto each piece.
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The fiberglass starts
to solidify very quickly,
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but he leaves it to set
overnight for a complete cure.
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They assemble the two halves
of the hot dog shaped body
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and apply bonding to the seams.
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A colorful paint job
completes the look.
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Next, computerized tools
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cut holes in a sheet
of food grade steel.
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These holes will accommodate
the sink, faucets,
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and other parts.
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Then, the cooler door
takes shape.
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Using a press,
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the worker bends up the edge
of a piece of steel
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that's been cut to size.
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He transfers the part
to another break press.
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This one is computerized.
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It folds back the bend to give
the door a strong, smooth edge.
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00:08:02,982 --> 00:08:07,318
He repeats this process
on two other sides.
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He then clamps a continuous
hinge to the only unfolded edge,
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00:08:12,824 --> 00:08:15,060
and he welds
and rivets the hinge to it.
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Work now begins on the chassis
of the hot dog cart.
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A worker welds heavy wall steel
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00:08:27,674 --> 00:08:29,876
tubing to create
a rugged framework.
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After painting it,
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he bolts the wheel axle
to brackets on the sides.
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He tightens the bolts
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to an exact torque
using a pneumatic wrench.
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00:08:51,197 --> 00:08:53,600
He screws taillights
to the bumper.
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00:08:53,601 --> 00:08:57,035
The lights are surrounded by
metal brackets to protect them
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from being damaged
by customers waiting in line.
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The brackets also
serve as a mounting plate.
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The team now transfers
the fiberglass cart body
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to the chassis.
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00:09:13,352 --> 00:09:14,754
They drill large holes
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to vent gas fumes
and smaller screw holes
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to secure the body
to the chassis.
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They line the cart with a molded
fiberglass and styrofoam unit.
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It has compartments for
the water tank and food cooler,
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00:09:34,540 --> 00:09:36,977
and it also serves
as an insulating layer.
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00:09:39,344 --> 00:09:42,112
They install the steel food
preparation surface,
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which has been equipped
with a sink and faucets.
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A member of the team tightens
a crimp ring around the hoses
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to supply water
to the sink faucets.
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00:09:55,227 --> 00:09:58,395
He runs a gas line
to the steamer's burners
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00:09:58,396 --> 00:10:00,733
and lowers the steamer
into place on the cart.
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00:10:05,271 --> 00:10:08,372
He assembles a barbecue
to the other side of the cart,
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00:10:08,373 --> 00:10:10,408
and this gives customers
a grilled option
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for their hot dogs.
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They hinge the cooler door
to the front of the cart.
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Once closed, the door
seals the insulated chamber
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00:10:27,260 --> 00:10:30,563
to keep hot dogs, sausages,
and sodas on ice.
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The team presses bold graphics
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00:10:38,237 --> 00:10:41,741
to the fiberglass shell
and peels off the paper liner.
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00:10:44,276 --> 00:10:48,047
And with that, this hot dog cart
is ready to hit the street,
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just in time for lunch.
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Narrator: Decades ago, people
had to get out of the car
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when arriving home in order
to open the garage door.
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Today, it's routine to open
and close your garage door
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at the push of a button,
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either on a wall mounted pad
or on a remote control.
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A garage door opener's motor
drives either a belt, a chain,
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or a screw rod,
like these models.
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In turn, they move a carriage
connected to the garage door.
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At this factory,
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the production line starts
and ends at the same place.
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They take one completed garage
door opener off the line,
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00:11:41,601 --> 00:11:42,933
then start a new one
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by attaching a power cord
to the unit's steel chassis.
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Then, they place the chassis
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00:11:49,574 --> 00:11:51,576
onto a traveling assembly
fixture
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and plug in the power cord
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to prep the unit
for testing later.
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They place the unit's plastic
housing next to the chassis,
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00:12:02,121 --> 00:12:04,823
then snap
in the plastic safety cover.
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00:12:04,824 --> 00:12:07,192
This goes over the direct
current motor,
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the equivalent
of 1 1/4 horsepower.
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00:12:11,164 --> 00:12:14,265
They attach an optical encoder
to the motor.
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00:12:14,266 --> 00:12:17,836
The encoder is a sensor
which reads the door's position
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00:12:17,837 --> 00:12:20,774
so that the motor knows when
to stop moving the carriage.
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They place the motor
against the safety cover,
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then screw it in place.
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In the housing,
they install the motion sensor.
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It turns on the opener's light
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as soon
as you walk into the garage
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00:12:37,223 --> 00:12:38,992
or when the garage door opens.
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00:12:42,093 --> 00:12:45,462
Next are the switches for
programming the remote control
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and for setting
the travel limits.
