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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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Automated machines
Changed manufacturing forever
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When they began
Assembling parts.
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Cnc assembly machines have taken
Automation to the next level.
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Cnc is an acronym
For computer numerical control.
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The machine is automated
By a computer
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Rather than by mechanics.
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To design
A cnc assembly machine,
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Engineers first
Analyze the sequence
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Of tasks required
To assemble the product.
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They then match each task
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To a pre-designed
Processing engine.
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The processing engines
Are linked together
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In a custom assembly sequence.
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Each engine is programmed
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To control
Its computer-guided motors,
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Which perform
The precise motions
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Required to execute a task.
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The cnc machine's engines
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Are mounted
On a sturdy base frame.
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To construct it,
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Workers cut steel tubes
To the required lengths.
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They grind a joint
In each piece...
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...Then weld the pieces together
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By melting steel welding wire
Into the joints.
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They bolt a steel tabletop
Onto the base frame.
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It has cutouts for each engine.
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It's been ground perfectly flat.
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So the engines will be level
With each other.
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Meanwhile,
An electrical technician
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Is assembling the machine's
Main control cabinet.
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It contains one industrial
Computer for each engine.
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A cnc machine has engines
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For performing rotary movements,
Linear movements,
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And for picking up
And placing parts.
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The motors inside each engine
Have their own computers.
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They're programmed
To perform movements
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At specific speeds and forces.
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Once the main control cabinet
Is assembled,
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Workers bolt it
To the base frame.
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Then they install steel bases
For the engines.
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Some cnc machines
Require robotic arms.
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A computer-guided
Milling machine
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Cuts rectangular bars
Of aluminum,
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Shaping them
Into robotic arm components.
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This precision-measuring device
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Ensures each milled part
Meets strict specifications.
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After the aluminum components
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Receive
An anti-corrosion coating,
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Workers assemble them
Into a robotic arm.
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These self-lubricating
Sleeve bearings
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Give the arm
The ability to rotate.
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They add a second assembled arm
To create a pair
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That works together
To perform an assigned task.
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Each arm is controlled
By its own motor,
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Which follows the commands
Of the engine's computer.
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This coupling securely
Connects each robotic arm
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To the shaft of its motor.
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Each engine on the machine
Can have up to eight motors.
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The motors can operate
Independently or in unison.
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This engine has robotic arms
That can pick up, hold,
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And release parts.
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To test the completed machine,
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A high-speed video camera
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Captures images
At 1,000 frames per second.
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The quality control team
Slows down the video to analyze
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And fine-tune the accuracy
And efficiency of every motion.
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Just a few simple taps
On the operator's touch screen
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Can adjust the arm
To move a millisecond faster.
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Or a millimeter further.
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Cnc machines can assemble
Small products at high speed.
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They also provide something
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Traditional assembly
Equipment can't --
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Flexibility.
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A single machine can be
Reprogrammed multiple times
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For assembling
Different products.
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Narrator:
When life gives you lemons,
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Why bother making lemonade
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When you can indulge
In a luscious lemon tart?
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Not too sour, not too sweet,
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A lemon tart
Is a delectable dessert
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That you can make yourself.
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Or even better,
Leave it to the baking pros
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And buy ready-made.
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This thaw-and-serve lemon tart
Has a shortbread shell
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And creamy lemon filling
Topped with buttercream.
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Each batch of dough produced
In this industrial mixer
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Yields 449 tart shells.
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The first step is to lightly
Blend margarine, sugar,
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And salt for 2 or 3 minutes.
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Next, add pasteurized eggs
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And mix for about 2 minutes
At slow speed.
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Fast mixing makes the dough
Too tight, causing it to crack.
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They add white flour
While continuing to mix slowly
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Until the ingredients
Are well-blended.
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Once the dough is ready, workers
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Put it through what is actually
A hamburger forming machine.
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It extrudes 1/4-pound
Dough patties.
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Workers place them in the middle
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Of a nonstick aluminum tart pan
Three at a time.
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They mount the pan on a press,
Covering it with plastic.
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A die strikes the pan,
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Flattening and spreading
The dough evenly.
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The pans go into the oven,
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Where they rotate
For 23 to 24 minutes
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At 350 degrees fahrenheit.
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The dough bakes
Into a shortbread tart shell.
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Lemon juice and lemon oil
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Are the key ingredients
In the creamy filling.
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First, workers melt margarine
On a stove...
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...Then mix in sugar,
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Lemon powder...
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...And food starch
To thicken the mix.
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They blend for 2 minutes,
Then add eggs.
