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Narrator: ceramic is one
Of the best insulation materials
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In the world.
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00:00:58,379 --> 00:01:02,068
Grills made with ceramic bodies
Can bake, roast, smoke,
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00:01:02,068 --> 00:01:04,103
And, of course, grill food.
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Ceramic grills retain more heat
Than metal ones,
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00:01:06,965 --> 00:01:10,620
Resulting in a juicier,
More flavorful meal.
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Ceramic grills
Use natural-lump charcoal.
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Natural charcoal is made
By carbonizing wood
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00:01:20,172 --> 00:01:23,758
Through a specialized
Heating process.
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Cooking with natural charcoal
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Is just like cooking
Over a campfire.
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00:01:30,724 --> 00:01:33,586
At this factory,
They begin by making a slurry.
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00:01:33,586 --> 00:01:37,379
The main ingredients
Are water, clay, feldspar,
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00:01:37,379 --> 00:01:40,379
And other raw materials.
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00:01:40,379 --> 00:01:42,758
When the slurry is fired
At a high temperature,
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It hardens
Into ceramic material.
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00:01:50,689 --> 00:01:53,620
Another team assembles
The two-part plaster mold
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To cast the base of the grill.
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00:01:57,068 --> 00:02:00,068
After cleaning off residue
From the previous casting,
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00:02:00,068 --> 00:02:04,034
They clamp the parts together.
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00:02:04,034 --> 00:02:06,034
The mold has two funnels.
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00:02:06,034 --> 00:02:09,482
One funnel pumps
The slurry into the mold.
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00:02:09,482 --> 00:02:13,000
The other allows air to exit
As the slurry fills the gap
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00:02:13,000 --> 00:02:15,448
Between the two parts
Of the mold.
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00:02:18,310 --> 00:02:21,000
They let the slurry set
For several hours.
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00:02:21,000 --> 00:02:23,896
The plaster mold absorbs 80%
Of the water,
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00:02:23,896 --> 00:02:28,448
Leaving a firm but damp casting.
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00:02:28,448 --> 00:02:30,241
They remove the top part
Of the mold
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00:02:30,241 --> 00:02:33,103
And trim off
Any excess material.
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00:02:35,000 --> 00:02:39,551
They cut out a rectangular hull
For the sliding draft door.
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00:02:39,551 --> 00:02:43,275
The door allows cold air
To enter the grill.
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00:02:43,275 --> 00:02:46,620
Then a worker uses a vacuum
Attached to a hoist
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00:02:46,620 --> 00:02:51,241
To remove the heavy grill base
From the mold.
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00:02:51,241 --> 00:02:53,137
They repeat this casting process
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00:02:53,137 --> 00:02:55,310
For the other ceramic parts
Of the grill,
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Including the top called
The dome and the fire box,
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Which sits inside the base
And holds the charcoal.
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00:03:05,413 --> 00:03:06,793
After each casting,
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00:03:06,793 --> 00:03:10,517
They scrape and sand
Away the excess material.
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00:03:16,482 --> 00:03:18,862
They roll the cast parts
Into a dryer
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00:03:18,862 --> 00:03:21,413
To remove
The remaining moisture.
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00:03:21,413 --> 00:03:23,068
For the next 30 hours,
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00:03:23,068 --> 00:03:24,482
Blowers circulate air
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That's heated to
180 degrees fahrenheit.
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After the parts cool,
The base and dome
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00:03:30,931 --> 00:03:34,965
Undergo a final touch up to
Perfect their exterior surfaces.
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Next, the parts are taken
To an automated glazing station.
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00:03:41,103 --> 00:03:45,862
A conveyor spins the parts
Under a shower of ceramic glaze.
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00:03:45,862 --> 00:03:47,586
A worker checks the coverage
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00:03:47,586 --> 00:03:50,758
And sprays a touch up
Where required.
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00:03:52,793 --> 00:03:56,413
The glaze dries
In about 20 seconds.
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00:03:58,241 --> 00:04:01,206
Workers vacuum up the excess...
