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Narrator:
Today on "How it's made"...
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...Horse-drawn carriages...
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00:00:31,931 --> 00:00:34,482
...Artificial eyes...
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00:00:37,965 --> 00:00:39,413
...Dog and cat food...
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...And mirrors.
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Nothing takes you
Back to the past
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Quite like a ride
In a horse-drawn carriage,
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00:00:58,448 --> 00:01:03,103
A timeless vehicle in both
Appearance and construction.
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Building one today
Still requires the expertise
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Of several
Traditional craftspeople,
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From ironworkers
To wheelwrights.
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The carriage's turning mechanism
Is a fifth wheel
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That is positioned horizontally
Above the two front wheels.
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Workers weld the fifth wheel
To the carriage's steel frame
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Then weld the boarding steps
To the frame.
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Until now the frame
Has been positioned upside down.
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Now they turn it right side up
To install the driver's seat.
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First they measure carefully
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To ensure
It's perfectly centered.
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Then they weld it in place.
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Once the frame is complete,
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It goes through an acid wash
To remove any residue.
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Then they buff the welded joints
To smooth out their surface.
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The carriage has drum brakes.
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Workers install them
Onto the axle
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00:02:00,275 --> 00:02:05,206
Then assemble the steel springs
That make up the suspension
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And bolt them onto the axle
As well.
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00:02:08,275 --> 00:02:13,275
Next, they connect
The brake line.
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00:02:13,275 --> 00:02:16,241
Then they install
The whole assembly
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Under the carriage's frame.
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Like in the olden days,
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They make the wheels
Out of wood.
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Metal isn't flexible enough
To withstand bumps in the road.
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They use ash
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Because it's a very hard wood
That doesn't rot easily.
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Workers position 16 spokes
Around a steel hub.
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They clamp the spokes in place,
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Compressing them
Against the hub.
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Then they secure them
With nuts and bolts.
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Next, they mark the spokes
In two places.
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The first line shows
How long to cut each spoke,
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The second line
How far to dowel the end.
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To form the dowel,
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They first shape the end
Into a cone.
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Then the cone into a dowel.
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Those doweled spokes will fit
Into corresponding holes
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They now drill into two
Semicircular strips of wood.
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The strips form
What's called the fellow,
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The round part of the wheel.
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Workers tighten the hub
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Then press a steel band called
A channel against the fellow.
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They cut the channel to size.
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Then weld the ends together.
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Finally,
They buff the joint smooth.
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Next, they drill eight holes
Through the channel
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00:03:58,827 --> 00:04:00,620
Then, using a tapering tool,
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Thread the holes
To fit the bolts
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That bind the channel
To the fellow.
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00:04:05,758 --> 00:04:09,758
Finally, they tighten the bolts
With a special gun.
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00:04:09,758 --> 00:04:12,862
The tires are made of rubber.
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They contain two steel wires
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To hold them in place
Over the wheel.
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Workers grease the channel
Of the now-painted wheel
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So that the tire
Will slip on easily.
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Then they mount the wheel
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On the automated
Tire-installation machine,
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Which pulls on the wires,
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Installing the tire
Tightly over the wheel.
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They solder the wire ends
Together
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Using bronze solder
For a stronger joint.
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Then -- here comes
The high-tech part --
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They bang the wheel on
The ground four or five times
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Until the distance
Between the tire ends closes,
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Covering the soldered wires
Inside.
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A tap of the hammer
Followed by a final bang
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Ensures the tire joint
Is secure.
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00:05:02,517 --> 00:05:05,551
Now they can mount the wheels
Onto the axles
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00:05:05,551 --> 00:05:09,862
And install the axles
Under the body of the carriage.
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After testing the fifth wheel
And the brakes...
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...It's time to apply
The finishing artistic touches.
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All they need now
Is a little horsepower.
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Narrator:
The ancient romans and egyptians
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Fashioned artificial eyes
Out of painted clay.
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By the 1500s,
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Europeans started making them
Out of enameled gold
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And soon out of glass,
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Which remained the norm
For hundreds of years.
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Today most artificial eyes
Are made of acrylic.
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If you've lost an eye
In an accident or to a disease,
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A specialist
Known as an ocularist
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Can fit you
With an artificial eye.