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After another 5 to 8 minutes
Of mixing,
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They pour in boiled
Lemon juice and lemon oil.
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Boiling these acidic ingredients
Prevents the fats from curdling.
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The filling is ready.
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So they move the bowl
From the mixer
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Over to the depositing line.
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A pump transfers the contents
To a hopper feeding a depositor.
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The depositor is pre-set
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To squirt 22 ounces
Of lemon filling in each tart.
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The filled tarts
Go into the oven for 11 minutes.
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The lemon tarts
Come out of the oven,
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Cool at room temperature
For 2 to 3 hours,
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Then go into a freezer
Overnight.
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The next day, workers
Remove the frozen tarts
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From the pans.
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They gently remove
Any specks of browning,
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Then spray on a light layer
Of glaze made from apricots.
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This adds a hint of sweetness.
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The glaze also prevents
The filling from cracking
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When it's thawed for serving.
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Next, they put the tart
In an automated cake slicer.
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The turntable rotates
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As the tart
Is cut into 12 slices
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With papers
In between each one.
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This is for restaurants
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Who serve the dessert
By the slice.
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Workers embellish each slice
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With a flower
Made of buttercream,
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A decadent mixture of butter,
Egg whites, and sugar.
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They complete each flower
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With a dot of lemon filling
In the center.
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This lemon tart is finished.
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They wrap it
In a cardboard cake band
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Printed with the brand name.
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They seal the tart
In plastic film,
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Insert it into a retail box,
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And ship it frozen
To a store or restaurant.
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To serve this tasty dessert,
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You simply defrost
At room temperature
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For about a half hour.
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Narrator: toy soldiers
Aren't just for children.
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They're a hobby for grown-ups
That dates back over a century.
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00:11:32,413 --> 00:11:35,172
The science-fiction novelist
H.G. Wells
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Published the first set of rules
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For toy solider war games
In 1913.
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The game is on.
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It's time to rally the troops.
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These mini soldiers are made
Of either metal or plastic
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And hand-painted
By the game players.
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No detail is overlooked
In making these war figures
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True to the historical period
Of the game.
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Players move the figures
Around tabletop scenery
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Like chessmen on a chess board.
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And like chess,
This is a game of strategy.
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It's a way to engage
In the tactical elements of war
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Without the violence
Of a real battle.
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Making miniature war figurines
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Starts with the construction
Of a model.
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With only one hand
And his prosthesis,
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A modeler expertly bends
Tin copper wire
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Into a framework for the model.
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Each soldier needs to be
1.1 inches in length.
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So he shapes and trims the wire
Accordingly.
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Once he completes
The wire skeleton,
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He sticks the leg prongs
Into a cork.
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This enables him to get
A firm grip on the skeleton
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As he builds up the figure
With epoxy putty.
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He sculpts a base layer
Using a dental tool
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That's usually used
For scraping plaque.
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After the base layer cures,
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He builds up the chest
And calf areas.
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After more curing time,
He sculpts the soldier's tunic.
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Using a tool with a fine point,
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He pits the surface to simulate
Medieval chain mail armor.
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With skillful artistry,
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The miniature soldier
Takes shape.
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He inserts a wire
Into a drilled shoulder socket
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And applies putty
To create a muscular effect.
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He builds up the sleeve and
Pierces it all the way around
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To continue
The chain mail effect.
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He carves the rounded rim
Of the hat.
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This small-scale soldier
Is in fighting form.
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He's used to make a mold
For tin soldiers
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00:14:04,275 --> 00:14:06,413
That will look just like him.
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Meanwhile,
Another member of the team
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Sculpts epoxy putty models
That are three times larger.
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These models are used
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00:14:17,413 --> 00:14:21,275
To mass-produce
Plastic war figures.
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00:14:21,275 --> 00:14:23,965
Going large first
And then scaling down
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Is the only way
To transfer all the details.
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00:14:31,068 --> 00:14:32,758
As he carves hair details
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00:14:32,758 --> 00:14:35,413
Into the head
Of this french cavalry figure,
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He's careful to not leave
Any protruding bits.
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Otherwise, plastic could snag
On molds made from them,
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Jeopardizing the production
Of the plastic versions.
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With curing time between layers,
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00:14:52,310 --> 00:14:56,034
It takes about a week to sculpt
This french cavalry model.
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They're ready to make molds
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00:15:02,206 --> 00:15:05,172
From the smaller scale
Models now.
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The mold maker
Arranges the epoxy models
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On a silicone rubber disk.
