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Narrator:
When it comes to windows,
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There's a variety of materials
To choose from.
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00:00:56,344 --> 00:00:59,413
Wood windows are typically
The most expensive option,
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00:00:59,413 --> 00:01:02,034
But they are also
The most versatile.
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They can be constructed
In any style,
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Stained any shade,
Or painted any color.
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Wooden windows
Can be custom made
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To match the home's
Existing windows.
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This style is called
A traditional double hung.
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Its upper and lower sections
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Open independently
Of each other.
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Manufacturers make windows
From a variety of woods.
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This company uses mahogany, a
Premium rot-resistant hardwood.
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This computer-guided saw
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Cuts pieces of wood
To the required length.
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The next machine,
Called the jointer,
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00:01:41,344 --> 00:01:44,724
Squares the edges
And smoothes the surfaces.
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Now, they mill each piece
To the final shape.
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A vacuum holds it steady
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00:01:50,310 --> 00:01:54,172
While a computer-guided router
Works at it from all angles.
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The router uses
Up to 33 different tools
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From its on-board magazine.
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This piece will be part
Of a curved window.
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00:02:02,206 --> 00:02:06,344
One tool cuts the basic shape,
Another tool profiles,
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And the other bores holes
For the dowels.
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00:02:10,551 --> 00:02:14,310
Twelve different tools later,
This is the final shape.
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An assembler
Pours glue in the holes...
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...Then inserts wood dowels.
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Their unique shape allows
The glue to surround the dowel,
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Maximizing adhesion.
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Using the dowels as a guide,
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He connects the two vertical
Pieces of the window, the rails,
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With the horizontal pieces,
The stiles.
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This forms the window's sash.
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He clamps the sash
In a hydraulic press.
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It's calibrated
To join the parts together
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With just the right amount
Of pressure.
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He dries the glue with a
Radio-frequency heating device.
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00:03:00,344 --> 00:03:03,068
They return the piece
To the computer-guided router
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For the final milling.
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00:03:05,172 --> 00:03:08,137
This sideways saw cuts a slot
Down each side
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For weather stripping.
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For double hung windows,
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Another tool cuts openings
Along the edge.
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These openings will hold
Weighted cords
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That counterbalance the sash.
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Then, they put the finished sash
Through a sanding machine.
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The machine removes tool marks
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And preps the surface
For a paint primer.
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They install the muntins,
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Short pieces inside the sash
That form decorative squares.
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First, the horizontal muntins,
Then the vertical ones.
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Each square will contain
Its own pane of glass.
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They sand the muntins by hand
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To smooth the surface
For finishing.
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Then, the sash is sprayed
With a water-based primer.
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00:04:08,000 --> 00:04:12,482
Once the primer dries, the sash
Goes to the glazing department.
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00:04:12,482 --> 00:04:16,793
This is where they cut
The glass panes to size.
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Windows can have single,
Double, or triple panes,
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Separated by
An aluminum spacer bar.
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This is a single-pane window.
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The glazer applies
A bead of caulk
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To the inner ledge
Of the sash...
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...Then sets the glass on it.
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He secures the glass in place
By one of two methods --
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Either by driving in tiny, flat
Nails called glazing points,
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Or by caulking the perimeter
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And applying small moldings
Called glazing beads.
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The glazing beads are fastened
To the sash with small nails.
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Once the glass is secure,
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The worker removes the
Excess caulk, cleans the glass,
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And inspects it
For any marks or scratches.
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The final step
Is to install the hardware.
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It varies by window style.
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A double-hung window
Has a bar lift on the bottom
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And a latch that locks
Together the two sashes.
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You release the latch
To open either one.
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Once the sashes are installed,
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They can be painted
To match any home's exterior.
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Narrator: the art of weaving has
Been around since the stone age.
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Traditional weavers use
Techniques and designs
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That reflect
Their cultural origins.
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Today's fashion industry
Has built on this tradition
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To produce fine wool garments.
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Designers keep a record
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Of the fabrics they have created
Over the years.
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They pin samples in books based
On quality, colors, and patterns
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For their customers
To choose from.
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This is what cashmere goat hair
Looks like
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When it arrives
At the wool mill.
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Short fibers, called flocks,
Go through a carding machine.
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This machine opens up the fibers
And mixes colors together.
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The carding process
Removes impurities
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And reduces the fibers
To a flat layer.
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The machine combs
And twists the layer of fiber
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In preparation for spinning.
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The spinner separates the layer
Into threads
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And winds each one
On bobbins of over 40 pounds.
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An operator loads yarn
Into a dyeing machine.
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The entire fiber-drying process
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Takes about two hours
For a reel this size.
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Uncarded locks of hair
Called wool tops
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Are used to make worsted yarn.