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You can get a ready-made model
Or a custom-made prosthesis,
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Like the one for which
This patient is being fitted.
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No two people's eye sockets
Are the same,
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So the first step
Is to take an impression.
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After inserting
An impression tray,
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They inject a material
Called alginate,
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Filling the entire
Socket cavity.
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After 90 seconds,
The alginate sets,
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And they can remove
The hardened impression.
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They place the impression
In a mold.
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And pour in a type of plaster.
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When the plaster has hardened,
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They remove the impression tray
And then the impression itself.
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What's left in the mold is
A plaster replica of the socket.
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Now they put a wad of acrylic
Plastic dough into the mold...
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...Lock the mold into a press,
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And submerge it
In a high-pressure curing unit
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For 25 minutes.
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Then they cool the mold
In cold water.
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Here's the original impression
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Compared to the acrylic model
They've just cast.
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This model is called
The fitting shape
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Because they use it
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To fit and mark the positioning
Of the fake iris.
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They accentuate the markings,
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Then attach a peg
With a drop of wax.
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The peg indicates
The natural angle of the iris
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When the patient
Is looking forward.
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Next, they add wax
Around the perimeter
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To enlarge the fitting shape.
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This excess
Will give the ocularist
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Some room to work with
For the final sizing.
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00:08:04,172 --> 00:08:07,620
Now they take this marked
And enlarged fitting shape
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And make a plaster mold.
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00:08:09,448 --> 00:08:11,965
They will later use that mold
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To cast
The actual artificial eye.
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But first they have to make
The iris.
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They take a curved,
Black acrylic disc
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And paint it
As realistically as possible
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With high-quality artist oils.
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The patient has to be present
So they can match the real eye.
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Next, they glue
An acrylic cornea
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With an appropriate-sized pupil
Onto the painted iris.
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At this point,
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The artificial iris
Is half an inch in diameter.
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If the patient's real iris
Is smaller,
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They trim down the replica
To match.
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The iris then goes
Into the plaster mold
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Covered with
White acrylic dough.
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After the same high-pressure
Curing process as before,
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Out comes the artificial eye
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Covered with
Excess white acrylic.
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They trim off that excess
And the peg
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Using a grinding tool
And a cutter.
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This refines the shape
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And exposes the iris
Buried underneath.
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They smooth the surface
Against a grinding stone
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And verify the measurements.
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00:09:17,862 --> 00:09:20,586
Then,
Using hard coloring pencils,
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They add finishing touches
To the iris
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And draw blood vessels.
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They label the eye
With the patient's initials
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And then apply
An acrylic coating
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To seal the pencil marks.
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To create veins
With some dimension,
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They use
The same acrylic coating
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To stick on
Some delicate silk threads.
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Once they're satisfied
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The artificial eye
Is a perfect match,
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They seal the artwork
With another acrylic coating.
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Once that cures,
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They polish the eye to a shine
With a cotton wheel.
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The shapes and colors
Of artificial eyes are endless
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Because patients' eye sockets
And irises vary greatly,
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As do their scleras,
The white of the eye.
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This artificial eye,
Or ocular prosthesis, is ready.
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The final step is to ensure
That the fit is perfect.
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The patient's ocular muscles
Attach to the implant,
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Enabling his artificial eye
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To move in unison
With his real eye.
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Narrator: so much for feeding
Fido scraps from the table.
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Today's pet food
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Is the stuff of sophisticated
Nutritional science.
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It's about protein,
Carbohydrates,
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Vitamins, minerals --
A well-balanced diet.
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00:11:02,103 --> 00:11:06,034
Want to bet some dogs and cats
Eat healthier than their owners?
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The formulas
For dog and cat food differ
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Because dogs and cats
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00:11:14,896 --> 00:11:17,413
Have different
Nutritional requirements.
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Cats, for instance,
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Need more fat and protein
In their diet than dogs do.
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But the basic ingredients
That factories grind up
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To make dog and cat food
Are similar.
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First, corn kernels.
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Then cereals, such as barley...
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Wheat...
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And rice.
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Workers weigh the ingredients,
Grind them in a mill,
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Then combine everything
In a mixer
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Until they have an even
And well-blended powder.
