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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Winter jackets, animation,
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Mushrooms, and gold rings.
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As anyone who's shivered
Through a cold winter knows,
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You've got your run-of-the-mill
Winter jackets
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And then,
Those really warm winter jackets
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That can run up to $1,000.
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The difference is what they're
Made of and how they're made.
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A top-of-the-line winter jacket
Gives you the warmth
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Without the weight.
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It's waterproof
And comfortable --
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No bulky stuffing
Or constrictive styling.
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The designer draws a pattern
By computer.
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00:01:07,896 --> 00:01:11,896
A software program then adapts
The pattern to different sizes.
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A giant printer puts it
To paper.
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The tailor spreads out
Several layers
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Of each of the fabrics
That'll make up the jacket.
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He lays out the pattern...
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...Then pins it in place.
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Next, he cuts through several
Layers of fabric at a time
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With electric scissors.
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These scissors maneuver
Much like a jigsaw
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Around the lines and curves
Of the pattern pieces.
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The finished jacket
Will actually be made up
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Of two jackets sewn together --
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An insulation jacket
On the inside
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And a windbreaker
On the outside.
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00:02:11,103 --> 00:02:15,000
The inner insulation jacket
Begins with a nylon lining.
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Then they layer
The key components --
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A film to stabilize and protect
The insulation,
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Then the thick polyester
Insulation itself.
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At this point, the insulation
Layer is larger than the lining.
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This ensures that every inch of
The jacket will have insulation.
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Working with one piece
At a time,
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They stitch the layers together.
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Each line of stitching is tacked
At the beginning and at the end
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For added strength.
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They cut off
The excess insulation,
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Then sew an overlock
Around each piece
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To hold the remaining insulation
Solidly in place.
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Once they've completed each
Piece of the insulation jacket,
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They sew it all together.
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Next step -- the windbreaker.
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The outer fabric is heavy nylon.
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The lining is a special fabric
With tiny holes,
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Large enough
To let humidity escape,
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00:03:10,931 --> 00:03:13,724
But small enough
To stop water droplets
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And wind from penetrating.
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This is what will allow
The jacket to breath,
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While at the same time,
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Making it windproof
And waterproof.
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Finally, it's time to put the
Two jacket components together.
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Using two separate
Strong threads,
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They sew seams
Made of knotted stitches.
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No seams go through the jacket
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Because that would break
The insulation barrier
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And let in cold air.
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They join
The two jackets together
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Only where they have to --
At the collar, the cuffs,
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The hem,
And along the zipper.
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And this isn't
Any ordinary zipper.
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It's made
Of corrosion-resistant nylon
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With a nickel-plated slider
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That lasts seven times longer
Than a normal slider.
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Until now, they've been sewing
The jacket turned inside out.
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Now they turn it right-side in
For finishing.
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These heavy-duty snaps
Have sturdy grips
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That anchor themselves between
The fibers in the material
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So they won't tear the fabric
With repeated use.
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Some jackets
Have decorative embroidery.
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Designers use a computer program
To prepare the pattern.
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00:04:36,620 --> 00:04:40,379
The automatic machine embroiders
Five jackets at once.
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This intricate owl pattern
Takes 1 1/4 hours to complete.
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The final result
Is a stylish jacket
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Whose secret weapon is
That hidden layer of insulation.
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It traps air inside your body,
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Then heats it up,
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Creating a cushion of warmth
Against the cold of winter.
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Narrator:
What is biophotonics?
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Well, bio is short for biology.
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Photonics is the physics
Of light.
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Biophotonics
Uses sophisticated imaging
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And other sensitive
Optical instruments
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To conduct biomedical research.
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Biophotonics has a range of uses
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From medical diagnosis
To drug screening.
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In the golden years
Of animated film,
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Teams of animators would draw
Every single illustration
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By hand.
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Today, they do much
Of their work by computer,
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But that doesn't mean
It's any less artistic.
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It all starts
With a screenplay --
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A script containing
Not just dialogue,
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But also physical descriptions
Of the characters
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And background scenery.
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The art director
Begins creating the characters.
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He draws in pencil.
