All language subtitles for S02E12 - Cars; Grocery Carts; Rapid Tooling and Prototyping; Collectible Coins (576p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Cars...
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Grocery carts...
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Rapid tooling and prototyping...
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And collectible coins.
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The automotive industry
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Has seen a lot of changes
In recent years.
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More and more robots are
Replacing workers
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On the assembly line,
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And it isn't
Just cars and trucks
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Coming off the line anymore.
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Today's hot wheels are
Sport-utility vehicles and vans.
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In the plant's body shop,
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They begin by putting together
The front structure of the van.
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It's made up of the radiator
Support, two side rails,
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And clips on the front
Of those side rails
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For the bumper structure.
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Then they put
This front structure
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Onto the automated
Production line.
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Meanwhile, robots weld what's
Known as the ladder assembly.
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It's the backbone that supports
The floor and sides of the van.
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It contains, among other things,
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The pockets
That will hold the seats.
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Now the robots
Take the front-end structure
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And the ladder assembly
And weld them together.
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Elsewhere, robots
Work on the body panel
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For the passenger side
Of the van.
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The entire panel
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Is made of one piece
Of galvanized steel.
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The robots weld reinforcements
Onto the panel
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So they can later attach
Interior finishing
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And other components.
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A transfer device swoops down
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And transfers the panel
To the next station.
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The driver's side body panel,
Coming off another welding line,
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Is headed there, too.
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At the next station,
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Robots have already installed
An underbody with a floor panel
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On top of the ladder-assembly
Unit we saw earlier.
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Now the robots weld the body
Side panels to the underbody.
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They also weld inner wheel wells
To the body's side panels.
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Then they weld on a roof.
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The van then rolls
Into the area of the body shop
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Called closures.
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That's where they install
The lift gate, the hood,
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And the doors.
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An inspector checks the gaps
Around the hood,
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Looks for dents and dings
In the body,
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And makes sure the doors
Are flush with the side panels.
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He marks any areas
That need repair or adjustments
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With removable ink.
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The engines arrive at the plant
Already assembled.
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Workers just have to install
And adjust a few components.
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Meanwhile, the van
Is off at the paint shop,
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Followed by the trim shop
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For glass, handles,
And interior components.
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In the chassis department,
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The engine, transmission, rear
Suspension, and brake assembly
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Are installed from underneath.
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This part of the assembly line
Has two tiers.
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The van goes on top,
The components on the bottom.
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The machines that install
The components have long pins
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That fit into holes
In the van's underbody.
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This positions the components
With precision.
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Workers hook up
The gas tank manually.
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The seats arrive ready-made
From a nearby factory.
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They simply clamp into place
In the seat pockets
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That were welded onto
The ladder assembly earlier.
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An automated machine attaches
The tire to the wheel rim.
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Then it inflates
And balances the tire.
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Workers mount the tires,
Starting the nuts by hand,
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Then tightening them with tools.
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Now the van comes off
The carrier
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And goes full weight on
Its wheels for the first time.
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Workers start up the ignition
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And run the van
Through a series of tests.
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It's taken the plant about 24
Hours to produce this vehicle,
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Which will soon be on its way
To a car dealership.
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Narrator:
Geomatics is a high-tech science
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Whose objective is to gather
Geographic information,
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Then study and use it.
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The tools of geomatics
Range from cartography
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To remote sensing
To satellite imaging.
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We wouldn't be able
To study the environment
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Or monitor and develop
Our natural resources
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Without geomatic data.
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An oklahoma grocer invented
The first shopping cart
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Back in 1937.
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He noticed his customers
Stopped shopping
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Once their hand baskets
Became too heavy to carry.
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His basket on wheels
Became a rollaway success.
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This factory makes
About 50 different models
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Of shopping carts.
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They're built with heavy-duty
Steel and carbon wire.
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A single cart is made up
Of more than 150 wire pieces
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Of various lengths
And diameters.
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Automated machines
Bend the wires
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To form the carts'
Numerous components.
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To make the cart's basket,
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A worker uses a guide
Called a jig loader
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To line up the wires
In a mesh formation.
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Then a machine automatically
Spot-welds them together.
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The next machine
Applies 20 tons of pressure
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To bend the wires
Into a basket shape.
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A robot welds the sides
Of the basket.
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A worker then trims off
The excess wire.
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An automated machine
Bends a piece of wire
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To form the handle
Of the shopping cart.
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They make the frame for the base
Of the cart, called the chassis,
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Out of one thick tube
That's 13 feet long.
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A robot welds the chassis
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Using wire melted
By an electrical current.
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This creates
A very strong joint.
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A die machine punches out
Casters that'll hold the wheels.