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He presses each one
Into the rubber.
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The ends leave little dents.
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He removes the model
And slices it into the rubber
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00:15:21,827 --> 00:15:24,241
With a surgical scalpel,
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00:15:24,241 --> 00:15:28,758
Cutting holes where the figures
Have left the indentations.
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00:15:28,758 --> 00:15:31,206
He removes the silicone cutouts,
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00:15:31,206 --> 00:15:35,172
Then carves a narrow channel
To connect the two slots.
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He inserts the model
Into the niche.
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00:15:42,103 --> 00:15:44,689
He repeats this process
With the other soldiers
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On the disk,
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Then places the disk
In a preheated steel vessel.
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00:15:51,896 --> 00:15:53,758
He puts a lid on the vessel
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00:15:53,758 --> 00:15:58,034
And transfers it
To a vulcanizing press.
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00:15:58,034 --> 00:16:02,862
In the press, heated plates
Squeeze it using pressure.
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00:16:02,862 --> 00:16:05,206
This softens the rubber inside,
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00:16:05,206 --> 00:16:08,655
Melting around the figures,
Picking up the contours.
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00:16:12,827 --> 00:16:16,379
This transfers the disk
Into a mold.
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00:16:19,241 --> 00:16:21,862
Coming up next, the miniatures
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Emerge from the mold shell
Battle-ready.
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Narrator:
In the age of video games,
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00:16:39,413 --> 00:16:42,931
Tabletop war games
Still have plenty of fans.
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00:16:42,931 --> 00:16:44,965
The challenge begins
With the acquisition
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00:16:44,965 --> 00:16:47,758
Of small armies of miniatures.
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00:16:47,758 --> 00:16:49,689
Players hand-paint the soldiers
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00:16:49,689 --> 00:16:52,862
And build elaborate backdrops
With scenery.
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00:16:52,862 --> 00:16:54,724
Then the games begin.
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00:16:59,896 --> 00:17:01,896
As production continues,
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00:17:01,896 --> 00:17:06,827
The mold-maker carves channels
Into the silicone disk.
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00:17:06,827 --> 00:17:08,793
He links the channels
To the impressions
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00:17:08,793 --> 00:17:11,517
Of miniature soldiers
And military machinery
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00:17:11,517 --> 00:17:13,689
That have been created
By the models.
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00:17:16,517 --> 00:17:20,000
The channels allow molten metal
To flow into the impressions
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00:17:20,000 --> 00:17:22,310
In order to cast copies.
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00:17:24,517 --> 00:17:25,896
In the storeroom,
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00:17:25,896 --> 00:17:28,862
There are thousands
Of silicone molds,
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00:17:28,862 --> 00:17:32,758
Each depicting
Different characters and props.
254
00:17:32,758 --> 00:17:34,275
When the order comes in,
255
00:17:34,275 --> 00:17:36,551
An apprentice
Makes the selection.
256
00:17:39,758 --> 00:17:43,724
Next, an operator puts the mold
In a casting machine.
257
00:17:46,517 --> 00:17:48,310
As the mold spins
In the machine,
258
00:17:48,310 --> 00:17:51,413
He adds molten tin
Through an opening in the lid.
259
00:17:51,413 --> 00:17:54,551
The spinning
Throws the liquid tin
260
00:17:54,551 --> 00:17:56,379
Into the mold crevices.
261
00:17:58,793 --> 00:18:01,448
After the casting solidifies
And cools,
262
00:18:01,448 --> 00:18:04,103
He extracts
The little tin soldiers.
263
00:18:08,000 --> 00:18:10,413
These tin war figures
Are on their way
264
00:18:10,413 --> 00:18:12,724
To the gaming front lines.
265
00:18:14,931 --> 00:18:18,068
Making plastic war figures
Starts with an epoxy resin
266
00:18:18,068 --> 00:18:20,620
For a pattern.
267
00:18:20,620 --> 00:18:22,827
They add a hardener
And blend the batch
268
00:18:22,827 --> 00:18:26,241
To the consistency
Of pancake batter.
269
00:18:26,241 --> 00:18:28,689
They transfer it
To a larger bucket
270
00:18:28,689 --> 00:18:30,793
And place it
In a vacuum chamber,
271
00:18:30,793 --> 00:18:32,482
Which pulls out the air.
272
00:18:32,482 --> 00:18:36,655
In the process,
The epoxy swells.
273
00:18:36,655 --> 00:18:39,103
Once the epoxy mixture deflates,
274
00:18:39,103 --> 00:18:41,827
A team brushes it
Onto sculpted military models
275
00:18:41,827 --> 00:18:44,103
Arranged in a steel box.