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When he's finished, he traces
The drawing in felt pen.
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Then he erases the pencil marks.
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He adds shadowing
To create relief.
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Once he's drawn
All the characters,
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He starts the backgrounds...
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...And then the objects
That appear in the backgrounds.
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The storyboard artist
Blocks out the film on paper,
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Drawing by drawing.
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The production team
Will follow this storyboard
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The way a dressmaker
Follows a pattern.
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They blow up the drawings,
Scan them into the computer,
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Then play them back
In chronological order.
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This creates
What's called an "Animatic" --
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A two-dimensional version
Of the film,
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Minus the animation.
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Should the director
Now decide to change,
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Say, a ground-level view
Of the street to an aerial view,
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He has the artist redraw
The street from that new angle.
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Meanwhile, the animators work on
Bringing the characters to life.
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Using specialized software,
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They build a skeleton to fit
Inside the character's body.
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When they move the skeleton,
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00:08:01,724 --> 00:08:04,482
The software makes
The body move with it.
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00:08:04,482 --> 00:08:07,310
They make the characters
Three-dimensional
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00:08:07,310 --> 00:08:10,275
Using a technique
Called wireframe animation.
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00:08:10,275 --> 00:08:13,206
First, they build
The shape of the character
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Using a wire structure.
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Then they add color
And clothing.
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00:08:24,896 --> 00:08:28,000
They further
Refine the character
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By modifying facial features,
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00:08:29,827 --> 00:08:33,724
By adding texture,
And by shadowing.
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They use specialized software
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To synchronize the character's
Mouth with the dialogue.
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The technician works
Syllable by syllable,
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Picking the mouth movement
That matches each sound.
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It's a painstaking process
That takes many months.
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Another animator applies
The lighting effects.
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Lighting is as important
In an animated cartoon
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As it is in a movie
With real people.
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00:09:09,724 --> 00:09:12,931
It creates relief, making
Everything look more realistic.
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00:09:21,655 --> 00:09:25,310
The animators cut and paste
The characters and objects
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Onto the backgrounds.
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With the characters' movements
Programmed into the computer,
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The animators turn
A two-dimensional
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Still version of the film into
A three-dimensional animation,
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Essentially a rough cut
Of the film.
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00:09:50,965 --> 00:09:55,724
Meanwhile, in the studio,
The soundtrack takes shape.
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00:09:55,724 --> 00:09:58,103
Actors record
The characters' dialogue.
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The sound technician weaves
Together the voices, the music,
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00:10:01,448 --> 00:10:06,310
And the sound effects using
Specially designed software.
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00:10:09,034 --> 00:10:12,517
They sync the soundtrack
To the rough cut of the film.
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00:10:12,517 --> 00:10:17,482
Then they refine the rough cut,
Playing with colors and textures
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00:10:17,482 --> 00:10:20,206
And smoothing out
The characters' movements.
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After a full year's work
And more than 42,000 drawings,
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This 24-minute computer-animated
Film is finally finished.
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Narrator:
Have you ever dined on fungus?
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Well, if you've eaten mushrooms,
You have.
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We like to think of those tasty
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Little umbrella-shaped things
As vegetables,
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But technically, they're fungi.
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Fungus omelette, anyone?
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Mushrooms grow in compost,
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And preparing that compost
Is a science in itself.
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It starts with horse manure
And straw.
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The correct balance of moisture
And air is critical,
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Because mushrooms
Need both to grow,
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So mushroom farmers have to
Turn the pile frequently
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To air it out, and they water
It daily for about a week.
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This kicks up plenty of chemical
And biological activity.
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Ammonia forms,
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And microorganisms grow
And reproduce,
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Releasing heat.
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Good compost requires
A nitrogen content of about 2%,
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So farmers add
A nitrogen supplement --
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Chicken manure.
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They also add gypsum --
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A mineral that improves
The structure of the compost
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And neutralizes its acidity.
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At the week to two-week mark,
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Depending on
How the compost is progressing,
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It goes into the composter,
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Which waters, aerates,
And blends it.
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The compost comes out
Chocolate brown,
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Smelling of ammonia.