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A machine called the extruder
Transforms that powder
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Into bite-sized pieces
Of pet food.
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00:12:05,862 --> 00:12:08,241
It steam-coats the mixture,
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Then forces it through dies
At high pressure.
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The dies shape it,
The way the tip of a pastry bag
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Shapes icing into swirls
Or roses.
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00:12:17,517 --> 00:12:20,827
Check out this dog-bone die.
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00:12:20,827 --> 00:12:24,896
As the continuous stream
Of shaped mixture exits the die,
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A spinning knife
Cuts it into pieces.
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00:12:33,413 --> 00:12:37,413
The company has different dies
To produce different shapes.
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This is a batch of round pieces.
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00:12:50,896 --> 00:12:55,137
Next stop, a hot-air dryer
For 25 minutes.
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00:12:55,137 --> 00:12:58,689
It heats the pieces
To 300 degrees fahrenheit
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00:12:58,689 --> 00:13:00,137
To draw out the moisture,
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00:13:00,137 --> 00:13:02,965
Then cools them
At room temperature.
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00:13:08,793 --> 00:13:13,620
Once the pieces exit the dryer,
They enter a revolving drum,
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Where they're sprayed with fat
And flavoring.
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The fat is designed
To add food energy
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While the flavoring
Gives the bland pieces
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An appetizing odor and taste --
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Appetizing for pets, that is.
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00:13:30,137 --> 00:13:34,758
The rotation ensures the pieces
Get coated evenly.
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00:13:41,758 --> 00:13:45,965
From here, the pieces go
Into storage silos.
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00:13:45,965 --> 00:13:48,551
When they leave the silos
For bagging,
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00:13:48,551 --> 00:13:51,517
The machinery screens out
Any crumbs.
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00:13:54,896 --> 00:13:58,586
The pet-food industry has made
Some interesting observations
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About the likes and dislikes
Of its four-legged clientele.
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00:14:02,206 --> 00:14:06,000
Apparently, cats and dogs
Aren't crazy about food
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00:14:06,000 --> 00:14:09,862
That's too dry,
Too hard to chew, or too mushy.
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00:14:09,862 --> 00:14:13,034
If the pieces are too small,
They'll swallow them whole
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00:14:13,034 --> 00:14:15,689
Without chewing
And not digest them properly.
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00:14:15,689 --> 00:14:18,310
But if the pieces are too big,
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00:14:18,310 --> 00:14:22,206
They'll gag and get turned off
To the food altogether.
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00:14:24,344 --> 00:14:26,310
In the packaging department,
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00:14:26,310 --> 00:14:30,344
Automated scales weigh
The exact quantity per package.
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00:14:30,344 --> 00:14:34,517
This batch is destined for bags
Weighing about 6 1/2 pounds.
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00:14:43,241 --> 00:14:47,620
The package sizes range
From just under one pound
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00:14:47,620 --> 00:14:50,793
All the way up to 44 pounds.
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00:14:52,034 --> 00:14:55,000
Shelf life is from 12
To 16 months,
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00:14:55,000 --> 00:14:57,000
Depending on the formula.
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00:15:08,413 --> 00:15:10,310
Pet-food experts say
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00:15:10,310 --> 00:15:13,689
Dogs and cats prefer food
With a fattier content
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00:15:13,689 --> 00:15:16,241
And a combined
Meat-and-cereal formula
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00:15:16,241 --> 00:15:19,344
Over just cereal alone,
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00:15:19,344 --> 00:15:23,068
But too much meat flavoring
Can turn them off.
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00:15:23,068 --> 00:15:26,137
Cats, as a rule,
Are more particular.
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00:15:26,137 --> 00:15:28,000
They favor more acidic food,
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00:15:28,000 --> 00:15:30,586
While dogs tend to have
A sweeter tooth.
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00:15:30,586 --> 00:15:34,379
And you thought kids
Were fussy eaters.
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00:15:44,517 --> 00:15:47,655
Narrator: no bathroom
Is complete without one.
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00:15:47,655 --> 00:15:49,517
And any parent will tell you
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00:15:49,517 --> 00:15:52,379
That no teenager
Can survive without one.
