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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: the metal bistro set
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Is a fixture in
European-style cafés
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And small restaurants.
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00:00:58,965 --> 00:01:02,931
The set consists of a small
Dining table and two chairs.
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A bistro set is also popular in
Homes with limited outdoor space
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As there's usually
Enough room for one
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On a balcony or small patio.
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The small restaurant bar
Known as the bistro
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Originated
In 19th century france.
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Its iconic dining sets
Are still being produced today
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In both traditional
And modern styles.
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This french factory makes them
Out of strips of flat steel
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With rounded edges.
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The first step is
To flatten the strip
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With pressure-applying rollers.
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The steel then enters a press
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Which does three operations
Simultaneously.
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It cuts pieces to
The required length,
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Rounds their ends, and punches
Out holes where required.
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These are parts
For the table legs.
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Meanwhile,
This computer-guided machine
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Bends a 1/2-inch steel rod
Into a circle to form a ring
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That will support the tabletop.
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This table is collapsible,
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Allowing it to fold flat
For storage.
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Therefore, two of the legs
Are hinged.
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A pin and notch lock them
In the open position.
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After putting together
The folding legs,
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A worker positions all
The parts for the base
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On an assembly fixture.
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Then he operates
A welding robot,
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Which welds all the crossbars,
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Reinforcing the legs
And the legs to the ring.
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It only takes about 2 minutes
To weld all these parts
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Into a folding table base.
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The manufacturers
Make the tabletop
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From a square piece
Of sheet steel.
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This machine first sheers
Off the corners,
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Transforming the square
Into a circle.
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Then it draws the edge upward
To form a 1/2-inch-high rim
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On what will eventually be
The underside of the tabletop.
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It also cuts a hole in
The center for an umbrella pole
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And draws that edge, as well.
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A worker mates the tabletop
To the folding base.
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He inserts the ring into
The tabletop's underside rim.
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Then he opens the base and uses
Spreading pliers to pull apart,
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00:03:28,034 --> 00:03:29,965
Then butt the ends of the ring.
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00:03:33,793 --> 00:03:36,172
Next, he shields
The underside of the table
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With a scrap piece of metal
And welds the butted ends.
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The table is now
Fully constructed.
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The chair parts are cut on the
Same press as the table legs.
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Each chair has two long legs
And two shorter legs.
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This machine
Simultaneously folds
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00:04:03,965 --> 00:04:06,206
And twists the two shorter ones
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And folds the two longer ones.
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The operator then connects them
With a crossbar.
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The next operator places these
Connected short legs
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In another machine.
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He adds washers to the
Protruding ends of the crossbar,
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Then the two long chair legs,
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Connecting them lower down
With the crossbar.
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The machine welds that
Crossbar and forms
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Each end of the other
Crossbar into a rivet,
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Which creates the folding point
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For this
Collapsible chair frame.
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The next operator places
The frame on another machine,
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Positioning three holes on each
Side onto upright steel pins.
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He lays two steel slats for
The chair back on these pins,
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Then five more for the seat
Onto identical pins riveted
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To a pair of steel bars.
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The machine then forms
The pins into rivets,
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Attaching all the slats.
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He then assembles the seat
To the frame,
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Completing the construction
Of the chair.
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The tables and chairs
Go on to the paint line.
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The first station washes
And dries the furniture.
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Next, a worker opens each one
To spray paint
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The articulation points.
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Then, automated nozzles
Paint the rest.
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This is industrial-grade powder
Paint known as powder coat.
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A 10-minute trip through
A tunnel oven
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At 370 degrees fahrenheit
Bakes it on.
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Workers apply product
Information stickers,
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Cushion protruding parts
With plastic covers,
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And enclose foot protectors.
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The bistro set is now ready.
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Just unfold and unwind.
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Narrator: in an electronic world
Where a few taps
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On a device keyboard sends
An invitation or greeting card,
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It's not all that common
Anymore to receive
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Something printed
The old-fashioned way.
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Yet there's nothing quite
As elegant as the crisp,
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Recessed print that traditional
Letterpress printing produces.
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Letterpress printing is
A centuries-old method
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That's making a comeback.
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The printing press makes
An impression in the paper
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With raised type
As it applies the ink.
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The printer first sketches
Out some design ideas.