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00:12:18,965 --> 00:12:20,551
Next, they pasteurize it,
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To kill off any insects
Or insect eggs.
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00:12:23,931 --> 00:12:28,241
They heat the compost
At 136 degrees for eight hours,
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00:12:28,241 --> 00:12:31,482
Then at 113 degrees
For five days.
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Then, over several more days,
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00:12:33,896 --> 00:12:36,620
They gradually cool it
To 77 degrees
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As microorganisms
Turn the ammonia
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Into a nitrogen protein --
A mushroom nutrient.
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The compost is finally ready.
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The farmer sows grains of wheat
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Inoculated
With mushroom mycelium --
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Fine threads of fungi that act
As the mushrooms' roots.
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00:12:53,827 --> 00:12:57,896
A layer of soil and peat moss
Goes on top of the compost.
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00:12:57,896 --> 00:13:00,793
The mycelium draws water
From the soil
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00:13:00,793 --> 00:13:03,517
And nutrients from the compost.
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00:13:03,517 --> 00:13:07,620
After about two weeks,
Tiny mushrooms begin to develop.
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They grow fast, doubling
Their size every 24 hours,
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And this in relative darkness.
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00:13:13,724 --> 00:13:17,172
Green plants need sunlight
For photosynthesis
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00:13:17,172 --> 00:13:19,551
But mushrooms don't.
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00:13:19,551 --> 00:13:23,241
What mushrooms do need is air,
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00:13:23,241 --> 00:13:27,172
Because they breathe in oxygen
And breathe out carbon dioxide.
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00:13:27,172 --> 00:13:30,068
Green plants do the opposite.
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00:14:03,379 --> 00:14:07,655
Another three days, and the tiny
Mushrooms are fully grown
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00:14:07,655 --> 00:14:10,862
And ready for harvesting.
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00:14:10,862 --> 00:14:14,724
Pickers have to be careful
Not to remove the roots
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00:14:14,724 --> 00:14:18,620
Because left intact, they'll
Sprout a new batch of mushrooms
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00:14:18,620 --> 00:14:22,448
Every three to five days
For about three weeks.
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00:14:24,724 --> 00:14:27,517
They put the harvested mushrooms
In a refrigerator
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00:14:27,517 --> 00:14:30,586
Just above freezing temperature,
For about a half-hour,
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00:14:30,586 --> 00:14:34,000
To stop the growing process.
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00:14:36,655 --> 00:14:40,000
On the packaging line,
They weigh the mushrooms
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00:14:40,000 --> 00:14:42,965
And arrange them in a container,
Buttons up.
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00:14:51,551 --> 00:14:54,068
A machine perforates
The plastic covering
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00:14:54,068 --> 00:14:56,275
To let the mushrooms breathe.
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00:14:56,275 --> 00:14:58,379
This ensures
A longer shelf life.
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00:15:08,137 --> 00:15:10,310
The mushrooms stay in a fridge
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00:15:10,310 --> 00:15:13,413
Until they leave for the store
The following day.
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00:15:24,344 --> 00:15:26,655
It's taken about 12 weeks
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00:15:26,655 --> 00:15:31,620
From the start of composting
To your supermarket shelf.
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00:15:41,758 --> 00:15:44,655
Narrator: gold jewelry has been
A symbol of wealth and status
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00:15:44,655 --> 00:15:46,275
Throughout the ages.
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00:15:46,275 --> 00:15:48,965
Today, though,
It isn't just for the rich.
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00:15:48,965 --> 00:15:52,793
Even ordinary people are likely
To have a gold ring or necklace,
228
00:15:52,793 --> 00:15:54,965
Just a little
Less diamond-studded.
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00:16:02,965 --> 00:16:05,448
As early as 2,000 b.C.,
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00:16:05,448 --> 00:16:08,310
Egyptian kings and queens
Adorned themselves
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00:16:08,310 --> 00:16:12,758
In golden jewelry
Encrusted with precious gems.
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00:16:12,758 --> 00:16:16,344
When the spanish sailed
To the new world in 1492,
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00:16:16,344 --> 00:16:20,620
They discovered mayan and aztec
Masterpieces of colored stones
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00:16:20,620 --> 00:16:23,655
And pure gold.
