All language subtitles for Incredible.Inventions.Series.1.09of10.The.Glider

Narrator: AROUND THE WORLD,
THE RACE TO WIN WARS

AND EXPLORE THE UNIVERSE
HAS CREATED SOME OF THE MOST

INCREDIBLE PRODUCTS
EVER DESIGNED.

AND WE USE THEM EVERY DAY,

UNAWARE OF THEIR
AMAZING ORIGINS.

ON "INCREDIBLE INVENTIONS,"

THE GLIDER, AN AIRCRAFT
WITH A BATTLEFIELD PEDIGREE,

SUPER GLUE, HOW THE QUEST
FOR BETTER GUN SIGHTS

LEADS TO THE PERFECT
DOMESTIC ADHESIVE.

THE AGA OVEN,
THE LUXURIOUS STOVE

WITH A WORLD WAR II
SPY CONNECTION.

WE REVEAL THE AMAZING HISTORY
AND ENGINEERING SCIENCE

BEHIND THESE
INCREDIBLE INVENTIONS.

-- Captions by VITAC --
www.vitac.com

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

FLYING SILENTLY THROUGH THE AIR,

THE MODERN GLIDER
IS A TRANQUIL WAY

TO ENJOY THE EXPERIENCE
OF FLIGHT.

BUT DID YOU KNOW THE GLIDER

PLAYS AN IMPORTANT ROLE
DURING WORLD WAR II?

FOR CENTURIES,
MAN LOOKS TO THE SKIES

AND DREAMS OF FLYING

BUT HAS NO IDEA HOW.

VARIOUS STRANGE
AND WACKY CONTRAPTIONS

ARE CREATED WITH LITTLE SUCCESS.

♪♪

EVEN GREAT MINDS
SUCH AS LEONARDO DA VINCI

ATTEMPTED TO DESIGN
A FLYING MACHINE

WITHOUT SUCCESS.

TECHNICALLY, A GLIDER DOES
TO REQUIRE AN ENGINE TO FLY.

IT'S SUPPORTED IN FLIGHT
BY THE REACTION OF AIR

AGAINST ITS LIFTING SURFACES.

THE FIRST GLIDERS
TO CARRY PEOPLE

ARE DESIGNED
BY SIR GEORGE CAYLEY

BETWEEN THE END OF THE 18th

AND BEGINNING
OF THE 19th CENTURIES.

ALTHOUGH THEY ONLY MANAGE
A FEW BRIEF HOPS IN THE AIR,

THEY CERTAINLY PAVE THE WAY
FOR FUTURE DEVELOPMENT.

OTTO LILIENTHAL
IS THE FIRST PERSON

TO MAKE REPEATED
SUCCESSFUL GLIDING FLIGHTS

AT THE END OF THE 19th CENTURY

AND CONVINCES THE PUBLIC
THAT FLYING MACHINES

MAY ONE DAY BECOME A REALITY.

THEN IN THE EARLY 20th CENTURY

COMES THE FIRST SUCCESSFUL
HIGH-ALTITUDE GLIDER FLIGHT

BY DANIEL MALONEY

FOLLOWED BY THE WORK
OF THE FAMOUS WRIGHT BROTHERS.

BY THE 1930s, GLIDERS
THAT RESEMBLE THE ONES

WE KNOW TODAY
ARE USED FOR SPORT.

HOWEVER, THEY ALSO HAVE
A BIG ROLE TO PLAY

DURING WORLD WAR II.

THE NAZIS TRAINING PILOTS
FOR THE LUFTWAFFE,

FORBIDDEN TO HAVE THE AIRCRAFT
BY THE TREATY OF VERSAILLES,

USED GLIDERS
TO TRAIN THEIR PILOTS.

THEN COME 1940,

THE GERMANS
WERE TOWING THEIR GLIDERS

BEHIND THEIR TRANSPORT AIRCRAFT.