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A worker feeds the ribbon-like
Thread into a blending machine.
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The blending process
Merges twelve threads
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Into one large strip.
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The machine re-combs
And twists the blended fibers,
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Then spins them
Into a single strand.
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The coning machine winds
The single thread around a cone
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By pulling it through
A tensioning device
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With a series of spindles
Underneath.
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This machine can comb 20 pounds
Of wool in about one hour.
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Another spinning machine slowly
Unwinds worsted-wool bobbins.
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It accelerates as the threads
Run through a tensioning device
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And onto spindles.
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Even though
The machine processes
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Dozens of bobbins
Simultaneously,
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This process will last
Several hours.
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The set of threads that will
Make up the woven cloth
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Is called the warp.
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Hundreds of parallel threads
Wind up on this roll,
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Called the warping machine.
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These rolls can stretch
Several miles long.
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The warp is now ready
For weaving.
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This shuttle loom
Holds the warp under tension
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While it interweaves
The over and under threads
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Using two sets
Of weaving needles.
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This moving part, the beater,
Keeps the fabric under tension
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00:09:29,241 --> 00:09:31,862
As it comes out of the loom
And onto the cloth beam.
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This rapier loom
Can weave fabrics
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Four or five times faster
Than an automatic shuttle loom,
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And about 200 times faster
Than a hand-operated loom.
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The completed fabric
Goes to quality control.
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A worker performs
A visual check,
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Looking for any defects
In the fabric.
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If she finds a broken thread,
She repairs it by hand.
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Using a sewing needle,
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She replaces the broken thread
With a new one.
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00:10:11,103 --> 00:10:14,000
Once the fabric
Passes quality control,
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It goes through
A two-hour cleaning process.
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Then, the cloth rolls through
A steaming machine
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Before accumulating at
The end of the production line.
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The finishing process
For a woven cloth
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Can take up to a week.
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Designers study the fabrics
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And choose arrangements
To make a collection.
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They mark selected patterns
With codes and cut out samples.
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00:10:43,206 --> 00:10:46,551
Then they make a sample booklet
Of their fabrics
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For customers to choose from.
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The fabric collection
Changes twice a year,
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Providing a wide variety
Of styles suited to the season.
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Narrator: plastic is
A convenient form of packaging,
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But can be harmful
To the environment.
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Most plastics don't decompose,
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So they litter the landscape
Forever.
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Machines called granulators
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Can help ease
This pollution problem.
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They grind the plastic waste
Into tiny chips
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That can then be recycled.
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Granulators greatly reduce
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The amount of waste
We humans produce.
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Instead of throwing plastics
Like these milk crates away,
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They can be tossed
In a granulator.
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They chop the waste
Into little pieces,
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Which can be used
To make new plastic containers.
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Making a granulator starts
With star-shaped rotors
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That will hold and rotate
The blades of the granulator.
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A worker machines
The center hole of the rotor
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00:11:59,206 --> 00:12:02,000
So that it will fit
A steel shaft.
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00:12:02,000 --> 00:12:06,172
Employees slide the shaft
Through the center of the rotor.
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00:12:08,482 --> 00:12:12,827
Multiple rotors are machined and
Installed on the steel shaft.
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The rotors are
Spaced evenly apart.
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A member of the team
Welds the rotors to the shaft.
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These welds will stop the rotors
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From sliding out of position
During grinding.
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Next, steel blades are exposed
To intense heat for 12 hours.
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Once they're red hot,
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An employee plunges them
Into cooling oil.
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00:12:41,241 --> 00:12:44,482
This removes stresses
And strengthens the metal.
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00:12:47,310 --> 00:12:50,172
Next, a grinding wheel
Refines the shape of the blade
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So it will fit nicely
To the rotors.
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It also hones the cutting edge
Until it's extremely sharp.
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They transfer
The rotor-and-shaft assembly
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To a metal cradle.
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00:13:07,275 --> 00:13:12,206
This rotor system is smaller
Than the one assembled earlier.
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It also has triangular rotors
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Designed to chop up
Plastic jugs.
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A worker screws six blades
To the rotors.
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00:13:23,448 --> 00:13:26,000
He then attaches four blades
To the casing,
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Placing them at different angles
Than the rotating blades.
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Together, these blades will
Chop plastic very effectively.
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But, the gap between the blades
Needs to be fine-tuned.
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A worker adjusts the gap
To the optimal width.
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00:13:51,482 --> 00:13:55,379
Now, it's over to
The granulator's lower casing.
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00:13:55,379 --> 00:13:58,862
A rotating blade shaves
The edges to specification.
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The next worker spray paints
The outer-casing parts.
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00:14:09,655 --> 00:14:14,068
This protects the steel
From rust.