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These are the points to which
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00:12:49,169 --> 00:12:54,072
the opener must move the door
to fully open and close it.
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00:12:54,073 --> 00:12:57,174
They then install the circuit
board, routing the antenna
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for the remote control receiver
to the outside.
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00:13:01,012 --> 00:13:03,780
They plug in the motion
sensor cable,
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00:13:03,781 --> 00:13:07,619
then wire and plug in the
connector for the light bulbs
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00:13:07,620 --> 00:13:11,021
and fasten the board in place
with screws.
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00:13:11,022 --> 00:13:15,025
They attach the electrical
ground wire to the chassis,
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00:13:15,026 --> 00:13:16,494
connect the power cable,
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00:13:16,495 --> 00:13:19,566
and then, the optical encoder
to the circuit board.
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00:13:22,035 --> 00:13:24,736
With all the internal components
installed now,
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00:13:24,737 --> 00:13:27,404
they affix the housing
to the chassis.
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00:13:27,405 --> 00:13:29,973
This completes the brain
of the garage door opener,
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00:13:29,974 --> 00:13:31,477
called the operator unit.
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00:13:34,347 --> 00:13:37,948
An automated testing machine
now checks all the functions,
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00:13:37,949 --> 00:13:40,718
simulating the load
of the garage door.
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00:13:40,719 --> 00:13:44,222
It also checks the light bulb
sockets and the connection ports
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00:13:44,223 --> 00:13:48,327
on the circuit board
for the safety beams.
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00:13:48,328 --> 00:13:50,995
The beams stop
and reverse the closing door
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00:13:50,996 --> 00:13:54,598
if they detect any object
in its path.
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00:13:54,599 --> 00:13:59,371
Once the operator unit
passes inspect,
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00:13:59,372 --> 00:14:03,574
it comes full circle to the end,
which is also the start,
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00:14:03,575 --> 00:14:04,710
of the production line.
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00:14:06,945 --> 00:14:09,715
A plastic lens
to enclose the light bulbs,
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00:14:09,716 --> 00:14:12,118
and the unit comes off the line.
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00:14:16,322 --> 00:14:21,226
The carriage rail
is milled from galvanized steel.
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00:14:21,227 --> 00:14:24,095
It has slots
for locking in plastic liners
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00:14:24,096 --> 00:14:26,566
which hold the screw rod.
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00:14:33,738 --> 00:14:35,405
To produce the screw rod,
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00:14:35,406 --> 00:14:38,242
the factory machines
a solid bar of steel
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00:14:38,243 --> 00:14:40,846
to the required dimensions
and profile.
220
00:14:40,847 --> 00:14:44,848
Then, with high pressure
rollers, it forms threads in it.
221
00:14:44,849 --> 00:14:48,653
Workers insert the screw rod
into the liners in the rail.
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00:14:48,654 --> 00:14:49,989
For the retail market,
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00:14:49,990 --> 00:14:52,924
rather than produce
one long rail and screw rod,
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00:14:52,925 --> 00:14:55,193
the factory
makes three shorter connecting
225
00:14:55,194 --> 00:14:58,829
sections that fit
into a smaller package.
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00:14:58,830 --> 00:15:02,134
This machine lubricates
the screw rod with grease.
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00:15:02,135 --> 00:15:04,903
It helps it rotate smoothly
in the rail liner
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00:15:04,904 --> 00:15:08,005
when the opener's motor
is running.
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00:15:08,006 --> 00:15:09,942
When the screw rod turns,
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00:15:09,943 --> 00:15:12,177
teeth on the base
of the carriage interlock
231
00:15:12,178 --> 00:15:13,345
with the threads,
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00:15:13,346 --> 00:15:15,681
moving the carriage
along the rail.
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00:15:15,682 --> 00:15:19,951
Workers first install the
carriage base at the factory.
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00:15:19,952 --> 00:15:21,184
Then, they pack
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00:15:21,185 --> 00:15:23,621
all the garage door opener
components for shipping,
236
00:15:23,622 --> 00:15:26,124
starting with the rail sections
and the operator unit.
237
00:15:30,862 --> 00:15:34,933
Last to go in are
the wall mounted control pad,
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00:15:34,934 --> 00:15:38,035
the remote controls,
and the safety beams,
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00:15:38,036 --> 00:15:42,140
which you install on each side
of the garage door opening.
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00:15:42,141 --> 00:15:44,342
When you install
the garage door opener,
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00:15:44,343 --> 00:15:47,779
you insert the screw rod
into the motor's drive shaft.
242
00:15:47,780 --> 00:15:50,148
Then, you assemble the rest
of the carriage,
243
00:15:50,149 --> 00:15:51,417
connecting it to an arm
244
00:15:51,418 --> 00:15:53,750
which attaches
to the garage door.