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00:04:04,344 --> 00:04:08,758
...Then temporarily assemble
The grill for firing.
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00:04:08,758 --> 00:04:13,172
They place the fire box
Inside the base,
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00:04:13,172 --> 00:04:18,310
The base plate
At the bottom of the fire box,
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00:04:18,310 --> 00:04:21,344
And the dome on top of the base.
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00:04:21,344 --> 00:04:25,724
They fire the grills
In a huge kiln for 24 hours.
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00:04:25,724 --> 00:04:27,551
They gradually increase
The temperature
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00:04:27,551 --> 00:04:30,862
To more than
2,300 degrees fahrenheit,
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00:04:30,862 --> 00:04:34,862
Hold it there for a set time,
Then gradually cool it down.
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00:04:34,862 --> 00:04:37,827
This firing process
Triggers a chemical reaction
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00:04:37,827 --> 00:04:40,275
That transforms
The clay-based slurry
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00:04:40,275 --> 00:04:44,000
Into hard, heat-resistant
Ceramic.
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00:04:44,000 --> 00:04:49,310
It also turns the glaze
On the surface into black glass.
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00:04:49,310 --> 00:04:50,724
After firing,
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00:04:50,724 --> 00:04:54,655
They attach the stainless steel
Draft door to the base.
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00:04:54,655 --> 00:04:58,034
They spread adhesive
On the top edge of the base...
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00:05:00,413 --> 00:05:05,206
...And apply a gasket
Made of heat-resistant material.
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00:05:05,206 --> 00:05:08,896
This creates an air seal
Between the base and the dome.
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00:05:08,896 --> 00:05:12,413
Then they attach the two parts
With a hinge.
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00:05:16,655 --> 00:05:20,275
They insert the fire box
And stamp it.
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00:05:23,620 --> 00:05:26,137
Then they glue a gasket
Around the neck of the dome
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00:05:26,137 --> 00:05:29,137
And install the top vent.
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00:05:29,137 --> 00:05:32,241
They place the cast-iron grate
That holds the charcoal
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00:05:32,241 --> 00:05:35,206
And the porcelain-coated cooking
Grates inside the grill.
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00:05:35,206 --> 00:05:37,862
The cast-iron grate
Holds the charcoal.
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The porcelain-coated grate
Is for cooking.
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00:05:40,379 --> 00:05:43,931
Finally,
They install the thermometer.
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00:05:43,931 --> 00:05:45,620
After lighting the charcoal,
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00:05:45,620 --> 00:05:48,206
Grillers can adjust the air flow
With the draft door
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00:05:48,206 --> 00:05:50,206
And top vent.
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The draft door and top vent
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00:05:51,758 --> 00:05:54,482
Must be fully closed
To shut off the grill.
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00:05:54,482 --> 00:05:58,068
This cuts off the air supply
And extinguishes the fire.
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00:06:07,137 --> 00:06:08,448
Narrator: many factories
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Use punching machines
To make the parts they need.
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00:06:13,275 --> 00:06:16,862
Older punching machines
Consisted of a large press
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00:06:16,862 --> 00:06:20,482
Powered by a separate hydraulic
Or pneumatic system.
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00:06:20,482 --> 00:06:22,137
Today's smaller
Punching machines
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00:06:22,137 --> 00:06:26,034
Contain both of these components
In a single device.
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00:06:28,379 --> 00:06:30,655
These punching machines
Are used in factories
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00:06:30,655 --> 00:06:33,827
That make aluminum window
And door frames.
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00:06:35,931 --> 00:06:37,379
A factory worker inserts
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00:06:37,379 --> 00:06:39,724
A strip of extruded aluminum
In the machine
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00:06:39,724 --> 00:06:43,000
And presses a foot pedal.
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00:06:43,000 --> 00:06:46,586
The punch strikes the die,
Making the required cut.
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00:06:49,068 --> 00:06:51,862
They construct the machine
Out of steel and aluminum,
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00:06:51,862 --> 00:06:55,586
Both of which arrive
At the factory as solid bars.