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They're made of thick steel for
Extra strength and durability.
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They spot-weld the casters
To the chassis.
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They clean the cart's
Metal components
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In a bath of soap and acid.
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They electroplate the metal
With nickel,
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Then with chrome
As a finishing coat.
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It's finally time
For the cart to take shape.
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They rivet the wheels
To the chassis...
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...Then install the bottom rack.
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The basket comes next.
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They print the warnings
On the plastic panel
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For the collapsible baby seat.
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Then the seat goes on along
With the plastic corner bumpers.
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They print the store's name
On the handle inserts.
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The handle goes on last.
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After some final adjustments
And a quality control check,
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The newly minted shopping cart
Is ready to roll.
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Narrator: every machine, from
Your vacuum cleaner to your car,
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Is made up of a series of parts.
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Those parts are designed
By specialized companies.
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They first build a prototype,
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Then make the molds or tools
Needed to manufacture the parts.
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They design the part in 3-d
On a computer.
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The computer
Then guides the machines
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That construct the prototype.
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One method divides
The 3-d drawing
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Into cross-sectional layers
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Just a few thousandths
Of an inch thick.
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It feeds this information
To a laser
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That's directed at a tray
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Filled with a light-sensitive
Liquid resin.
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The laser's light
Hardens the resin
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In the shape of the part
Layer by layer,
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Eventually constructing
The prototype.
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They rotate the prototype
Under ultraviolet light
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For a few hours
To cure the resin.
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Then they polish or paint
The prototype
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According to the requirements
Of the design.
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Another prototyping method
Works much the same way
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But uses a fine, powdered
Plastic instead of resin.
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The computer guides the laser
To melt the powder
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In the shape of the part,
Again layer by layer.
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They extract
The hardened prototype
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From the unmelted powder.
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A third method of prototyping
Doesn't use a laser at all.
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The computer simply guides
Machinery to carve the prototype
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Out of a hard material
Such as a wood composite.
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Once a prototype is ready,
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They use it to construct
A model of the part
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Out of a very durable resin.
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They'll use that model
To make a mold,
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Then they'll use that mold
To cast the part out of metal.
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The resin model dries
At room temperature in 24 hours.
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Its surface must be smooth or
Else the mold will have defects.
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They attach channels
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That will guide the molten metal
Into the mold.
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Next, they fill the model with a
Mix of sand and a binding agent.
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They smooth out the surface,
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Then number it
For tracking purposes.
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The sand mix
Takes about 15 minutes
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To harden into a mold.
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Now they can
Finally cast the part.
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They carefully
Pour in the molten medal,
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In this case, magnesium,
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Heat it to about
1,300-degrees fahrenheit.
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They block the hole with sand
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To prevent the metal
From reacting to the air.
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The metal takes about
10 to 20 minutes to harden,
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Depending on the size
Of the mold.
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They crack the mold open
On a vibrating conveyer.
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They use a plaster mold
To cast parts
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That require
A better surface finish.
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Workers position a box
Around the prototype
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To contain the plaster.
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The mold goes into an oven
At about 570-degrees fahrenheit.
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00:14:11,137 --> 00:14:14,137
It takes
48 to 72 hours to cure,
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But it's not ready
For casting just yet.
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Workers first have to pierce
Some holes in it
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00:14:20,241 --> 00:14:21,689
To let all the air escape
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00:14:21,689 --> 00:14:24,551
Or the metal won't flow
Into all the crevices.
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00:14:24,551 --> 00:14:28,137
And they have to put in filters
To keep out impurities.
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00:14:28,137 --> 00:14:31,689
They strap the two halves
Of the plaster mold together,
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Securing them with metal screws.
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00:14:39,862 --> 00:14:44,275
Workers carefully
Pour in molten magnesium,
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Using a special gas to prevent
The metal from catching fire.
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Again, they seal
The opening with sand.
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00:14:53,931 --> 00:14:58,758
It takes the metal anywhere from
20 minutes to an hour to cool.
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00:14:58,758 --> 00:15:03,000
Then they break open the plaster
To remove the metal part.
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They cut off the channels
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00:15:04,896 --> 00:15:07,862
Through which
They poured in the metal
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And polish the part
Using grinders and sanders.
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00:15:11,344 --> 00:15:12,689
Then they paint it
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Using special spray paint
That adheres to magnesium.
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00:15:16,172 --> 00:15:19,206
The part is finally finished.
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00:15:19,206 --> 00:15:20,827
It takes several weeks
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00:15:20,827 --> 00:15:23,862
To prototype and tool
Metal machine parts.