245
00:15:53,751 --> 00:15:58,055
Motor runs,
screw rod turns, carriage moves,
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00:15:58,056 --> 00:16:00,559
and your garage door
opens or closes.
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00:16:08,900 --> 00:16:10,568
Narrator: The bicycle
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00:16:10,569 --> 00:16:12,971
is the most efficient mode
of transport ever invented.
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Ninety nine percent
of the effort
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00:16:14,506 --> 00:16:17,875
put into turning a pedal
is transferred to movement,
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00:16:17,876 --> 00:16:20,377
so the lighter the bike,
the better.
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00:16:20,378 --> 00:16:22,246
Using cutting edge materials,
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00:16:22,247 --> 00:16:25,584
a high performance seat can
weigh as little as five ounces.
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00:16:28,755 --> 00:16:30,556
This company made a special seat
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00:16:30,557 --> 00:16:33,256
for a past tour de France
winner.
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00:16:33,257 --> 00:16:36,928
In fact, half the cyclists on
the prestigious pro tour racing
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00:16:36,929 --> 00:16:39,029
circuit use their seats.
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00:16:39,030 --> 00:16:42,199
The design process begins with
the simplest tools
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00:16:42,200 --> 00:16:44,068
pencils and paper.
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00:16:44,069 --> 00:16:47,038
Designers sketch
out a few basic ideas.
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00:16:47,039 --> 00:16:49,908
Specialists then transform
the sketched ideas
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00:16:49,909 --> 00:16:52,175
into 3D digital images.
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00:16:52,176 --> 00:16:56,680
The manufacturers machine model
those images into a prototype.
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00:16:56,681 --> 00:17:00,651
After testing, they
begin the manufacturing process.
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00:17:00,652 --> 00:17:02,187
A worker places a base,
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00:17:02,188 --> 00:17:05,556
or shell,
on the upper segment of a mold.
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00:17:05,557 --> 00:17:07,258
This company makes their shells
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00:17:07,259 --> 00:17:09,695
from a variety
of carbon fiber materials.
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00:17:11,830 --> 00:17:15,232
Polyurethane pours into
the other section of the mold.
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00:17:15,233 --> 00:17:16,800
This is the part of the mold
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00:17:16,801 --> 00:17:18,868
that will give the seat
its shape.
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00:17:18,869 --> 00:17:20,504
When the mold closes,
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00:17:20,505 --> 00:17:23,741
it cooks at a mere 104 degrees
fahrenheit.
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00:17:23,742 --> 00:17:26,810
A chemical reaction takes place
inside the mold,
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00:17:26,811 --> 00:17:30,748
which causes the polyurethane
to expand.
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00:17:30,749 --> 00:17:32,049
Five minutes later,
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00:17:32,050 --> 00:17:35,787
an operator removes the seats
from the molds.
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00:17:35,788 --> 00:17:40,724
Here, we see what the shells
look like before and after.
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00:17:40,725 --> 00:17:43,827
A worker removes excess
polyurethane from the edges
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00:17:43,828 --> 00:17:45,730
with a knife.
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00:17:45,731 --> 00:17:47,965
While the polyurethane cures,
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00:17:47,966 --> 00:17:49,968
workers
prepare the cover material.
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00:17:49,969 --> 00:17:52,537
The material is
a proprietary microfiber
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00:17:52,538 --> 00:17:55,039
specially made for this company.
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00:17:55,040 --> 00:17:58,343
Not only does this material need
to be flexible, waterproof,
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00:17:58,344 --> 00:17:59,378
and comfortable,
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00:17:59,379 --> 00:18:02,780
it has to be incredibly durable.
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00:18:02,781 --> 00:18:05,316
Once they've cut the material
into strips,
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00:18:05,317 --> 00:18:08,987
the workers
stack them on a stamping press.
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00:18:08,988 --> 00:18:13,090
A die has been custom made
to match the design of the seat.
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00:18:13,091 --> 00:18:15,826
The stamping press
descends with enough force
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00:18:15,827 --> 00:18:19,364
to cut through multiple layers.
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00:18:19,365 --> 00:18:22,634
It's now time to join
the three panels of material
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00:18:22,635 --> 00:18:24,469
that make up the seat cover.
295
00:18:24,470 --> 00:18:26,971
This facility
has two different methods
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00:18:26,972 --> 00:18:29,507
for attaching the pieces
to each other.
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00:18:29,508 --> 00:18:30,942
In this case,
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00:18:30,943 --> 00:18:33,679
a skilled worker carefully
stitches the material together.