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00:06:57,931 --> 00:07:00,896
First they saw the bars
Into smaller pieces
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00:07:00,896 --> 00:07:04,551
So they can make the machine's
Various components.
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00:07:14,068 --> 00:07:15,758
They place the aluminum pieces
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00:07:15,758 --> 00:07:18,620
In a computer-guided
Milling machine.
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00:07:21,068 --> 00:07:23,931
It uses a series of tools
To shape the metal
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00:07:23,931 --> 00:07:26,103
Into a specific component.
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00:07:32,068 --> 00:07:35,310
This piece is called
A punch guide.
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00:07:35,310 --> 00:07:37,310
Its job is to align
The punch tool
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00:07:37,310 --> 00:07:40,172
So that it strikes the die
Correctly.
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00:07:42,275 --> 00:07:44,310
A worker grinds the edges
Of the part
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Until they're smooth.
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A different milling machine
Cuts more resilient parts
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Out of steel bars.
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00:08:02,310 --> 00:08:04,068
It, too, is computer guided
113
00:08:04,068 --> 00:08:06,862
And follows
Technical specifications.
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00:08:13,586 --> 00:08:16,448
This steel component
Is the punch tool.
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00:08:19,793 --> 00:08:23,758
It strikes through a steel die
Manufactured the same way.
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00:08:27,413 --> 00:08:28,724
Every machine part
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00:08:28,724 --> 00:08:31,310
Undergoes a meticulous
Quality-control inspection.
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00:08:31,310 --> 00:08:36,620
This computer-guided sensor
Checks each piece.
119
00:08:36,620 --> 00:08:38,655
Once all the parts
Have passed testing,
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00:08:38,655 --> 00:08:40,620
Workers begin assembling.
121
00:08:40,620 --> 00:08:43,241
The machine's base houses
The air cylinder.
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00:08:43,241 --> 00:08:45,482
They position the die
On top of the base
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00:08:45,482 --> 00:08:49,000
And screw it in place.
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00:08:49,000 --> 00:08:50,758
Then they install the punch,
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00:08:50,758 --> 00:08:54,206
Carefully centering it
Over the die.
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00:08:54,206 --> 00:08:58,310
A worker hooks up hoses
To the air cylinder.
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00:08:58,310 --> 00:08:59,655
He tests everything
128
00:08:59,655 --> 00:09:02,034
To make sure it's properly
Aligned with the die,
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00:09:02,034 --> 00:09:04,275
Then he fastens it with screws.
130
00:09:04,275 --> 00:09:07,103
They install the floor
Of the machine's second level.
131
00:09:07,103 --> 00:09:09,448
A machine can hold up
To three different dies
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00:09:09,448 --> 00:09:12,068
On three separate levels.
133
00:09:12,068 --> 00:09:15,655
They position the second die
On the guide pins,
134
00:09:18,068 --> 00:09:22,068
Then install the ceiling
Of the second level.
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00:09:22,068 --> 00:09:24,827
They glue the punches
To the ceiling.
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00:09:31,034 --> 00:09:32,931
This level has several punches,
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00:09:32,931 --> 00:09:34,965
Allowing the machine
To make different cuts
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00:09:34,965 --> 00:09:36,689
Using the same die.
139
00:09:36,689 --> 00:09:39,827
The cuts can be simultaneous
Or continuous.
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00:09:47,965 --> 00:09:49,551
They install a punch selector
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00:09:49,551 --> 00:09:54,241
Which allows users to activate
Or deactivate each punch.
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00:09:58,172 --> 00:10:00,137
Once installation is complete,
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00:10:00,137 --> 00:10:03,344
They test the alignment
Of the punches.
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00:10:05,206 --> 00:10:07,862
Then they mount safety covers
On the machine.
145
00:10:07,862 --> 00:10:09,448
They prevent workers' hands
146
00:10:09,448 --> 00:10:14,137
From accidentally getting caught
Between a punch and die.
147
00:10:14,137 --> 00:10:18,068
Next, they make the pneumatic
System that powers the machine.
148
00:10:18,068 --> 00:10:21,206
First, they attach air hoses
To the foot pedal.