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00:15:52,379 --> 00:15:57,103
Mirror, mirror on the wall,
How do they make you, after all?
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00:15:57,103 --> 00:16:00,068
Well, "How it's made"
Is about to show you.
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00:16:00,068 --> 00:16:04,206
But first, let's reflect
On the history of mirrors.
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00:16:09,241 --> 00:16:14,517
The earliest mirrors were curved
Pieces of highly polished metal,
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00:16:14,517 --> 00:16:16,413
Such as brass or bronze.
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00:16:16,413 --> 00:16:19,586
They're even mentioned
In the bible.
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00:16:19,586 --> 00:16:21,793
Then, in the 14th century,
251
00:16:21,793 --> 00:16:25,103
The venetians invented
Very crude glass mirrors
252
00:16:25,103 --> 00:16:27,655
That reflected off
A metallic backing.
253
00:16:27,655 --> 00:16:30,068
They later perfected
This technique
254
00:16:30,068 --> 00:16:32,551
Using an amalgam
Of tin and mercury.
255
00:16:32,551 --> 00:16:35,689
Eventually, the secret
Of mirror-making spread
256
00:16:35,689 --> 00:16:37,275
To other cities.
257
00:16:37,275 --> 00:16:40,275
By 1835,
A german chemist developed
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00:16:40,275 --> 00:16:44,206
The silver-backed mirror
That we know today.
259
00:16:52,379 --> 00:16:55,413
A mirror starts out
As clear glass.
260
00:16:55,413 --> 00:16:59,448
A robot lays each panel
Horizontally on a conveyor belt,
261
00:16:59,448 --> 00:17:03,689
Which transports it
To the washing station.
262
00:17:03,689 --> 00:17:07,758
There, sprayers blast the glass
With water and cerium oxide,
263
00:17:07,758 --> 00:17:10,793
A powder derived
From a type of soil.
264
00:17:10,793 --> 00:17:13,931
Rotating brushes scrub
And polish
265
00:17:13,931 --> 00:17:17,206
Both the top
And bottom surfaces,
266
00:17:17,206 --> 00:17:19,586
Removing oils
And other contaminants.
267
00:17:19,586 --> 00:17:23,965
This washing process takes
About a minute per panel.
268
00:17:23,965 --> 00:17:26,620
Next, sprayers rinse the glass
269
00:17:26,620 --> 00:17:29,413
With piping-hot
Demineralized water,
270
00:17:29,413 --> 00:17:32,793
Demineralized because
The minerals in plain tap water
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00:17:32,793 --> 00:17:35,931
Would damage the metals
They apply next.
272
00:17:35,931 --> 00:17:39,275
The first metal
Is liquefied tin,
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00:17:39,275 --> 00:17:43,137
Which goes on what will be
The back of the mirror.
274
00:17:43,137 --> 00:17:46,896
It allows the second metal,
Silver, to adhere
275
00:17:46,896 --> 00:17:49,931
Because silver won't stick
Directly to glass.
276
00:17:49,931 --> 00:17:52,551
The silver
Is also in liquid form
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00:17:52,551 --> 00:17:55,275
Mixed with a chemical activator.
278
00:17:55,275 --> 00:17:58,827
Within seconds of interacting
With the tin, it hardens.
279
00:17:58,827 --> 00:18:02,275
And as it does,
You begin to see a reflection.
280
00:18:02,275 --> 00:18:04,241
It's this silver backing
281
00:18:04,241 --> 00:18:07,689
That transforms clear glass
Into a mirror.
282
00:18:07,689 --> 00:18:10,310
Sprayers rinse off
The excess silver,
283
00:18:10,310 --> 00:18:13,586
Which gets recycled
Back into the system.
284
00:18:16,482 --> 00:18:20,517
The factory will seal the silver
Backing with two coats of paint.
285
00:18:20,517 --> 00:18:22,103
Paint by itself, however,
286
00:18:22,103 --> 00:18:25,310
Isn't enough to protect
The silver in the long term.
287
00:18:25,310 --> 00:18:29,068
So they first spray on
A layer of copper.
288
00:18:37,344 --> 00:18:39,965
Sprayers rinse off
The excess copper.