THEY HAD 10 MEN.
AND THEY USED THESE GLIDERS

TO ATTACK EBEN-EMAEL,
THE GREAT FORTRESS,

AS THE BLITZKRIEG
ROLLED THROUGH BELGIUM.

AND THEY WERE VERY SUCCESSFUL.

Narrator: THE ALLIES ALSO FIND
AN IMPORTANT USE FOR GLIDERS

BY CARRYING HEAVY EQUIPMENT
AND TROOPS TO THEIR TARGETS

WHILE LANDING QUIETLY.

♪♪

ALTHOUGH NO LONGER USED
BY THE MILITARY TODAY,

THIS VERSATILE AIRCRAFT
STILL TAKES ON MANY FORMS

FROM HANG GLIDERS TO SAILPLANES

AND IS FLOWN BY THOUSANDS
OF ENTHUSIASTS EVERYWHERE.

PIPISTREL, A SLOVENIAN-BASED
LIGHT-AIRCRAFT MANUFACTURER

THAT HAS BEEN PRODUCING GLIDERS
SINCE THE 1980s.

THE PRODUCTION OF A GLIDER

BEGINS WITH RESEARCH
AND DEVELOPMENT.

FIRST, 3-D MODELS
OF THE AIRCRAFT ARE CREATED.

THIS ALLOWS THE R&D TEAM

TO RUN SIMULATIONS
ON THE PLANES.

TESTS INCLUDE VIRTUAL
WIND TUNNELS,

WHICH SHOW HOW AERODYNAMICALLY
EFFECTIVE THE GLIDER WILL BE.

THE SHAPE DEVELOPED
IN THE R&D STAGE

IS PROGRAMMED INTO
AN EIGHT-AXIS CNC CUTTER.

SOFT MATERIALS,
SUCH AS POLYSTYRENE

OR WOOD, ARE THEN CUT.

THESE SHAPES CAN BE
EITHER POSITIVE OR NEGATIVE.

AN POSITIVE SHAPE
CAN BE DIRECTLY USED

TO FORM THE SHAPE
OF THE AIRCRAFT.

AND A NEGATIVE SHAPE
IS USED AS A MOLD.

THESE MOLDS AND SHAPES

ARE THEN TURNED
INTO REAL-LIFE AIRPLANES

USING MANY COMPOSITE MATERIALS

SUCH AS FIBERGLASS
FOR THE WINGS

AND CARBON FIBER
FOR THE FUSELAGE.

THE FUSELAGE IS ALSO REINFORCED

WITH KEVLAR THAT PROTECTS
THE GLIDER'S PASSENGERS

BY PREVENTING THE CARBON
FROM SHATTERING

IN THE EVENT OF AN ACCIDENT.

THE SANDING, PAINTING,
AND SHAPING

OF THE MOLD IS ALL DONE
IN A VACUUM VENTILATION CHAMBER.

THE TECHNICIANS THEN APPLY

UP TO 30 LAYERS OF FIBER
INTO THE MOLD

OR ONTO THE SHAPE

AND LAMINATE THIS
WITH EPOXY RESIN.

COMPOSITE MATERIALS,
SUCH AS CARBON FIBER,

ARE CREATED BY WEAVING CARBON

OR GLASS FIBERS INTO A MAT

THAT CAN BE EASILY
MOLDED OR SHAPED.

WHEN THE EPOXY RESIN IS APPLIED,

THEY TURN INTO HARD
AND STRONG REINFORCED MATERIALS

WITH AN AMAZING
WEIGHT-TO-STRENGTH RATIO,

MAKING THEM IDEAL
FOR AIRCRAFT SUCH AS GLIDERS.

EVERY AIRCRAFT CONSISTS
OF AROUND 5,000 DIFFERENT PARTS

FROM OVER 400 SUPPLIERS.

INSPECTIONS ARE VITAL.

ALL PARTS ARE CHECKED ON ARRIVAL
AND RECEIVE A BAR CODE.