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00:14:14,068 --> 00:14:16,103
After the paint dries,
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00:14:16,103 --> 00:14:18,344
They install the blade system
In the outer casing
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00:14:18,344 --> 00:14:22,275
And add a wire-mesh screen.
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00:14:22,275 --> 00:14:23,965
The screen acts as a sifter,
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00:14:23,965 --> 00:14:26,620
Allowing only plastic
Small enough for recycling
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To travel through the holes.
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00:14:30,379 --> 00:14:35,379
Now, the upper housing
Is lowered onto the blade unit.
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00:14:35,379 --> 00:14:38,551
A long hinge
Is added into the holes
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00:14:38,551 --> 00:14:41,931
So the plastic granulator
Can be opened for maintenance.
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00:14:46,517 --> 00:14:51,344
They give the blade system a
Test spin, and it turns freely.
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00:14:51,344 --> 00:14:55,827
Another employee assembles
A hopper for the granulator.
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00:14:55,827 --> 00:14:59,068
He drapes a steel curtain
Over the opening
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00:14:59,068 --> 00:15:03,517
To keep in
Any flying plastic chips.
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00:15:03,517 --> 00:15:07,448
Using a crane, the team lowers
The hopper onto the granulator.
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00:15:10,413 --> 00:15:12,448
They confirm
That the two components
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00:15:12,448 --> 00:15:14,793
Are correctly aligned,
And bolt them together.
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00:15:18,310 --> 00:15:22,517
Next, a 50 horsepower motor is
Installed below the blade shaft.
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00:15:22,517 --> 00:15:24,586
Then, they loop a pulley
From a flywheel
216
00:15:24,586 --> 00:15:27,517
On the blade shaft to the motor.
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00:15:27,517 --> 00:15:30,034
Now, the workers cover
The pulley system and motor
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00:15:30,034 --> 00:15:32,379
With the steel housing.
219
00:15:32,379 --> 00:15:34,517
Then, a drawer is installed
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00:15:34,517 --> 00:15:38,413
To collect the plastic chips
As they fall.
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00:15:38,413 --> 00:15:42,827
They're now ready
To power up the granulator.
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00:15:42,827 --> 00:15:46,413
Every machine is tested before
It leaves the factory
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00:15:46,413 --> 00:15:48,172
To confirm
That it's fully functional.
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This plastic granulator
Is now ready
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00:15:57,517 --> 00:16:00,620
To take on the growing problem
Of plastic waste.
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00:16:15,172 --> 00:16:18,862
Narrator: glass lends a sparkle
To any interior.
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00:16:18,862 --> 00:16:22,000
From a bathroom sink
To a staircase,
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00:16:22,000 --> 00:16:25,586
Architectural glass is both
Functional and artistic.
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00:16:25,586 --> 00:16:30,758
The glass can be either handmade
Or mechanically formed.
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00:16:34,827 --> 00:16:37,206
It's called architectural glass
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00:16:37,206 --> 00:16:40,379
Because an architect usually
Designs its aesthetic features
232
00:16:40,379 --> 00:16:42,862
And the objects
The glass will be paired with.
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00:16:44,931 --> 00:16:47,689
This company fuses
Multiple sheets of glass,
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00:16:47,689 --> 00:16:49,689
Each about
A quarter of an inch thick,
235
00:16:49,689 --> 00:16:52,034
To create a finished product
Of any thickness.
236
00:16:56,931 --> 00:17:00,068
For example, this
Soon-to-be kitchen countertop
237
00:17:00,068 --> 00:17:02,827
Uses 5 sheets of standard glass.
238
00:17:05,275 --> 00:17:08,034
Grabbing one at a time
With handled suction cups,
239
00:17:08,034 --> 00:17:09,344
They gently place it
240
00:17:09,344 --> 00:17:12,241
On a pneumatically operated
Cutting table.
241
00:17:12,241 --> 00:17:14,965
They measure and cut
The correct size
242
00:17:14,965 --> 00:17:17,862
Using a square angle
With a diamond tip blade.
243
00:17:17,862 --> 00:17:22,620
Diamonds are the only material
That can cut glass.
244
00:17:27,068 --> 00:17:31,758
This kiln is a specialized oven
For baking glass.
245
00:17:31,758 --> 00:17:34,689
A craftsman sprinkles
White powder
246
00:17:34,689 --> 00:17:36,586
Onto the base of the kiln.
247
00:17:36,586 --> 00:17:39,448
The powder will leave a texture
In the sheet of glass.
248
00:17:41,793 --> 00:17:44,137
Next, he sprinkles
Ground-up, colored glass
249
00:17:44,137 --> 00:17:46,000
Across the glass sheet
250
00:17:46,000 --> 00:17:49,655
To give the kitchen countertop
A unique color scheme.