149
00:10:21,206 --> 00:10:23,344
The operator will step on
The pedal
150
00:10:23,344 --> 00:10:24,689
To punch out the metal.
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00:10:24,689 --> 00:10:26,793
Then they hook up the other end
Of the hoses
152
00:10:26,793 --> 00:10:30,034
To the compressed air-supply
Line.
153
00:10:30,034 --> 00:10:32,241
Now the pneumatic
Punching machine
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00:10:32,241 --> 00:10:36,965
Is ready to be used
At the window-and-door factory.
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00:10:36,965 --> 00:10:39,551
A worker inserts a strip
Of extruded aluminum
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00:10:39,551 --> 00:10:43,000
Into the first die
To notch the end,
157
00:10:43,000 --> 00:10:44,344
Then into the second die
158
00:10:44,344 --> 00:10:49,862
To punch three holes
To join the window-frame parts.
159
00:10:49,862 --> 00:10:52,482
Finally, the third die
Punches three screw holes
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00:10:52,482 --> 00:10:54,344
On the opposite side.
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00:10:58,034 --> 00:10:59,379
The machine saves time
162
00:10:59,379 --> 00:11:03,068
Because they don't have
To switch dies between each cut.
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00:11:19,862 --> 00:11:23,931
Narrator: water is essential
To life on earth.
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00:11:23,931 --> 00:11:25,413
We need it to survive,
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00:11:25,413 --> 00:11:27,896
But we also use it
For entertainment.
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00:11:27,896 --> 00:11:30,137
Water-jet fountains
Captivate audiences
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00:11:30,137 --> 00:11:32,068
With incredible displays.
168
00:11:32,068 --> 00:11:34,448
Some even use lights
To change the appearance
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00:11:34,448 --> 00:11:36,517
Of the water's color.
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00:11:41,793 --> 00:11:44,758
These water-jet fountains
Send spiraling ribbons of color
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00:11:44,758 --> 00:11:45,793
Into the air.
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00:11:45,793 --> 00:11:48,068
The effect is magical.
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00:11:49,896 --> 00:11:53,379
Production starts
With this cast-bronze part.
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00:11:53,379 --> 00:11:54,896
Computerized tools
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00:11:54,896 --> 00:12:00,103
Transform it it into a flange
That will be installed on-site.
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00:12:00,103 --> 00:12:02,862
The flange is designed
To prevent leaks where the pipe
177
00:12:02,862 --> 00:12:05,862
Meets the concrete pool.
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00:12:05,862 --> 00:12:08,172
The next part
Is a stainless-steel faceplate
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00:12:08,172 --> 00:12:09,379
For the fountain.
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00:12:09,379 --> 00:12:11,724
An employee places it
On a template,
181
00:12:11,724 --> 00:12:16,724
Closes a u.V.-light shield,
And activates a laser.
182
00:12:16,724 --> 00:12:18,793
The laser etches
Product information
183
00:12:18,793 --> 00:12:20,689
Into the steel.
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00:12:20,689 --> 00:12:25,896
This branding is permanent
And won't wear off.
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00:12:25,896 --> 00:12:29,241
Next, a technician assembles
The colored l.E.D. Lights.
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00:12:29,241 --> 00:12:31,689
He connects the circuitry
To a cable,
187
00:12:31,689 --> 00:12:35,137
Then slides the bulb and its
Housing on to the circuitry.
188
00:12:35,137 --> 00:12:37,379
He screws a metal ring
On to the base
189
00:12:37,379 --> 00:12:39,551
To keep the light watertight.
190
00:12:42,689 --> 00:12:44,931
He immerses the light
In a clear water tank
191
00:12:44,931 --> 00:12:47,965
To test it.
192
00:12:47,965 --> 00:12:51,034
He switches on a vacuum
To suck air out of the tank,
193
00:12:51,034 --> 00:12:54,206
Simulating underwater pressure.
194
00:12:55,620 --> 00:12:57,586
He checks for bubbles
Around the light,
195
00:12:57,586 --> 00:12:59,655
Which would indicate a leak.