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00:16:23,655 --> 00:16:26,965
Today, elaborate gold jewelry
And precious gems
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00:16:26,965 --> 00:16:30,275
Are well beyond the reach
Of the average person,
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00:16:30,275 --> 00:16:32,689
Except for the diamond ring --
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00:16:32,689 --> 00:16:36,206
Still the customary symbol
Of engagements.
239
00:16:41,448 --> 00:16:45,172
The client
And the jewelry designer
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00:16:45,172 --> 00:16:47,275
First decide
How the ring will look.
241
00:16:47,275 --> 00:16:49,793
The designer then measures
The client's finger
242
00:16:49,793 --> 00:16:53,137
To determine her ring size.
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00:16:53,137 --> 00:16:56,586
He then sketches out the design
They've agreed upon --
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00:16:56,586 --> 00:16:59,034
A grooved band
With three diamonds.
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00:16:59,034 --> 00:17:02,793
The model maker works
With a special carving wax.
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00:17:02,793 --> 00:17:04,172
Using a compass,
247
00:17:04,172 --> 00:17:07,551
He measures and marks
The width of the band,
248
00:17:07,551 --> 00:17:11,241
Then carefully saws it off.
249
00:17:11,241 --> 00:17:13,206
He takes his gauge
250
00:17:13,206 --> 00:17:15,655
And puts it on a stick
With ring-size markings,
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00:17:15,655 --> 00:17:17,206
Called a mandrel.
252
00:17:17,206 --> 00:17:20,586
He adjusts his compass
To the ring size,
253
00:17:20,586 --> 00:17:23,724
Then scores the finger hole
On the block of wax.
254
00:17:23,724 --> 00:17:25,758
He then takes his drill
255
00:17:25,758 --> 00:17:28,517
And carefully carves out
The hole he scored.
256
00:17:33,275 --> 00:17:37,310
Then he grinds off the wax
On the outside of the band.
257
00:17:37,310 --> 00:17:40,758
Using the compass again, he
Scores the middle of the band,
258
00:17:40,758 --> 00:17:42,448
Where he'll make the groove.
259
00:17:42,448 --> 00:17:45,793
Then, using a fine drill bit,
He carves out the groove.
260
00:17:45,793 --> 00:17:48,620
With a file,
He then refines the groove
261
00:17:48,620 --> 00:17:51,103
And shapes
The curves of the ring
262
00:17:51,103 --> 00:17:52,896
According to the design.
263
00:17:54,896 --> 00:17:57,793
After putting wax prongs
On the band,
264
00:17:57,793 --> 00:18:00,068
He attaches a wax stem
To the model.
265
00:18:00,068 --> 00:18:03,344
He then positions the stem
Into the base of the cylinder
266
00:18:03,344 --> 00:18:07,275
That the jeweler will use
To cast the ring.
267
00:18:07,275 --> 00:18:10,206
The base goes onto the platform
Of a vacuum machine.
268
00:18:10,206 --> 00:18:12,862
The jeweler puts a cylinder
On top of the base,
269
00:18:12,862 --> 00:18:15,103
Then pours in a special plaster.
270
00:18:17,137 --> 00:18:19,724
The vacuum sucks all the air
Out of the plaster.
271
00:18:19,724 --> 00:18:22,482
This is a key part
Of the process,
272
00:18:22,482 --> 00:18:24,310
Because if
Any air bubbles remain,
273
00:18:24,310 --> 00:18:27,586
The finished ring will be
Out of shape.
274
00:18:27,586 --> 00:18:30,034
In less than a minute,
The vacuuming is done,
275
00:18:30,034 --> 00:18:32,206
And the cylinder
Goes into the furnace
276
00:18:32,206 --> 00:18:34,793
At 1,350 degrees fahrenheit.
277
00:18:36,758 --> 00:18:38,344
The wax model evaporates,
278
00:18:38,344 --> 00:18:41,034
Leaving a void the exact shape
Of the ring
279
00:18:41,034 --> 00:18:42,586
In the hardened plaster.
280
00:18:42,586 --> 00:18:45,517
Next, they melt the gold.