THESE BAR CODES
ARE UNIQUE TO EACH PART

AND EVEN CONTAIN
IMPORTANT INFORMATION,

SUCH AS THE WEIGHT.

DURING THE FINAL ASSEMBLY,

ALL THE SYSTEM AND SUBSYSTEMS
OF THE AIRCRAFT

ARE ASSEMBLED AND FITTED.

THESE RANGE FROM PEDALS
TO THE PARACHUTE

RESCUE SYSTEM,
AS WELL AS THE ENGINE,

IN THE CASE OF
SELF-PROPELLED GLIDERS.

USING THE BAR CODES,
A CENTRAL COMPUTER

TOTALS UP THE WEIGHT
ADDED BY EACH PART,

ENSURING THE GLIDER WON'T BE
OVER THE MAXIMUM TAKE-OFF WEIGHT

OF 945 POUNDS.

EVERY GLIDER IS CUSTOM ORDERED.

SO THE EXACT COMPONENTS USED
DIFFER ON EACH.

THEY CAN RANGE
FROM A FEW BASIC INSTRUMENTS,

SUCH AS HEIGHT
AND SPEED INDICATORS,

TO MUCH MORE
SOPHISTICATED EQUIPMENT.

THE CUSTOMER CAN ALSO SPECIFY
THE LOCATION OF EACH INSTRUMENT.

SO THE WORKERS DRILL HOLES
TO FIT THESE.

AT THE END OF THE ASSEMBLY,

ALL THE AIRCRAFT
ARE GIVEN A FINAL GROUND CHECK.

WHALES AND TALE SURFACES
ARE FITTED TO THE FUSELAGE

AND ALIGNED
WITH LASER MEASUREMENTS.

THE GLIDER'S WEIGHT IS COMPARED
TO THE TOTAL WEIGHT COMPUTED

FROM THE DIFFERENT BAR CODES.

IF THIS WEIGHT IS ACCURATE,

THE GLIDER CAN THEN BE TESTED.

EACH AIRCRAFT IS FLOWN
FOR AT LEAST 5 HOURS

BY A HIGHLY TRAINED TEST PILOT.

THESE PILOTS WILL PERFORM
A WIDE RANGE OF TESTS

TO ENSURE ALL SYSTEMS
ARE WORKING CORRECTLY.

THE AIRCRAFT IS THEN
SERVICED AGAIN

IN ORDER TO RETURN
TO ITS ZERO-HOUR CONDITION.

WHEN THIS IS COMPLETE,
THE GLIDER IS READY

TO BE SENT OFF TO THE SKIES.

THE GLIDER, TRULY
AN INCREDIBLE INVENTION.

A SMASHED VASE OR BROKEN TOY?

CHANCES ARE YOU'LL
NEED SUPER GLUE.

THE STORY OF THIS INCREDIBLE
INVENTION AFTER THE BREAK.

Narrator: THERE'S A GOOD CHANCE
THAT AT SOME POINT IN YOUR LIFE,

YOU'VE NEEDED TO USE SUPER GLUE.

IT'S AN ESPECIALLY HANDY
ADHESIVE TO USE

ON A NUMBER OF BROKEN OBJECTS.

WHILE SUPER GLUE,
ALSO KNOWN AS CYANOACRYLATE,

IS A COMMON
HOUSEHOLD ITEM TODAY,

HAVE YOU EVER WONDERED
HOW IT WAS DEVELOPED?

AND DID YOU KNOW THAT IT HAS
A WORLD WAR II CONNECTION?

♪♪

ADHESIVES HAVE BEEN MADE

FOR THOUSANDS OF YEARS
FROM BIRCH TAR.

BUT WHAT ABOUT THE SUPER
STICKY GLUE WE KNOW TODAY?

LIKE SO MANY GREAT INVENTIONS,

IT'S DISCOVERED BY ACCIDENT.