196
00:13:06,206 --> 00:13:07,620
He programs the light
197
00:13:07,620 --> 00:13:11,862
For the water show so that
Different colors flash on cue.
198
00:13:14,034 --> 00:13:17,655
The next employee
Prepares an epoxy sealant.
199
00:13:17,655 --> 00:13:19,103
He pours the epoxy
200
00:13:19,103 --> 00:13:22,482
Into the solenoid controller
For the water-fountain jets.
201
00:13:25,068 --> 00:13:28,896
It takes two hours to dry.
202
00:13:28,896 --> 00:13:30,206
Once solidified,
203
00:13:30,206 --> 00:13:33,551
It will protect the components
From water damage.
204
00:13:33,551 --> 00:13:36,896
Then he assembles the carriage
For the fountain jets.
205
00:13:38,482 --> 00:13:41,241
He places the carriage
On a spring-loaded slide
206
00:13:41,241 --> 00:13:45,896
And secures
It with long-threaded rods.
207
00:13:45,896 --> 00:13:48,448
The worker applies sealant
To the ends of the rods
208
00:13:48,448 --> 00:13:51,793
And screws on the nuts.
209
00:13:51,793 --> 00:13:54,206
He installs a plastic
Nozzle cup.
210
00:13:54,206 --> 00:13:55,758
He secures it to the carriage
211
00:13:55,758 --> 00:13:59,000
With a center pin
That has a swiveling mechanism.
212
00:14:04,758 --> 00:14:06,586
He transfers
The carriage assembly
213
00:14:06,586 --> 00:14:11,551
To a water-distribution manifold
214
00:14:11,551 --> 00:14:14,103
And screws it in place.
215
00:14:20,206 --> 00:14:21,517
He tests the carriage
216
00:14:21,517 --> 00:14:25,103
And confirms that it
Slides freely on the springs.
217
00:14:30,000 --> 00:14:31,655
Then he runs plastic tubing
218
00:14:31,655 --> 00:14:33,965
From the water-distribution
Manifold
219
00:14:33,965 --> 00:14:36,310
To the spouts
Of the nozzle cups.
220
00:14:40,862 --> 00:14:44,827
The worker secures the joints
With plastic zip ties.
221
00:14:49,965 --> 00:14:53,448
Then he trims the ties
Using a special gun.
222
00:14:54,896 --> 00:15:00,793
He attaches the solenoid
Controller to the carriage
223
00:15:00,793 --> 00:15:03,655
And connects the controller
To the various air tubes
224
00:15:03,655 --> 00:15:05,827
That lead to the waterspouts.
225
00:15:10,034 --> 00:15:11,827
He places the water-jet assembly
226
00:15:11,827 --> 00:15:13,965
On the back
Of a steel mounting plate
227
00:15:13,965 --> 00:15:16,517
And secures it with screws.
228
00:15:20,758 --> 00:15:24,310
He inserts two l.E.D. Lights
In specially designed slots,
229
00:15:24,310 --> 00:15:26,517
Then screws them in place.
230
00:15:30,034 --> 00:15:32,724
This water-jet fountain
Is now complete.
231
00:15:32,724 --> 00:15:37,586
He hooks it up to a compressed
Air source for a dry-bench test.
232
00:15:37,586 --> 00:15:40,931
He confirms that the compressed
Air moves the carriage correctly
233
00:15:40,931 --> 00:15:44,931
In the programmed sequence.
234
00:15:44,931 --> 00:15:48,034
He also connects the water jet
To a mechanical sequencer
235
00:15:48,034 --> 00:15:50,448
To verify that it's functional.
236
00:15:53,103 --> 00:15:54,931
After it passes the tests,
237
00:15:54,931 --> 00:15:57,655
He seals the perimeter
Of the jet with a rubber gasket
238
00:15:57,655 --> 00:15:59,620
And the faceplate.
239
00:16:02,655 --> 00:16:07,517
This water-jet fountain
Is ready for installation.
240
00:16:07,517 --> 00:16:09,241
When combined
With other fountains,
241
00:16:09,241 --> 00:16:12,517
It will put on quite a show.