289
00:18:39,965 --> 00:18:42,551
Then the panel passes through
A dryer
290
00:18:42,551 --> 00:18:45,896
At almost 160 degrees
Fahrenheit.
291
00:18:45,896 --> 00:18:48,551
This evaporates the moisture
On the surface
292
00:18:48,551 --> 00:18:51,000
In just 75 seconds.
293
00:18:52,689 --> 00:18:54,827
Now the panel passes,
Copper side up,
294
00:18:54,827 --> 00:18:57,551
Through what is called
The curtain coater,
295
00:18:57,551 --> 00:19:01,103
A machine that runs
A continuous curtain of paint
296
00:19:01,103 --> 00:19:03,137
Across the conveyor belt.
297
00:19:03,137 --> 00:19:06,344
With its fresh coat of paint,
298
00:19:06,344 --> 00:19:08,413
The mirror then passes through
An oven
299
00:19:08,413 --> 00:19:10,275
Heated to 210 degrees
Fahrenheit.
300
00:19:10,275 --> 00:19:15,206
After a minute and 45 seconds,
The paint is cured.
301
00:19:15,206 --> 00:19:17,620
Now the second coat of paint.
302
00:19:17,620 --> 00:19:19,931
There's no reason
For the different color
303
00:19:19,931 --> 00:19:22,551
Other than to differentiate
The coats.
304
00:19:22,551 --> 00:19:25,793
This time, the curing period
Is twice as long
305
00:19:25,793 --> 00:19:31,310
And at a higher temperature,
Close to 245 degrees fahrenheit.
306
00:19:31,310 --> 00:19:34,862
After an acid wash to remove
Any metal residues,
307
00:19:34,862 --> 00:19:39,551
They stand the panel upright
To inspect it.
308
00:19:39,551 --> 00:19:43,034
If they find a fault,
Such as a bubble in the glass,
309
00:19:43,034 --> 00:19:45,586
They cut that portion out.
310
00:19:48,827 --> 00:19:52,068
The factory now cuts
These large panels
311
00:19:52,068 --> 00:19:54,896
Into whatever size and shape
The customer has ordered
312
00:19:54,896 --> 00:19:58,137
Using a special
Mirror-cutting machine
313
00:19:58,137 --> 00:20:01,896
That's precision-guided
By computer software.
314
00:20:05,310 --> 00:20:08,793
It scores the mirror
Using a carbide wheel.
315
00:20:08,793 --> 00:20:11,379
Carbide is a strong metal.
316
00:20:13,448 --> 00:20:15,103
To make round mirrors,
317
00:20:15,103 --> 00:20:18,413
The machine first scores
The panel into squares.
318
00:20:18,413 --> 00:20:20,724
Then, in each square,
It scores a circle.
319
00:20:20,724 --> 00:20:23,103
Using special tools,
320
00:20:23,103 --> 00:20:26,517
Workers separate the squares,
Then the circles.
321
00:20:37,724 --> 00:20:39,862
To make beveled mirrors,
322
00:20:39,862 --> 00:20:42,655
They use what's called
The shape-bevel machine.
323
00:20:45,413 --> 00:20:48,379
First, it carves out the edge.
324
00:20:50,379 --> 00:20:54,965
Then polishes it to a shine
Using concentrated cerium oxide,
325
00:20:54,965 --> 00:20:57,586
A stronger version
Of what they used earlier
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00:20:57,586 --> 00:21:01,482
To clean the glass surface
Before plating it with metals.
327
00:21:04,724 --> 00:21:07,241
Mirror factories
Also ship whole panels
328
00:21:07,241 --> 00:21:10,034
To shops that do the cutting
Themselves,
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00:21:10,034 --> 00:21:14,655
A fragile feat that's certainly
Not for the superstitious.
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00:21:14,655 --> 00:21:17,655
--captions by vitac--
Www.Vitac.Com
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00:21:17,655 --> 00:21:20,655
Captions paid for by
Discovery communications, inc.
332
00:21:22,448 --> 00:21:24,586
If you have any comments
About the show
333
00:21:24,586 --> 00:21:27,310
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Topics for future shows,
334
00:21:27,310 --> 00:21:28,965
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