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00:15:23,862 --> 00:15:25,241
When you think about it,
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00:15:25,241 --> 00:15:27,448
Even the machine
That make these parts
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00:15:27,448 --> 00:15:32,034
Are made of parts that were
Created with this method.
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Narrator:
The first people to make coins
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00:15:49,413 --> 00:15:54,241
Were the lydians
In asia minor in 640 b.C.
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00:15:54,241 --> 00:15:55,931
About 40 years later,
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00:15:55,931 --> 00:15:58,896
The concept spread
To ancient greece,
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00:15:58,896 --> 00:16:01,862
Where coins often featured
An owl --
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00:16:01,862 --> 00:16:05,448
The symbol
Of the goddess athena.
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00:16:05,448 --> 00:16:07,517
Around 500 b.C.,
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00:16:07,517 --> 00:16:11,172
The chinese invented coins made
Of cheap metals like copper,
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00:16:11,172 --> 00:16:13,758
Instead of gold and silver.
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00:16:13,758 --> 00:16:17,275
Today's currency coins
Are still made of copper,
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00:16:17,275 --> 00:16:20,103
Nickel, and other
Inexpensive materials.
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00:16:27,103 --> 00:16:31,344
The mint manufactures collector
Coins using sterling silver
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00:16:31,344 --> 00:16:35,310
As well as sterling scraps left
Over from making other coins.
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00:16:35,310 --> 00:16:37,620
The silver goes
Into a casting furnace
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00:16:37,620 --> 00:16:41,034
At 2,100 degrees fahrenheit.
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00:16:41,034 --> 00:16:44,620
The melted silver is cast
Into a continuous bar
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00:16:44,620 --> 00:16:47,862
About 1 1/2 inches high
By 5 inches wide.
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00:16:47,862 --> 00:16:51,931
A machine cuts the continuous
Bar into individual bars
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00:16:51,931 --> 00:16:53,655
About 30 inches long.
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00:16:55,689 --> 00:16:59,172
Each bar goes into what's called
The roughing mill.
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00:16:59,172 --> 00:17:02,137
The mill's two rollers squash
The bar flat,
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00:17:02,137 --> 00:17:05,206
Using up to 9 tons of force.
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00:17:05,206 --> 00:17:09,344
It takes up to a dozen passes
To flatten the bar
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00:17:09,344 --> 00:17:12,172
Into a strip
Just half an inch thick.
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00:17:12,172 --> 00:17:14,862
A machine called
The finishing mill
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00:17:14,862 --> 00:17:17,275
Thins the strip out even more
242
00:17:17,275 --> 00:17:20,241
To what will be the final
Thickness of the coin,
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00:17:20,241 --> 00:17:24,551
Anywhere from 3/100ths of
An inch to 2/10ths of an inch,
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00:17:24,551 --> 00:17:27,172
Depending on the denomination.
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00:17:27,172 --> 00:17:30,965
Next, the blanking machine
Stamps out blank coins.
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00:17:30,965 --> 00:17:32,965
The silver that's left over,
Called sisel,
247
00:17:32,965 --> 00:17:35,103
Goes back
Into the casting furnace,
248
00:17:35,103 --> 00:17:39,103
Where it's melted down
Into fresh bars of silver.
249
00:17:39,103 --> 00:17:43,517
The next stop for the blanks
Is the rimming machine,
250
00:17:43,517 --> 00:17:46,137
Whose spinning wheel presses
A raised edge,
251
00:17:46,137 --> 00:17:48,758
Or rim, on each one.
252
00:17:48,758 --> 00:17:51,931
The blanks then go into a tub
Filled with water,
253
00:17:51,931 --> 00:17:54,517
Cleaning solutions,
And steel beads.
254
00:17:54,517 --> 00:17:56,482
The beads act
As an abrasive agent,
255
00:17:56,482 --> 00:17:59,793
Smoothing and polishing
The blanks.
256
00:17:59,793 --> 00:18:02,034
After a 20-minute cycle,
257
00:18:02,034 --> 00:18:04,758
They empty the tub's contents
Into a sifter
258
00:18:04,758 --> 00:18:07,068
To separate the blanks
From the beads.
259
00:18:07,068 --> 00:18:09,758
Workers then towel dry
The blanks by hand.
260
00:18:09,758 --> 00:18:12,965
This ensures there will be
No water stains on the coins.
261
00:18:12,965 --> 00:18:15,241
Throughout
The coin-making process,
262
00:18:15,241 --> 00:18:18,137
As the silver is worked,
It becomes brittle --
263
00:18:18,137 --> 00:18:21,586
So brittle that it could easily
Break when struck.
264
00:18:21,586 --> 00:18:23,413
That's why at several stages
265
00:18:23,413 --> 00:18:28,344
The metal goes through an oven
Called an annealing furnace.