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Then he detours into
Digital technology,
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Finalizing the colors
And composition
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And choosing the font
In traditional metal type.
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He cuts paper to the size of
The greeting card he's making.
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The paper is 100 percent cotton,
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Which is more pliable than
Standard wood-fiber paper,
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Thus enabling
A deeper impression.
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Cotton paper is more delicate,
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So he has to cushion it
While cutting.
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Otherwise, the clamp holding
The stack would dent the paper.
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Now it's time to set up.
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He locates the selected font
In the type cabinet.
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Each individual character,
Called a sort, is backwards
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Because backwards
Type prints forwards.
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He finds the sorts for the first
Line of text and lines
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Them up left to right
And upside down
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In what's called
A composing stick.
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Once he completes the type
Of the line, called a form,
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He clamps it in position.
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Then he takes a metal frame,
Called a chase,
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And mounts the form
At a specific position
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Inside the frame,
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Filling the excess space with
Blocks of wood called furniture.
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Just below the piece
Of furniture
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That's underneath the form,
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He places a compression device
Called a quoin
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And expands it with a key.
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This locks the form in position.
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He chooses each ink color
From a fan deck,
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Then follows
The recipe to mix it.
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This is color extender,
Which works like paint thinner,
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Diluting a dark color
To a lighter shade.
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He mixes the color
Extender into the ink,
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Blending the two
Ingredients thoroughly.
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When the color matches
The fan deck sample,
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He places a glob
On a piece of cardboard
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And takes the mixture over
To the printing press.
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He applies it in dots
All over the ink disc.
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Then he pumps on the treadle
To run the rollers back
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00:08:59,241 --> 00:09:01,482
And forth across the disc.
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00:09:01,482 --> 00:09:05,965
This spreads the ink over
The disc and onto the rollers.
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He inserts the chase
Containing the form
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00:09:08,241 --> 00:09:12,172
Into what's called
The bed of the press.
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Now for the test run.
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The printer pulls the lever
To bring the bed
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00:09:16,896 --> 00:09:18,275
And platen together
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00:09:18,275 --> 00:09:20,448
So that the form,
Inked by the rollers,
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Creates an ink-filled
Impression in the paper.
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If the print is off a bit,
He marks the correct position
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By pencil
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00:09:29,620 --> 00:09:33,034
And installs gauge pins,
Which will hold the paper there.
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Now he's ready
To start printing.
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There's no automation here.
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He manually places one sheet
At a time in the gauge pins.
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The ink dries quickly
Because it's rubber based
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And because cotton
Paper absorbs well.
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This printer's technique is a
Hybrid of traditional
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And modern approaches,
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As he uses
Computer-generated graphics.
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He sends the digital file
To a company
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That makes a polymer
Printing plate,
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Which he mounts
On an aluminum base
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That fits in the chase
Of the press.
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00:10:10,965 --> 00:10:13,206
He switches plates
To do the next graphic
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In a different color,
Layered over the first.
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00:10:22,931 --> 00:10:26,551
The polymer plates marry
The old and new technology
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00:10:26,551 --> 00:10:29,310
By making it possible
To print computer-generated
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Graphics
By traditional letterpress.
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After printing the inside
Of this greeting card, as well,
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He uses a scoring rule
Mounted in another press
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To make a perfectly
Straight fold line
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Down the middle of the paper.
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The result is beautiful,
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Textured print
On elegant cotton paper
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Just like the good old days
Before ink-jets,
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E-cards, and e-vites.
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Narrator: bamboo-ceramic lights
Add a touch of zen to any space.
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Made of ceramic
And inspired by bamboo,
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They resemble bundles
Of tropical grasses,
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But they're not
Exact replications.
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These light fixtures offer
An artistic interpretation
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Of an exotic element
From the natural world.
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00:11:38,000 --> 00:11:40,655
Trying to create
A tropical ambiance?
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It's all in the lighting.
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These ceramic lights celebrate
The natural beauty of bamboo
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And set the mood.
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Making the ceramic casing
Starts with a slurry of clay
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And water known as slip.
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A propeller mixer evenly
Distributes the particles.
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00:11:58,793 --> 00:12:02,517
The slip flows through a hose
And into plaster molds.
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The artisan controls
The amount going in,
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Ensuring that each one
Is filled just below the brim.