299
00:18:36,815 --> 00:18:38,750
A different method
of joining the panels
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00:18:38,751 --> 00:18:42,587
involves a process
called thermal welding.
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00:18:42,588 --> 00:18:44,754
An operator skives, or thins,
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00:18:44,755 --> 00:18:47,924
the edges by shaving them
so that there won't be a bump
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00:18:47,925 --> 00:18:50,828
where they overlap.
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00:18:50,829 --> 00:18:54,231
Double sided tape
will hold the material together.
305
00:18:54,232 --> 00:18:59,270
A special tape dispenser applies
the tape to the skived edges.
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00:18:59,271 --> 00:19:05,109
A worker positions the panels,
carefully overlapping the edges.
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00:19:05,110 --> 00:19:06,478
A vacuum system removes air
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00:19:06,479 --> 00:19:09,814
from between the top and bottom
sections of the press,
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00:19:09,815 --> 00:19:11,449
holding the panels in position
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00:19:11,450 --> 00:19:14,253
and ensuring there will be
no bubbles at the seams.
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00:19:14,254 --> 00:19:17,422
The press then
heats the material
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00:19:17,423 --> 00:19:20,025
up to 280 degrees fahrenheit,
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00:19:20,026 --> 00:19:24,995
ensuring that the adhesive bonds
the panels together.
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00:19:24,996 --> 00:19:27,097
The design
of the shell for this seat
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00:19:27,098 --> 00:19:28,666
has several slots in it
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00:19:28,667 --> 00:19:31,235
to help create
the right combination
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00:19:31,236 --> 00:19:32,869
of flexibility and rigidity.
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00:19:32,870 --> 00:19:34,271
A laser machine
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00:19:34,272 --> 00:19:37,908
cuts stripes in the cover fabric
to create a graphic element
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00:19:37,909 --> 00:19:39,711
that reflects this design
feature.
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00:19:41,880 --> 00:19:44,516
Workers glue silver material
under the stripes
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00:19:44,517 --> 00:19:45,783
to highlight them,
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00:19:45,784 --> 00:19:49,887
then brush glue all over
the underside of the cover.
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00:19:49,888 --> 00:19:53,458
Mounting the cover on the seat
requires two operators.
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00:19:53,459 --> 00:19:56,461
They place the cover glue side
down on the seat,
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00:19:56,462 --> 00:19:58,663
ensuring
that it's positioned perfectly
327
00:19:58,664 --> 00:20:00,532
and that there are no
air pockets.
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00:20:02,733 --> 00:20:05,337
They work the cover
into a small recess
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00:20:05,338 --> 00:20:08,205
that runs around the perimeter
of the base.
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00:20:08,206 --> 00:20:10,607
They will then trim off
the excess material
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00:20:10,608 --> 00:20:12,443
with a utility knife.
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00:20:12,444 --> 00:20:14,679
The amount
of skilled manual craftsmanship
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00:20:14,680 --> 00:20:16,815
required to build these seats
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00:20:16,816 --> 00:20:19,517
is a key feature
of their quality,
335
00:20:19,518 --> 00:20:23,788
but the company also relies
on state of the art technology.
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00:20:23,789 --> 00:20:27,759
Bicycle seats sit on a framework
called a rail.
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00:20:27,760 --> 00:20:30,528
This facility makes rails
from both carbon fiber
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00:20:30,529 --> 00:20:32,364
and metal alloys,
339
00:20:32,365 --> 00:20:34,534
and it tests each one
with a dynamometer.
340
00:20:36,601 --> 00:20:37,836
Workers put glue
341
00:20:37,837 --> 00:20:40,604
in the attachment points
on the bottom of the seat
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00:20:40,605 --> 00:20:44,808
to ensure that it
passes a stringent safety test.
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00:20:44,809 --> 00:20:49,113
A customized machine bends
the seat to fit into the rail.
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00:20:49,114 --> 00:20:52,284
The seat will then be bent back
in the other direction
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00:20:52,285 --> 00:20:55,418
to return it
to its original shape.
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00:20:55,419 --> 00:20:58,055
The seat is now finished.
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00:20:58,056 --> 00:21:00,258
Fusing
state of the art technology
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00:21:00,259 --> 00:21:02,093
with skilled craftsmanship,
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00:21:02,094 --> 00:21:05,497
this company
makes 520,000 bicycle seats
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00:21:05,498 --> 00:21:06,766
every year.
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00:21:14,106 --> 00:21:16,307
If you have any comments
about the show,
352
00:21:16,308 --> 00:21:18,910
or if you'd like to suggest
topics for future shows,
353
00:21:18,911 --> 00:21:24,350
drop us a line at
sciencechannel.com/howitsmade.
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