266
00:18:28,344 --> 00:18:31,827
The coin design comprises
Artwork or a photograph
267
00:18:31,827 --> 00:18:34,655
Or a combination of both.
268
00:18:34,655 --> 00:18:37,689
This coin will feature
A photograph of queen elizabeth
269
00:18:37,689 --> 00:18:40,137
Provided by buckingham palace.
270
00:18:40,137 --> 00:18:42,931
The artist uses
A computer program
271
00:18:42,931 --> 00:18:45,000
To design a collage
Of various elements.
272
00:18:45,000 --> 00:18:49,172
Once mint officials approve
The final design,
273
00:18:49,172 --> 00:18:53,137
The process of engraving
Can begin.
274
00:18:53,137 --> 00:18:57,758
They take a plaster disk that's
10 1/2 inches in diameter.
275
00:18:57,758 --> 00:19:00,689
The computer guides
The engraving machine
276
00:19:00,689 --> 00:19:03,655
To turn the one-dimensional
Computer design
277
00:19:03,655 --> 00:19:07,344
Into a three-dimensional version
In rough detail.
278
00:19:07,344 --> 00:19:10,724
This creates a plaster model
Of the design in the negative.
279
00:19:10,724 --> 00:19:14,689
They now use this negative
To cast a plaster positive.
280
00:19:14,689 --> 00:19:18,241
An artist then enhances
The detail by hand.
281
00:19:18,241 --> 00:19:22,448
Once that's done, they cast
A negative plaster mold.
282
00:19:22,448 --> 00:19:25,793
From that, they then cast
A positive mold,
283
00:19:25,793 --> 00:19:27,793
This time in rubber.
284
00:19:27,793 --> 00:19:29,482
From the rubber,
285
00:19:29,482 --> 00:19:33,068
They cast a negative mold
Out of hard, black epoxy.
286
00:19:33,068 --> 00:19:36,896
They mount the epoxy model on
A machine called a pantograph,
287
00:19:36,896 --> 00:19:40,344
Which is essentially
A reducing machine.
288
00:19:40,344 --> 00:19:42,344
It traces the model
289
00:19:42,344 --> 00:19:44,965
And cuts a version 1 1/2 times
Smaller in brass.
290
00:19:44,965 --> 00:19:48,862
This reduction process
Takes 36 hours.
291
00:19:48,862 --> 00:19:51,620
Then an engraver
Takes the brass model
292
00:19:51,620 --> 00:19:54,551
And fine-tunes the design
Under a microscope.
293
00:19:54,551 --> 00:19:57,827
At this stage, the engraver
Also adds the lettering,
294
00:19:57,827 --> 00:19:59,689
Noting the year,
The denomination,
295
00:19:59,689 --> 00:20:02,241
And the country of issue.
296
00:20:02,241 --> 00:20:05,620
Then comes another
36-hour reduction process.
297
00:20:05,620 --> 00:20:08,793
They reduce this brass model
To 1 1/2 half times its size
298
00:20:08,793 --> 00:20:11,586
To create what's called
A matrix --
299
00:20:11,586 --> 00:20:14,206
A negative model made
Of high-grade steel
300
00:20:14,206 --> 00:20:16,896
That's the final size
Of the coin.
301
00:20:16,896 --> 00:20:20,034
Then they strike the matrix
Onto a block of steel
302
00:20:20,034 --> 00:20:23,172
Which creates a positive
Called a punch.
303
00:20:23,172 --> 00:20:26,103
Then they strike the punch
Onto another steel block
304
00:20:26,103 --> 00:20:30,068
To create a negative
Called a die.
305
00:20:30,068 --> 00:20:33,517
The coins are made one at a time
In the coin press.
306
00:20:33,517 --> 00:20:38,103
There are two dies per coin,
One for each side,
307
00:20:38,103 --> 00:20:40,448
Positioned above and below
The blank.
308
00:20:40,448 --> 00:20:43,862
They strike simultaneously,
Not once but twice,
309
00:20:43,862 --> 00:20:46,344
To create
A high-quality impression.
310
00:20:46,344 --> 00:20:50,137
In contrast, circulation coins
Are struck just once
311
00:20:50,137 --> 00:20:51,724
On high-speed machines
312
00:20:51,724 --> 00:20:55,206
That make several hundred coins
Per minute.
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00:20:59,379 --> 00:21:02,206
If you have any comments
About the show
314
00:21:02,206 --> 00:21:05,655
Or if you'd like to suggest
Topics for future shows,
315
00:21:05,655 --> 00:21:07,931
Drop us a line at...
25524
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