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00:12:08,655 --> 00:12:13,517
Over 3 hours, the clay thickens
And congeals along the edges.
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00:12:13,517 --> 00:12:17,413
After pouring out the remaining
Slip, he trims the clay casting,
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00:12:17,413 --> 00:12:21,655
Which has a putty-like
Consistency.
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After leaving it to
Solidify a bit more,
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He carefully
Disassembles the mold,
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00:12:26,862 --> 00:12:30,482
Revealing the clay casting
With a bamboo-like detail.
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00:12:35,655 --> 00:12:39,724
After curing overnight,
The casting further solidifies,
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00:12:39,724 --> 00:12:42,275
And the color lightens.
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00:12:42,275 --> 00:12:46,068
Using a knife, he adds more
Definition to some of the detail
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00:12:46,068 --> 00:12:49,551
And cleans up the rough edges.
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00:12:49,551 --> 00:12:52,344
He also shaves off
Protrusions formed
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Where the mold parts
Came together.
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00:12:56,482 --> 00:13:00,103
He lightly sands the entire
Bamboo ceramic casting
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To smooth over any
Remaining imperfections.
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00:13:08,793 --> 00:13:14,344
Using a wet sea sponge,
He washes the entire casting.
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00:13:14,344 --> 00:13:16,655
This softens the clay
On the surface
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00:13:16,655 --> 00:13:20,344
And gets rid of any minute
Scratches left by the sanding.
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00:13:24,620 --> 00:13:28,137
The artisan then cuts holes
In the back of the casting.
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00:13:28,137 --> 00:13:30,275
One is for installing
The light socket,
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00:13:30,275 --> 00:13:34,068
And the other is to run wires
To the electrical junction box.
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00:13:36,620 --> 00:13:39,862
With the clay surface
Still moist, he carves nodes,
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Or joints,
Into the bamboo canes.
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00:13:43,586 --> 00:13:47,862
He also cuts wide vertical lines
To create the effect of cracks
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00:13:47,862 --> 00:13:52,586
That occur in bamboo
Naturally when they dry out.
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00:13:52,586 --> 00:13:55,241
After firing the clay
Casting in a kiln
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00:13:55,241 --> 00:13:57,000
And then cooling it overnight,
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00:13:57,000 --> 00:13:58,344
The material has become
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00:13:58,344 --> 00:14:01,344
A strong,
Durable piece of ceramic.
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00:14:01,344 --> 00:14:04,655
This craftsperson examines it
For imperfections
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00:14:04,655 --> 00:14:08,137
And then begins
The painting process.
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00:14:08,137 --> 00:14:12,344
She sprays a very light yellow
Paint onto the bamboo ceramic.
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00:14:12,344 --> 00:14:15,344
This gives the piece
Just a hint of color,
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00:14:15,344 --> 00:14:19,724
But it provides
The desired undertone.
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00:14:19,724 --> 00:14:23,172
Next, she mixes a green oil
Paint with thinner
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00:14:23,172 --> 00:14:26,482
And then brushes the mix
Into the grooves and notches.
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00:14:26,482 --> 00:14:28,862
This accentuates these areas.
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00:14:32,793 --> 00:14:34,724
She also brushes it
Onto the edges
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00:14:34,724 --> 00:14:36,551
Of the bamboo ceramic light box
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00:14:36,551 --> 00:14:38,655
To better define the profile.
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00:14:41,724 --> 00:14:43,931
Using a soft cotton cloth,
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00:14:43,931 --> 00:14:46,379
She blots up some paint
From the palette
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00:14:46,379 --> 00:14:48,344
And wipes it on the ceramic.
235
00:14:48,344 --> 00:14:50,275
This softens the brush strokes
236
00:14:50,275 --> 00:14:53,724
And gives the ceramic cane
Structure a hint of green.
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00:14:56,034 --> 00:14:58,724
She sets the light casing
On a revolving stand
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00:14:58,724 --> 00:15:01,862
And inspects the coverage.
239
00:15:01,862 --> 00:15:04,448
She then applies a liberal
Amount of brown paint
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00:15:04,448 --> 00:15:06,965
To the entire piece,
241
00:15:06,965 --> 00:15:09,310
And the brown color
Completely overpowers
242
00:15:09,310 --> 00:15:11,310
The green and yellow paints.
