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Narrator: the ballpoint pen
Was designed as the answer
2
00:00:54,551 --> 00:00:56,896
To the fountain pen's
Many annoyances --
3
00:00:56,896 --> 00:01:00,137
The hassle of having to manually
Refill the barrel with ink
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00:01:00,137 --> 00:01:02,344
That dried slowly
And often smudged.
5
00:01:02,344 --> 00:01:05,413
The ballpoint has a tiny
Steel ball in its tip
6
00:01:05,413 --> 00:01:09,034
That applies quick-drying ink
From a ready-made cartridge.
7
00:01:13,413 --> 00:01:17,344
When the ink cartridge inside
These retractable pens runs out,
8
00:01:17,344 --> 00:01:20,344
You simply replace it
With a new one.
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00:01:20,344 --> 00:01:22,448
Working from the initial design,
10
00:01:22,448 --> 00:01:24,275
The pen factory makes molds
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00:01:24,275 --> 00:01:26,896
For all the pens'
Plastic components.
12
00:01:28,620 --> 00:01:32,275
The injection molder first
Shoots hot liquid plastic
13
00:01:32,275 --> 00:01:34,724
Into molds for the barrel's
Rigid core,
14
00:01:34,724 --> 00:01:37,551
Then into other molds
For its soft rubber grip.
15
00:01:38,931 --> 00:01:43,482
The tubes for the ink cartridges
Are also made of plastic.
16
00:01:43,482 --> 00:01:47,103
Machinery aligns them
In the same direction,
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00:01:47,103 --> 00:01:50,793
Then prints on the company name,
Model number, and tip size.
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00:01:54,103 --> 00:01:57,689
Here, a filling machine
Injects 0.8 grams of ink
19
00:01:57,689 --> 00:01:59,034
Through the tip.
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00:01:59,034 --> 00:02:01,931
To prevent the ink
From evaporating,
21
00:02:01,931 --> 00:02:06,000
It plugs the other end with
0.1 grams of silicone paste.
22
00:02:07,172 --> 00:02:09,689
Meanwhile,
High-precision machines
23
00:02:09,689 --> 00:02:12,103
Progressively shape
The pen's tip
24
00:02:12,103 --> 00:02:14,137
Out of stainless-steel blanks.
25
00:02:16,931 --> 00:02:19,586
The equipment drills
A 1-millimeter channel
26
00:02:19,586 --> 00:02:21,034
Through the blank,
27
00:02:21,034 --> 00:02:24,241
Then, in quick succession,
Fashions the tip into a cone,
28
00:02:24,241 --> 00:02:27,379
Cuts five tiny ink-flow channels
In the ball socket,
29
00:02:27,379 --> 00:02:29,586
And seats
A 1-millimeter-diameter
30
00:02:29,586 --> 00:02:31,896
Stainless-steel ball
In the center.
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00:02:35,034 --> 00:02:37,931
Another machine
Then inserts a finished tip
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00:02:37,931 --> 00:02:39,586
In each ink-filled tube.
33
00:02:44,482 --> 00:02:49,655
A scanner then checks the length
And the ball of each cartridge.
34
00:02:49,655 --> 00:02:52,103
This magnification
Shows the width
35
00:02:52,103 --> 00:02:55,482
Of the five ink-flow channels
Next to a human hair.
36
00:02:55,482 --> 00:02:58,413
Random samples undergo
An air-pressure test
37
00:02:58,413 --> 00:03:01,379
To check the ball's position
And movement.
38
00:03:01,379 --> 00:03:05,793
Anything less than perfect
Will clog the pen.
39
00:03:05,793 --> 00:03:09,724
They close off the end of the
Cartridge with a plastic cap.
40
00:03:12,689 --> 00:03:15,586
The cartridge is now
Going to a centrifuge,
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00:03:15,586 --> 00:03:17,655
Which forces the ink to the tip,
42
00:03:17,655 --> 00:03:21,310
Eliminating any air bubbles
That would obstruct ink flow.
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00:03:26,620 --> 00:03:30,379
Every cartridge passes through
This writing-test machine.