242
00:16:12,517 --> 00:16:14,448
Onlookers will be so engaged,
243
00:16:14,448 --> 00:16:16,931
They won't mind
Getting a little wet.
244
00:16:32,379 --> 00:16:34,689
Narrator: people have been
Surfing on wooden boards
245
00:16:34,689 --> 00:16:36,379
For thousands of years.
246
00:16:36,379 --> 00:16:37,655
These early surfboards
247
00:16:37,655 --> 00:16:40,551
Were heavy because they were
Made of solid wood.
248
00:16:40,551 --> 00:16:43,724
Today, surfers
Are taking this classic material
249
00:16:43,724 --> 00:16:45,931
And giving it a modern twist,
250
00:16:45,931 --> 00:16:47,931
Creating beautiful,
Lightweight boards
251
00:16:47,931 --> 00:16:50,103
From sustainable resources.
252
00:16:53,724 --> 00:16:55,724
When most people
Think of surfboards,
253
00:16:55,724 --> 00:16:57,689
They picture
Brightly colored boards
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Made of foam and fiberglass.
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But wooden surfboards are making
A not-so-surprising comeback.
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Every waterborne vessel
Was originally made from trees
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Because,
No matter what, wood floats.
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They start by gluing two planks
Of poplar to a strip of oak.
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Using a template,
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A craftsman draws the shape
He wants for the surfboard.
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He uses a japanese pull saw
To cut the shape out by hand.
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This is the basic outline
Of the surfboard.
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A cnc router
Quickly and accurately cuts
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The inner support framework
From poplar plywood.
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The builder sources wood
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From suppliers who use
Sustainable forestry practices.
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Using his pull saw,
The craftsman
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Carefully frees the pieces
Of the support framework.
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Then he smoothes the edges
With a block sander.
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He begins fitting the pieces
Together to form the framework.
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For the spine, the builder
Uses fast-drying superglue.
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It bonds powerfully and quickly,
Allowing him to work fast.
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After completing the spine,
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He starts gluing
And inserting the ribs.
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The finished frame resembles
The skeleton of a large fish.
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Once the support structure
Has dried, the craftsman
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Places it on the bottom skin
Of the surfboard.
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He positions it carefully
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And securely clamps it in place
On a purpose-built jig.
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Then he traces the lines
Of the frame on to the skin.
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He measures and marks
A set distance
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From the end of each rib.
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He squeezes a bead
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Of epoxy-based glue
Over the network of lines
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Before lifting the frame
Into position on the skin.
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He clamps everything down
And lets it dry overnight.
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The sides of the surfboard,
Called the rails,
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Consist of 12 strips of wood
Glued and clamped together.
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The rails take several days
To make.
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After that process is complete,
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The builder lays a bead
Of polyurethane glue
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On the frame and rails.
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Then he lowers the surfboard's
Top skin into position
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And secures it with dozens
Of clamps.
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He lets the fully assembled
Board dry overnight.
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Now the board is ready for
The last phase of production.
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First, the craftsman shapes
And smoothes the wood
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To give the object
Its final shape.
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He trims the excess wood
Off the sides using the rails
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As a cutting guide.
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He rounds the top edges
Of the board
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With a small,
Japanese-made wood plane.
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The builder also uses
A special tool called a saw rasp
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To finish the edges.
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He uses a square
To make sure the bottom and top
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Are even
When shaping the nose and tail.
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The saw rasp allows him
To quickly and efficiently
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Bring the board
To its final shape.
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Next, the craftsman
Uses a sanding block
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With increasingly finer
Grits of sandpaper
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To create a smooth surface.
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He signs the bottom of the board
With a pencil,
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Then burns it into the wood with
A tool called a pyrography pen.
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He adds a layer
Of fiberglass and epoxy
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To give the wood
A tough outer shell.
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Customers can choose
To have a fin box
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With a removable fin
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Or they can opt
For a permanent wooden one.
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Traditional material
Plus an innovative design
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Results in wooden surfboards
That are built to last.
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