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00:15:15,758 --> 00:15:18,482
She rubs off a lot
Of the brown paint.
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00:15:18,482 --> 00:15:22,965
This tones it down and subtly
Brings out the other colors.
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00:15:22,965 --> 00:15:26,172
This produces color variations
That evoke the different tones
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00:15:26,172 --> 00:15:28,551
Of dry bamboo.
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00:15:28,551 --> 00:15:31,689
The paint transforms the piece.
248
00:15:31,689 --> 00:15:35,000
A technician inserts the socket
And pulls the wires
249
00:15:35,000 --> 00:15:37,275
Through one of the holes
And out the back.
250
00:15:39,862 --> 00:15:42,689
He secures the socket
In the light box from the back
251
00:15:42,689 --> 00:15:46,241
With a washer and nut,
252
00:15:46,241 --> 00:15:51,241
And that completes this
Bamboo ceramic light fixture.
253
00:15:51,241 --> 00:15:53,655
Making it takes roughly 1 week,
254
00:15:53,655 --> 00:15:56,310
But the final result
Is very unique.
255
00:15:58,344 --> 00:16:00,137
While providing illumination,
256
00:16:00,137 --> 00:16:03,586
It may also be an object
Of conversation.
257
00:16:16,413 --> 00:16:20,137
Narrator: asphalt compactors are
The heavy rollers of paving.
258
00:16:20,137 --> 00:16:23,896
They're equipped with vibrating
Drums that weigh several tons.
259
00:16:23,896 --> 00:16:27,827
The sheer load, in combination
With the mechanical vibrations,
260
00:16:27,827 --> 00:16:29,862
Compact new pavement.
261
00:16:29,862 --> 00:16:33,000
This locks the aggregate
Particles together in order
262
00:16:33,000 --> 00:16:35,758
To provide a strong
And stable road.
263
00:16:38,241 --> 00:16:41,000
The asphalt compactor vibrates
As it applies
264
00:16:41,000 --> 00:16:42,965
Its weight to fresh pavement,
265
00:16:42,965 --> 00:16:45,172
And this process
Removes air pockets
266
00:16:45,172 --> 00:16:48,482
That could ruin
The newly laid road.
267
00:16:48,482 --> 00:16:51,448
To make this critical piece
Of road-building equipment,
268
00:16:51,448 --> 00:16:56,137
A computerized plasma torch
Cuts through heavy-gauge steel.
269
00:16:56,137 --> 00:16:59,758
The operator selects the
Programs that guide the cutting.
270
00:16:59,758 --> 00:17:02,965
The torch cuts out the
Compactor's body panels,
271
00:17:02,965 --> 00:17:06,448
The plates for the rollers,
And many other parts.
272
00:17:06,448 --> 00:17:10,827
A worker welds the front of
The compactor frame together,
273
00:17:10,827 --> 00:17:12,586
And he attaches bracket plates
274
00:17:12,586 --> 00:17:15,000
For a pivot-hinge
Steering system.
275
00:17:17,068 --> 00:17:22,275
Another worker guides a steel
Plate into a rolling machine.
276
00:17:22,275 --> 00:17:24,206
The machine shapes
The thick steel
277
00:17:24,206 --> 00:17:26,586
Into the shell
Of a compactor roller.
278
00:17:28,965 --> 00:17:31,344
The machine requires
A few passes
279
00:17:31,344 --> 00:17:34,241
To establish the correct radius.
280
00:17:34,241 --> 00:17:37,793
A crane then transfers
The rolled steel to a fixture
281
00:17:37,793 --> 00:17:40,862
That positions
Bulkheads within the shell.
282
00:17:40,862 --> 00:17:43,137
It then lifts the shell
With the bulkheads
283
00:17:43,137 --> 00:17:45,068
And fixture onto a table,
284
00:17:45,068 --> 00:17:49,241
And a worker wraps
Cables around it.
285
00:17:49,241 --> 00:17:52,758
He adjusts the length of the
Cables with a thick steel pin.
286
00:17:55,482 --> 00:17:58,413
He tucks brackets behind
The cables at the seams
287
00:17:58,413 --> 00:18:02,206
To protect them during the
Welding that will come later.
288
00:18:02,206 --> 00:18:03,620
He installs chains
289
00:18:03,620 --> 00:18:08,241
And tightens them to hold
The shell steady on the table.