281
00:18:45,517 --> 00:18:49,344
The gold content of jewelry
Is measured by karat.
282
00:18:49,344 --> 00:18:52,448
The lower the karat, the less
Gold and the more alloy,
283
00:18:52,448 --> 00:18:55,862
Or cheaper metals such
As nickel, silver, and copper.
284
00:18:55,862 --> 00:18:57,896
After five hours,
285
00:18:57,896 --> 00:19:00,000
The cylinder comes
Out of the furnace
286
00:19:00,000 --> 00:19:02,068
And goes into
The casting machine.
287
00:19:04,965 --> 00:19:07,413
The machine spins
For about a minute.
288
00:19:07,413 --> 00:19:10,448
The centrifugal force
Shoots the liquefied gold
289
00:19:10,448 --> 00:19:13,931
Into the plaster mold
That's inside the cylinder.
290
00:19:20,172 --> 00:19:23,310
The jeweler then immerses
The cylinder in cold water.
291
00:19:23,310 --> 00:19:26,758
This cools the gold and makes
The plaster disintegrate.
292
00:19:26,758 --> 00:19:30,551
What's left
Is the cast gold ring,
293
00:19:30,551 --> 00:19:35,620
But its surface is rough,
So on to the finishing process.
294
00:19:35,620 --> 00:19:39,206
The jeweler saws off the stem
And gets to work.
295
00:19:39,206 --> 00:19:43,172
He files and grinds the ring
Until the surface is smooth.
296
00:19:48,965 --> 00:19:53,448
Then he stamps on his trademark
And the karat marking.
297
00:19:56,206 --> 00:19:59,172
Then he hammers the ring
On the mandrel
298
00:19:59,172 --> 00:20:00,827
To make it perfectly round.
299
00:20:00,827 --> 00:20:06,000
The jeweler then hands it off
To a specialist in polishing.
300
00:20:06,000 --> 00:20:09,000
The polisher runs the ring
Against a series
301
00:20:09,000 --> 00:20:12,172
Of buffing wheels
Until it's bright and shiny.
302
00:20:12,172 --> 00:20:14,000
The polisher then hands it off
303
00:20:14,000 --> 00:20:16,310
To a specialist
In setting gemstones.
304
00:20:16,310 --> 00:20:18,172
The setter straightens
The prongs
305
00:20:18,172 --> 00:20:19,551
That'll hold the diamonds.
306
00:20:19,551 --> 00:20:22,275
Then, with a delicate drill bit,
307
00:20:22,275 --> 00:20:25,655
He carefully carves out
The inside of the prongs.
308
00:20:25,655 --> 00:20:29,724
The edges of the diamonds will
Fit directly into these slots.
309
00:20:31,724 --> 00:20:36,068
He readjusts the prongs,
Then sets the diamonds,
310
00:20:36,068 --> 00:20:39,000
Making sure the prongs
Hold them down securely.
311
00:20:41,482 --> 00:20:44,448
That's a 1-carat diamond
In the middle,
312
00:20:44,448 --> 00:20:48,034
A 1/2-carat diamond
On each side.
313
00:20:48,034 --> 00:20:50,310
The jeweler then immerses
The finished ring
314
00:20:50,310 --> 00:20:51,793
Into the ultrasonic machine.
315
00:20:51,793 --> 00:20:56,103
The vibrations in the water
Penetrate every nook and cranny,
316
00:20:56,103 --> 00:20:57,482
Washing the ring.
317
00:20:57,482 --> 00:21:00,862
Finally, he puts the ring
Under a jet of hot steam
318
00:21:00,862 --> 00:21:04,482
To blast away
Any remaining residue.
319
00:21:04,482 --> 00:21:06,344
And voilĂ .
320
00:21:06,344 --> 00:21:09,896
With a ring like that,
Who wouldn't say "I do"?
321
00:21:12,965 --> 00:21:16,000
If you have any comments
About the show
322
00:21:16,000 --> 00:21:18,689
Or if you'd like to suggest
Topics for future shows,
323
00:21:18,689 --> 00:21:21,310
Drop us a line at...
26071
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