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00:03:30,379 --> 00:03:32,241
That blue light is a sensor
45
00:03:32,241 --> 00:03:36,137
That triggers the machine to
Reject any defective cartridge.
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00:03:39,068 --> 00:03:42,965
The components now come together
In the assembly department.
47
00:03:42,965 --> 00:03:46,448
The machine assembles the clip,
Sleeve, and barrel.
48
00:03:46,448 --> 00:03:49,724
The clip is made of
Chrome-plated spring steel,
49
00:03:49,724 --> 00:03:53,172
A strong metal that regains
Its shape when flexed.
50
00:03:53,172 --> 00:03:56,034
The machine then flips
The assembly over
51
00:03:56,034 --> 00:03:58,620
To receive
The internal components.
52
00:03:58,620 --> 00:04:02,413
First, the pen's two-part
Push-button mechanism.
53
00:04:02,413 --> 00:04:05,724
Part one --
The plastic push button.
54
00:04:05,724 --> 00:04:08,793
Part two --
A device called a rotor.
55
00:04:08,793 --> 00:04:12,793
Which each click, it rotates
The refill 45 degrees
56
00:04:12,793 --> 00:04:14,827
So the tip wears evenly.
57
00:04:16,931 --> 00:04:20,103
The ink cartridge
Goes in tip-side up,
58
00:04:20,103 --> 00:04:24,344
The plug on the back
Fitting into the rotor.
59
00:04:24,344 --> 00:04:28,517
This device forces spring-steel
Wire through a coiling block.
60
00:04:28,517 --> 00:04:30,448
This produces a tiny spring
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00:04:30,448 --> 00:04:34,241
That provides resistance
To the push-button mechanism.
62
00:04:36,172 --> 00:04:40,931
A grabber places the spring
Over the cartridge tip.
63
00:04:47,068 --> 00:04:48,862
Now they close up the pen
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00:04:48,862 --> 00:04:51,620
By adjoining the barrel's
Bottom part.
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00:04:53,103 --> 00:04:56,241
The machine screws
The two parts together
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00:04:56,241 --> 00:04:58,103
To a specific tightness.
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00:04:58,103 --> 00:05:01,620
The final assembly machine tests
The push-button mechanism
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00:05:01,620 --> 00:05:04,103
To ensure it retracts
The tip properly.
69
00:05:04,103 --> 00:05:07,068
This also prepares the pens
For packaging,
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00:05:07,068 --> 00:05:10,275
As they go into the boxes
With tips retracted.
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00:05:15,517 --> 00:05:20,068
The factory subjects random
Samples to endurance testing.
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00:05:20,068 --> 00:05:23,862
This device clicks
The push button 100,000 times.
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00:05:23,862 --> 00:05:27,827
Only then does a printer
Put the logo on the barrel.
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00:05:30,172 --> 00:05:34,103
This company's engineering of
Its ink-flow channels and tip
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00:05:34,103 --> 00:05:37,758
Delivers on average 2.5 miles
Of writing per cartridge.
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00:05:46,068 --> 00:05:48,586
Narrator:
Salt comes from three sources --
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00:05:48,586 --> 00:05:51,551
Salt mines, land
That at one time was seabed,
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00:05:51,551 --> 00:05:54,034
And from oceans
And saltwater lakes.
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00:05:54,034 --> 00:05:57,068
Factories extract salt
From water by evaporation,
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00:05:57,068 --> 00:05:59,034
Either mechanically or naturally
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00:05:59,034 --> 00:06:01,344
By letting the sun
Work its magic
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00:06:01,344 --> 00:06:03,793
And produce what's called
Solar salt.
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00:06:08,793 --> 00:06:11,137
This large hunk of salt crystals
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00:06:11,137 --> 00:06:13,931
Comes from great salt lake
In utah.
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00:06:15,241 --> 00:06:16,724
At full water level,
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00:06:16,724 --> 00:06:20,034
The lake is seven times saltier
Than the ocean.
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00:06:25,344 --> 00:06:29,482
Harvesters scoop up salt from
Shallow crystallization ponds
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00:06:29,482 --> 00:06:31,241
And load it into trucks.