276
00:18:46,517 --> 00:18:50,655
After filling all the crevices,
They dispense more epoxy.
277
00:18:50,655 --> 00:18:53,000
A chute ensures a gentle flow,
278
00:18:53,000 --> 00:18:56,482
Preventing the buildup
Of more bubbles.
279
00:18:56,482 --> 00:18:58,793
They repeat this on the other
Side of the models
280
00:18:58,793 --> 00:19:00,862
To create a two-part pattern.
281
00:19:02,827 --> 00:19:04,620
Once the epoxy hardens,
282
00:19:04,620 --> 00:19:06,172
They mill the outside
Of the pattern
283
00:19:06,172 --> 00:19:08,965
To pre-determined measurements.
284
00:19:08,965 --> 00:19:12,724
An employee then opens it
And discards the models.
285
00:19:12,724 --> 00:19:15,655
He inspects the impressions
They've left.
286
00:19:15,655 --> 00:19:19,482
They use this pattern to make
A smaller-scale mold from steel.
287
00:19:22,862 --> 00:19:26,034
Using an automated saw,
They carve smaller pieces
288
00:19:26,034 --> 00:19:28,517
From a block
Of nickel chrome steel.
289
00:19:31,896 --> 00:19:34,827
An automated milling tool
Machines the smaller blocks
290
00:19:34,827 --> 00:19:36,758
So the two of them
Will fit together
291
00:19:36,758 --> 00:19:39,000
To create one mold set.
292
00:19:41,586 --> 00:19:43,862
A carriage shunts the block
Back and forth
293
00:19:43,862 --> 00:19:45,517
Between an abrasive wheel
294
00:19:45,517 --> 00:19:49,000
To grind the surface
To precise measurements.
295
00:19:52,655 --> 00:19:54,586
A mold-maker
Follows the impressions
296
00:19:54,586 --> 00:19:56,931
In the epoxy pattern
With a stylus,
297
00:19:56,931 --> 00:19:59,000
Which moves
A needle-like cutter.
298
00:20:01,413 --> 00:20:04,517
The cutter etches a template
Into the steel block
299
00:20:04,517 --> 00:20:05,793
That's three times smaller
300
00:20:05,793 --> 00:20:07,793
Than the one
In the epoxy pattern.
301
00:20:12,034 --> 00:20:15,620
Using a wand that generates
High-frequency vibrations,
302
00:20:15,620 --> 00:20:20,000
He polishes the etchings
In the steel mold.
303
00:20:20,000 --> 00:20:21,413
It's a gentle polish
304
00:20:21,413 --> 00:20:24,448
That doesn't damage any of
The etching in the mold block.
305
00:20:28,758 --> 00:20:30,413
They drill channels in the steel
306
00:20:30,413 --> 00:20:33,896
To allow plastic to flow
To the impressions.
307
00:20:33,896 --> 00:20:37,620
They also insert
Water-cooling pipes.
308
00:20:37,620 --> 00:20:42,206
They're ready to mass-produce
Plastic war figures.
309
00:20:42,206 --> 00:20:44,137
The machine melts plastic
310
00:20:44,137 --> 00:20:47,413
And injects it under pressure
Into the mold set.
311
00:20:47,413 --> 00:20:49,689
The plastic hardens,
And the machine
312
00:20:49,689 --> 00:20:53,517
Ejects the little soldiers
Connected by runners.
313
00:20:53,517 --> 00:20:56,724
This particular production
Includes miniature rifles
314
00:20:56,724 --> 00:20:59,655
And other
Military paraphernalia.
315
00:20:59,655 --> 00:21:03,551
They pack the plastic soldiers,
Their horses, and their guns
316
00:21:03,551 --> 00:21:05,689
Into boxes for retail
317
00:21:05,689 --> 00:21:08,000
Along with instructions
For painting.
318
00:21:13,172 --> 00:21:15,379
After painting,
The plastic soldiers
319
00:21:15,379 --> 00:21:18,862
And their tin comrades
Are in tip-top military form
320
00:21:18,862 --> 00:21:22,000
And ready for battle.
321
00:21:22,000 --> 00:21:23,517
There will be casualties.
322
00:21:23,517 --> 00:21:27,827
But of course,
It's all just for fun.
323
00:21:27,827 --> 00:21:30,965
These miniature war figures
Are survivors.
324
00:21:30,965 --> 00:21:34,137
They will live on
To fight many more battles.
25492
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