251
00:17:49,655 --> 00:17:52,827
They sandwich the glass
With another sheet of glass,
252
00:17:52,827 --> 00:17:54,620
Repeating this coloring process
253
00:17:54,620 --> 00:17:56,689
With each
Of the remaining layers.
254
00:18:05,655 --> 00:18:08,551
Once the last sheet of glass
Is put in place,
255
00:18:08,551 --> 00:18:10,551
They clean the top surface.
256
00:18:14,310 --> 00:18:18,000
Now, it's time to close the kiln
And bake the glass.
257
00:18:27,655 --> 00:18:31,965
Inside the kiln, the five layers
Fuse into one unit.
258
00:18:35,344 --> 00:18:38,689
At another kiln, a stack
Of glass has been fused together
259
00:18:38,689 --> 00:18:40,586
And is ready for the next step.
260
00:18:40,586 --> 00:18:42,000
Workers open the kiln
261
00:18:42,000 --> 00:18:45,241
And carefully transfer the
Newly formed glass countertop
262
00:18:45,241 --> 00:18:46,827
Onto a rolling cart.
263
00:18:53,620 --> 00:18:56,965
They take the counter
To the polishing machine.
264
00:18:56,965 --> 00:18:59,310
With stones and water,
265
00:18:59,310 --> 00:19:01,413
The machine
Grinds down the edges
266
00:19:01,413 --> 00:19:03,862
Until the layering
Is no longer visible.
267
00:19:06,724 --> 00:19:08,379
The finished glass countertop
268
00:19:08,379 --> 00:19:10,758
Is strong enough
To span over nine feet
269
00:19:10,758 --> 00:19:12,620
Without structural support.
270
00:19:15,758 --> 00:19:18,413
And because of
The heating-and-cooling process,
271
00:19:18,413 --> 00:19:22,379
The glass is now scratch-proof
And chip-resistant.
272
00:19:22,379 --> 00:19:25,482
You can even chop food
Directly on the surface.
273
00:19:25,482 --> 00:19:28,241
At a different kiln,
They're making a sink.
274
00:19:28,241 --> 00:19:31,172
First, they use
A textured glass stamp
275
00:19:31,172 --> 00:19:33,172
To press a pattern
In the powder.
276
00:19:35,241 --> 00:19:38,551
Then, they place three layers
Of glass over the pattern,
277
00:19:38,551 --> 00:19:40,413
Carefully aligning the edges.
278
00:19:47,241 --> 00:19:49,586
After baking,
The three layers are fused
279
00:19:49,586 --> 00:19:53,206
Into one thick circle of glass.
280
00:19:53,206 --> 00:19:54,551
The bottom of the glass
281
00:19:54,551 --> 00:19:56,413
Has taken on the pattern
Of the powder,
282
00:19:56,413 --> 00:19:58,379
Leaving a unique look.
283
00:19:58,379 --> 00:20:00,586
This will be
The outside surface of the sink.
284
00:20:04,793 --> 00:20:07,793
They place the glass
Over a sink-shaped mold
285
00:20:07,793 --> 00:20:09,517
In a different type of kiln.
286
00:20:12,379 --> 00:20:17,275
Over several hours, the glass
Melts into the sink-shaped mold.
287
00:20:17,275 --> 00:20:21,758
Once the glass cools,
They extract what is now a sink.
288
00:20:24,034 --> 00:20:27,172
They carefully measure and
Mark where the drain hole goes,
289
00:20:27,172 --> 00:20:30,103
Then they drill the hole
With a diamond bit.
290
00:20:32,137 --> 00:20:34,034
This generates a lot of heat,
291
00:20:34,034 --> 00:20:37,655
So they must continuously
Cool the bit with cold water.
292
00:20:37,655 --> 00:20:41,793
Otherwise, the tool
Could overheat and jam.
293
00:20:41,793 --> 00:20:45,068
The glass sink is finished.
294
00:20:48,000 --> 00:20:49,586
They use the same technique
295
00:20:49,586 --> 00:20:53,000
To produce glass sinks
In various colors and shapes.
296
00:20:57,655 --> 00:20:59,310
Sometimes, these sinks
297
00:20:59,310 --> 00:21:02,034
Are even integrated
With glass countertops.
298
00:21:02,034 --> 00:21:04,482
Countless other
Interior-design components
299
00:21:04,482 --> 00:21:07,241
Can be made
From architectural glass.
300
00:21:07,241 --> 00:21:10,241
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00:21:10,241 --> 00:21:13,241
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302
00:21:19,068 --> 00:21:21,275
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303
00:21:21,275 --> 00:21:24,068
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304
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