IN 1942, THE SCIENTIST
HARRY COOVER JR.

RESEARCHES MATERIALS TO MAKE
A CLEAR PLASTIC GUN SCOPE.

IN THE PROCESS, HIS RESEARCH
GROUP DISCOVERS A FORMULA

FOR A VERY CLEAR SUBSTANCE

THAT WOULD STICK TO ANYTHING
AND EVERYTHING.

ALTHOUGH IT CAN'T BE USED
FOR THE SCOPE,

COOVER NEVER FORGETS
ABOUT HIS NEW ADHESIVE.

BECAUSE IT WASN'T
WHAT HE WAS LOOKING FOR,

HE LEFT IT TO THE SIDE
AND DIDN'T DO ANYTHING

UNTIL ABOUT 1951

WHEN KODAK,
OF THE KODAK CAMERA FAME,

REDISCOVERED IT AND REALIZED

IT COULD ACTUALLY HAVE
A POTENTIAL USE AS A GLUE.

IN 1951, EASTMAN KODAK TOOK
A LOOK AGAIN AT THIS PRODUCT

THAT THEY HAD MADE
AND DECIDED THAT THIS PRODUCT,

WHICH STUCK TO EVERYTHING ELSE,

COULD BE COMMERCIALIZED
INTO A GLUE FOR COMMERCIAL USE

WITHIN THE HOUSEHOLD
AND POTENTIALLY OTHER USES.

Narrator: THE PRODUCT
THAT STICKS TO EVERYTHING

FINALLY GETS TO MARKET IN 1958.

NOW, LET'S HAVE A CLOSER LOOK

AT THIS GAME-CHANGING ADHESIVE'S
CHEMICAL PROPERTIES.

CYANOACRYLATE
CONSISTS OF MONOMERS

OF CYANOACRYLATE MOLECULES.

IT IS AN ACRYLIC RESIN

THAT POLYMERIZES
IN THE PRESENCE OF WATER,

FORMING LONG CHAINS
THAT BOND SURFACES TOGETHER.

BECAUSE OF ITS REACTION
TO MOISTURE,

IT TURNS INTO PLASTIC
IN JUST A FEW SECONDS.

THAT REACTION IS
WHAT MAKES THE SUPER GLUE

MUCH MORE FAST-ACTING

AND STRONGER THAN OTHERS.

SUPER GLUE WORKS AND DOESN'T
STICK TO ITSELF IN THE BOTTLE

BECAUSE IT'S ACTUALLY A REACTION

WITH THE CYANOACRYLATE
AND WATER.

AND THIS REACTION
REQUIRES WATER TO WORK.

IF YOU KEEP IT IN A BOTTLE THAT
HAS NO WATER, IT WON'T WORK.

IT'LL STILL SIT AS A LIQUID.

THIS IS WHY IF YOU
TAKE SUPER GLUE,

PUT IT ON PLASTIC BAGS,

SOME OF THE OLDER-STYLE ONES,
AND STICK THEM TOGETHER,

YOU CAN PULL THEM APART
AFTER A FEW MINUTES

BECAUSE THERE'S NO WATER
ON THE SURFACE.

Narrator: BUT DID YOU KNOW THAT
SUPER GLUE HAS ALSO SAVED LIVES?

IT'S TRUE.
DURING THE VIETNAM WAR,

SOLDIERS USED IT
AS A QUICK-FIX SOLUTION

FOR TENDING BATTLE WOUNDS.

Gazard:
THE ARMY USED SUPER GLUE

TO STICK WOUNDS TOGETHER
IN THE VIETNAM WAR.

IT'S NOT ADVISABLE TO DO THIS.

IT WAS USED AS A STOPGAP
BECAUSE IN THE VIETNAM WAR,

IF YOU WERE OUT IN THE MIDDLE
OF THE JUNGLE AND WERE SHOT,

THE MOST COMMON REASON

FOR YOU TO DIE
WAS BECAUSE YOU BLED OUT.