290
00:18:08,241 --> 00:18:11,103
He then activates
What's called the squeezer.
291
00:18:11,103 --> 00:18:14,241
Hydraulically powered,
This machine pulls the cables
292
00:18:14,241 --> 00:18:16,413
To close the gap in the shell,
293
00:18:16,413 --> 00:18:18,896
And while the cable
Keeps the seam tight,
294
00:18:18,896 --> 00:18:24,206
The worker tack welds the seam
And bulkheads from the inside.
295
00:18:24,206 --> 00:18:26,931
With the tack welds
Holding everything together,
296
00:18:26,931 --> 00:18:31,206
A robot does the full welds on
Both the seam and the bulkheads.
297
00:18:33,344 --> 00:18:36,655
The seam weld is large
And protrudes from the shell...
298
00:18:39,103 --> 00:18:41,448
So the next worker
Grinds the seam flush
299
00:18:41,448 --> 00:18:42,862
To the rest of the shell,
300
00:18:42,862 --> 00:18:47,379
Allowing the roller
To operate smoothly.
301
00:18:47,379 --> 00:18:51,310
After a thorough wash, the
Roller goes into a paint booth
302
00:18:51,310 --> 00:18:55,793
To be sprayed first with epoxy
Primer and then urethane paint.
303
00:18:59,275 --> 00:19:01,931
The rollers spend about
50 minutes in an oven
304
00:19:01,931 --> 00:19:05,344
To bake on the coatings.
305
00:19:05,344 --> 00:19:10,379
An electric tug transfers them
To the assembly line.
306
00:19:10,379 --> 00:19:16,275
Here, the rear half of the
Compactor frame is taking shape.
307
00:19:16,275 --> 00:19:18,758
A worker bolts the hitch
To the frame.
308
00:19:23,413 --> 00:19:26,655
He attaches a hydraulic
Steering cylinder to the hitch
309
00:19:26,655 --> 00:19:29,310
And secures it with
A thick steel pin.
310
00:19:31,310 --> 00:19:35,758
The next worker screws
Guide pins to the hitch.
311
00:19:35,758 --> 00:19:38,551
He runs hydraulic hoses
To the front section
312
00:19:38,551 --> 00:19:42,103
And links the rear
Structure to the front.
313
00:19:42,103 --> 00:19:46,241
Next, workers lower the diesel
Engine into the front frame.
314
00:19:46,241 --> 00:19:48,655
They anchor the engine
By driving thick bolts
315
00:19:48,655 --> 00:19:51,034
Into substantial engine mounts.
316
00:19:53,310 --> 00:19:55,931
A center pivot link provides
A second connection
317
00:19:55,931 --> 00:19:59,206
Between the front and back
Parts of the compactor.
318
00:20:04,241 --> 00:20:07,896
A worker torques the bolts that
Secure the link to the back.
319
00:20:12,137 --> 00:20:13,413
Moving forward,
320
00:20:13,413 --> 00:20:16,448
Workers lower the operator
Platform into place,
321
00:20:16,448 --> 00:20:20,206
Complete with a seat
And the controls.
322
00:20:20,206 --> 00:20:23,034
They secure the control base
To the frame with bolts
323
00:20:23,034 --> 00:20:26,137
In each of the four corners.
324
00:20:26,137 --> 00:20:29,448
The compactor is now ready
For the two rollers.
325
00:20:29,448 --> 00:20:31,758
They've been equipped
With vibrating mechanisms
326
00:20:31,758 --> 00:20:34,000
Since we saw them last.
327
00:20:34,000 --> 00:20:37,068
The team bolts the back
Roller in place
328
00:20:37,068 --> 00:20:38,482
And then connects the lines
329
00:20:38,482 --> 00:20:40,965
To the hydraulic systems
That drive it.
330
00:20:47,689 --> 00:20:50,517
They install the second roller
And connect the hydraulic
331
00:20:50,517 --> 00:20:53,068
And electrical lines.
332
00:20:53,068 --> 00:20:54,931
They calibrate the rollers
To ensure
333
00:20:54,931 --> 00:20:58,724
They operate at the same speed.
334
00:20:58,724 --> 00:21:02,448
They adjust the pivot
Steering if needed,
335
00:21:02,448 --> 00:21:05,517
And then it's time to roll.
27475
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