IT WASN'T ACTUALLY
THE ACTUAL INJURY ITSELF.

SO YOU NEEDED A MEANS
TO SORT OF CLOSE UP THE WOUND

AND HOLD IT TOGETHER BEFORE
THE OPERATION COULD BE DONE

WHEN YOU WERE TRANSPORTED
TO A BETTER MEDICAL CARE.

DR. COOVER OF EASTMAN KODAK,

HE WORKED OUT HOW TO APPLY IT
AS A SPRAY.

AND SPECIALLY TRAINED
SURGICAL TEAMS

WERE INVOLVED WITH USING THAT

IN THE WAR TO SAVE LIVES.

Narrator:
AND THAT'S NOT THE ONLY
INTERESTING SUPER GLUE STORY.

THERE ARE SOME MISUSES
OF SUPER GLUE.

IF YOU REMEMBER
THAT SUPER GLUE'S

ACTUALLY VERY QUICK
TO FORM THE BOND,

SO YOU WANT IT TO GLUE FAST --

THERE WAS A CASINO GAMBLER
WHO WENT INTO THE TOILETS,

SAT DOWN TO DO HIS BUSINESS,

AND FOUND THAT HE WAS
STUCK TO THE SEAT

BECAUSE SOMEONE HAD PUT
SUPER GLUE ON THE SEAT.

AND WHEN HE SAT DOWN,
IT WASN'T VERY LONG,

AND HE WAS STUCK TO THE SEAT.

HE THEN HAD TO WANDER
OUT INTO THE CASINO

WITH PART OF THE TOILET
ATTACHED TO HIM

TO TRY TO GET SOME HELP.

Narrator: MISHAPS ASIDE, WHEN
SUPER GLUE IS USED CORRECTLY,

THERE REALLY AREN'T MANY
BETTER WAYS TO FIX THINGS FAST.

VERY FEW ACCIDENTAL DISCOVERIES

ARE SO SIMPLE YET SO VERSATILE.

SUPER GLUE, THE INCREDIBLE
INVENTION THAT STICKS.

STICK AROUND,
AND WE'LL SHOW YOU

HOW SUPER GLUE CAN BE USED
IN THE FIGHT AGAINST CRIME

WHEN "INCREDIBLE INVENTIONS"
RETURNS.

Narrator: SUPER GLUE MAY HAVE
AMAZING STICKING QUALITIES.

BUT CAN IT HELP SOLVE CRIME?
WELL, MAYBE.

THERE'S BEEN A BURGLARY.

BUT THE THIEF
LEFT BEHIND SOME SUNGLASSES.

WE CAN'T SEE ANY FINGERPRINTS.

SO IT'S UP TO OUR
INTREPID DETECTIVE

TO FIND THE THIEF'S PRINTS
USING A COFFEE PERCOLATOR

AND THE POWER OF SUPER GLUE.

IT'S CALLED FINGERPRINT FUMING.

BUT HOW DOES IT ACTUALLY WORK?

TO BEGIN, THE MATERIALS --
A COFFEE PERCOLATOR,

A METAL TIN LID,

A TUBE OF SUPER GLUE,
AND THE THIEF'S SUNGLASSES.

PLEASE REMEMBER THAT YOU
SHOULDN'T REALLY DO THIS AT HOME

AND THAT THE GLUE IS TOXIC
AND CAN EASILY STICK TO SKIN.

♪♪

WE TAKE THE TIN LID,

PLACE A FEW DROPS OF SUPER GLUE
ONTO ITS SURFACE,

AND CAREFULLY POP IT
INTO THE POT.

WE THEN ADD THE PIECE
OF EVIDENCE TO THE POT --

IN THIS CASE, THE SUNGLASSES --

MAKING SURE IT DOESN'T
TOUCH THE GLUE.

NOW, WE TURN ON
THE PERCOLATOR...

♪♪

...SIT BACK,
AND WAIT FOR THE RESULTS.

YOU NEED TO BE PATIENT
AS THE PERCOLATOR

GENTLY WARMS UP THE CONTENTS
OF THE COFFEE POT.

WHILE WE WAIT,
LET'S EXPLAIN THE SCIENCE

BEHIND FINGERPRINT FUMING.

THE HEAT IN THE COFFEE POT

WILL EVENTUALLY CAUSE THE DROPS
OF SUPER GLUE TO VAPORIZE.

FINGERPRINTS ARE ACTUALLY
COMPOSED OF SWEAT,

AMINO ACIDS,
FATTY ACIDS PROTEINS,

POTASSIUM, AND SODIUM.

AND THE GLUE IS HIGHLY
ATTRACTED TO THESE SUBSTANCES.

SO ITS FUMES STICK TO THE PRINTS

AND WILL REVEAL
THE TRACE OF THE PRINTS,

OR SO WE HOPE.

YOU CAN SEE THAT PROCESS
IN ACTION.

AND THERE YOU GO.

WE CAN NOW FIND OUT
WHO THE VILLAIN IS.

SO LET'S GO GET HIM.

EVERYBODY NEEDS TO COOK.

BUT SOME ENJOY IT
MORE THAN OTHERS.

WHICHEVER CAMP YOU'RE IN,

LET'S AGREE
THAT IT CAN SOMETIMES BE,

WELL, TRYING.

LUCKILY, KITCHEN APPLIANCES
HAVE EVOLVED TO MAKE

THE COOKING EXPERIENCE
MORE ENJOYABLE AND EASIER.

BUT DID YOU KNOW
ONE KITCHEN INVENTION

COMES FROM A MISHAP
DURING A SCIENCE EXPERIMENT

AND IS LATER USED
BY A WORLD WAR II SPY?

THIS IS THE AGA OVEN.

THE AGA IS ONE
OF THE GREATEST REVOLUTIONS

IN KITCHEN APPLIANCES
DURING THE 20th CENTURY.

ITS INVENTOR, NOBEL PRIZE-WINNER
GUSTAF DáLEN, IS BLINDED IN 1912

WHEN A PRESSURE TEST
GOES TRAGICALLY WRONG.

AFTER THE ACCIDENT,
DáLEN UNDERGOES

A LONG PERIOD
OF RECOVERY AT HOME

WITH HIS WIFE BY HIS SIDE.

HE REALIZES HOW EXHAUSTING
COOKING IS FOR HER.

DESPITE HIS BLINDNESS,
HE RESOLVES TO DESIGN A STOVE

THAT WILL MAKE THE JOB EASIER.

HE ASKS HIS WIFE WHAT THE
PROBLEMS WERE IN THE HOUSEHOLD.

AND SHE SAID, WELL, THE FACT

SHE'S ALWAYS GOT TO TEND
TO THE RANGE COOKER.

I MEAN, WORKING
ON A RANGE COOKER,

EVEN IF YOU'RE DOING IT TODAY,
IT IS A FULL-TIME JOB.

YOU HAVE TO KEEP IT
KIND OF FIRED WITH COAL.

YOU HAVE TO WATCH
FOR TEMPERATURE CONSTANTLY.

SO HE HAD BEEN WORKING
ON "RADIAL HEAT"

AND CAME UP WITH THIS DESIGN
FOR AN OVEN

WHICH WOULD CONTAIN THE HEAT,

WHICH, ONCE THE HEAT WAS IN IT,
WOULD STAY THERE

AND STAY AT AMBIENT
TEMPERATURES.

SO THIS IS WHERE
THE AGA CAME FROM.

IT WAS THE FIRST,
LIKE, RADIAL HEAT OVEN.

Narrator: DáLEN DEVELOPS A UNIT
WITH TWO OVENS

AND FOUR STOVE PLATES.

THE AGA IS INVENTED.

IT'S INTRODUCED IN ENGLAND
DURING THE 1930s

UNDER AGA RAYBURN
AND STANLEY BRANDS.

AT FIRST, PEOPLE USED CHARCOAL
FOR STEADY HEAT.

AND SOON ENOUGH,
THE OVEN BECOMES POPULAR

FOR ELITE HOUSEHOLDS
AT THE TIME.

AND ITS CONNECTION
TO WORLD WAR II?

MASTER ADVERTISER DAVID OGILVY
BEGINS SELLING AGAs

DURING HIS EARLY 20s

AND QUICKLY MAKES
QUITE A NAME FOR HIMSELF.

WHEN WORLD WAR II BREAKS OUT,

OGILVY FINDS HIMSELF WORKING

FOR BRITISH INTELLIGENCE
IN THE U.S.

AND IT'S THE FORMER
AGA SALESMAN'S

GROUND-BREAKING RESEARCH
INTO HUMAN BEHAVIOR

THAT IS ADOPTED BY ALLIED SPIES

ALL OVER EUROPE DURING THE WAR.

TODAY, THE AGA OVEN
IS STILL SEEN

AS A SYMBOL OF STYLE
AND LUXURY EVERYWHERE.

VERY FEW APPLIANCES
HAVE HAD THE SAME LASTING IMPACT

ON THE WAY WE COOK.

AND FOR THAT REASON ALONE,

IT REALLY IS
AN INCREDIBLE INVENTION.

♪♪

BUT JUST HOW IS SUCH
AN INCREDIBLE INVENTION

LIKE THE AGA OVEN BUILT?

FIND OUT WHEN WE RETURN.

Narrator: AT THE COALBROOKDALE
FOUNDRY IN SHROPSHIRE, ENGLAND,

THE PROCESS OF BUILDING THE AGA

BEGINS WITH FULLY RECYCLED
AND RECLAIMED SCRAP IRON,

SUCH THINGS AS BRAKE DISKS
AND CAST COLUMNS

AND EVEN OLD AGAs THEMSELVES.

THE SCRAP IS COLLECTED,
MIXED WITH ALLOY ELEMENTS,

AND FED INTO THE FURNACE
WITH COAL FUEL

TO REACH TEMPERATURES OF MORE
THAN 3,000 DEGREES FAHRENHEIT.

THE FURNACE CAN MELT 5 TONS
OF CAST IRON PER HOUR.

ONCE MELTED, THE MOLTEN IRON

IS TAKEN TO TWO OF THE LINES
IN A CONTAINER OR LARGE LADLE.

♪♪

THE MOLTEN IRON INSIDE

IS STILL AT A BLISTERING
2,500 DEGREES FAHRENHEIT.

USING A MIXTURE
OF SAND, CLAY, AND WATER,

THE MOLDING MACHINE CAN CREATE
MOLDS OF ANY OVEN PART,

DOOR FRONT, OR TOP.

♪♪

THE MOLDING MACHINE
MAKES SAND MOLD NEGATIVES

OF A PATTERN,
WHICH ARE THEN SPLIT IN HALF

SO THAT WHEN THE TWO HALVES
ARE PUT TOGETHER,

THEY CREATE A CAVITY FOR THE
MOLTEN METAL TO BE POURED INTO.

THE TWO HALVES
ARE CLAMPED TOGETHER

AND SENT ALONG
THE PRODUCTION LINE,

WHERE THE MOLTEN METAL IS POURED

BY AN AUTO-POUR FURNACE.

♪♪

ONCE THE MOLD HAS BEEN FILLED,

IT IS MOVED ALONG
THE CONVEYOR BELT,

WHERE THE METAL
INSIDE QUICKLY COOLS.

ONCE COOLED SUFFICIENTLY,

IT IS TIME TO RETRIEVE
THE CASTINGS.

EACH MOLD IS SENT DOWN
THE VIBRATING GRID,

BREAKING OPEN THE SAND MOLD,
AND THE CASTINGS ARE REVEALED.

THEY ARE INSPECTED,
AND ANY REMAINING MOLD

IS BROKEN OFF BY HAND,
THEN PLACED INTO BINS

TO COOL DOWN FURTHER
TO ROOM TEMPERATURE.

♪♪

THE FRESH CASTINGS
ARE SENT TO A SHOT BLAST,

WHERE STEEL SHOT IS FIRED
AT THE CASTINGS

TO REMOVE ANY REMAINING
SAND PARTICLES.

THE BRAND-NEW OVEN PARTS
ARE SENT TO A WORKSHOP ON-SITE.

THERE, USING HAND-HELD
AND PEDESTAL GRINDERS,

WORKERS REMOVE ANY BLEMISHES
AND ROUGH EDGES

TO GIVE THE OVEN PARTS
A NICE, SMOOTH FINISH.

♪♪

THE FINISHED PARTS ARE THEN SENT
TO THE TELFORD FACTORY,

WHERE THEY ARE PREPARED

FOR AGA's FAMOUS
ENAMEL FINISH AND ASSEMBLY.

THE CAST-IRON PARTS ARE COATED

WITH A PRIMARY UNDERCOAT
AND TRANSPARENT ENAMEL,

WHICH WILL PROTECT
THE PIECES IN THE FURNACE.

ENAMEL IS MADE UP
OF TINY PARTICLES OF GLASS

AND IS SPRAYED
ONTO THE CAST IRON.

IT IS THEN BAKED IN A FURNACE
UNTIL IT IS RED-HOT.

THIS FUSES THE ENAMEL
ONTO THE CAST IRON,

A PROCESS THAT IS
REPEATED THREE TIMES

TO PRODUCE A SMOOTH,
HIGH-GLOSS FINISH,

WHICH IS VERY EASY
TO KEEP CLEAN.

THE DOOR PARTS AND TOPS
ARE ALL COLOR-MATCHED

FOR EACH INDIVIDUAL MODULE.

NEXT, IT IS ON
TO THE ASSEMBLY LINE.

THE FINISHED OVEN PARTS
ARE BOLTED TOGETHER.

AND HEAT-PROOF SEALANT
IS USED TO LINE THE EDGES

OF EACH COMPONENT.

♪♪

THE OVEN STARTS TO TAKE SHAPE

AS ALL THE UNITS
ARE FITTED INTO PLACE.

THE TWO HOT PLATES, WHICH SIT
AT THE TOP OF THE OVEN,

ARE FITTED
WITH INSULATED CAST IRON

AND CHROME LIDS
TO STOP THE WARMTH

FROM ESCAPING THE COOKER
WHEN NOT IN USE.

THE HEATING ELEMENTS,
GAS OR ELECTRIC,

ARE FIXED ON THE INSIDE.

THE OVENS ARE THEN
INSULATED WITH SILICATE WOOL

BEFORE THE ENAMELED
OUTER SHELL IS FITTED.

AND FINALLY, THE FAMOUS
ENAMEL DOORS ARE ADDED

TO COMPLETE THE OVEN
BEFORE IT IS INSPECTED

AND TESTED PRIOR TO PACKAGING
AND SENT OFF TO THE CUSTOMER.

THE AGA OVEN,
A REAL INCREDIBLE INVENTION.

SO THERE YOU HAVE IT -- A GLANCE
THROUGH THE HIDDEN HISTORY

AND SUPER SCIENCE
OF SOME AMAZING PRODUCTS

WE USE EVERY DAY -- THE GLIDER,

SUPER GLUE, AND THE AGA OVEN.

THEY MAY SEEM
COMMON AND ORDINARY.

HOWEVER, THESE PRODUCTS
HELPED CHANGE THE WORLD

ONE INCREDIBLE INVENTION
AT A TIME.