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00:06:34,379 --> 00:06:38,034
It's the end result of
A two-year evaporation cycle,
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00:06:38,034 --> 00:06:40,827
Which has seen the lake water,
Called brine,
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00:06:40,827 --> 00:06:44,689
Slowly give off its moisture in
A series of concentrating ponds.
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00:06:44,689 --> 00:06:48,344
What remains is a bed of salt
Crystals about 12 inches deep.
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00:06:58,482 --> 00:07:03,482
The truck dumps its cargo onto
The factory's conveyor system.
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00:07:03,482 --> 00:07:06,206
First stop is a rinsing station
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00:07:06,206 --> 00:07:10,275
To remove contaminants
Such as algae and dust.
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00:07:10,275 --> 00:07:12,586
Using freshwater
Would dissolve the salt,
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00:07:12,586 --> 00:07:17,000
So they flush the crystals
With lake brine.
98
00:07:17,000 --> 00:07:20,827
Next, hot-air dryers remove
The moisture and salt dust
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00:07:20,827 --> 00:07:23,172
Within about 3.5 minutes.
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00:07:27,758 --> 00:07:29,965
The salt crystals then roll
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00:07:29,965 --> 00:07:32,068
Across a series
Of sorting screens
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00:07:32,068 --> 00:07:34,310
With progressively
Smaller openings.
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00:07:35,586 --> 00:07:38,862
This classifies the salt
Crystals into three grades --
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00:07:38,862 --> 00:07:41,551
Coarse, medium, and fine.
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00:07:46,068 --> 00:07:48,965
Each grade goes
Onto a separate conveyor
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00:07:48,965 --> 00:07:52,241
That transports it
To a designated storage bin.
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00:07:55,137 --> 00:07:57,655
The factory uses
Medium-grade salt
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00:07:57,655 --> 00:08:00,896
To make pellets
For water-softening equipment.
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00:08:00,896 --> 00:08:04,551
This press compresses the
Crystals into pellet shapes
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00:08:04,551 --> 00:08:06,034
Along with certain additives
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00:08:06,034 --> 00:08:09,103
To help the water-softening
Equipment perform better.
112
00:08:10,620 --> 00:08:14,068
Some municipal water supplies
Have a high mineral content.
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00:08:14,068 --> 00:08:16,896
This hard water makes soap
Difficult to lather
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00:08:16,896 --> 00:08:20,586
And leaves stains on sinks,
Bathtubs, and toilets.
115
00:08:21,965 --> 00:08:24,103
Salt triggers
A chemical reaction
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00:08:24,103 --> 00:08:26,413
That dissolves
The problem minerals.
117
00:08:32,206 --> 00:08:35,413
The factory packages
Water-softening solar salt
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In bags, as well.
119
00:08:38,379 --> 00:08:41,827
It also produces a variety
Of other solar-salt products
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00:08:41,827 --> 00:08:43,586
Such as swimming-pool salt,
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00:08:43,586 --> 00:08:46,241
Road salt for melting ice
In the winter,
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00:08:46,241 --> 00:08:48,137
And, of course, culinary salt.
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00:08:51,206 --> 00:08:54,413
The factory's automated
Packaging equipment
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00:08:54,413 --> 00:08:57,034
Fills both paper
And plastic bags.
125
00:09:02,517 --> 00:09:06,275
This company also sells solar
Salt to several industries
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00:09:06,275 --> 00:09:09,965
For use as an ingredient
In products such as detergent.
127
00:09:11,241 --> 00:09:14,275
There's also
The agricultural market.
128
00:09:14,275 --> 00:09:19,000
Farmers buy blocks of solar salt
Plain or enriched with minerals
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00:09:19,000 --> 00:09:21,413
As a nutrient for their cattle.
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00:09:21,413 --> 00:09:24,689
The factory produces different
Salt and mineral formulations,
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00:09:24,689 --> 00:09:27,551
Each dyed a different color
For easy identification.
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00:09:39,344 --> 00:09:41,482
To produce salt for cattle,
133
00:09:41,482 --> 00:09:46,448
The machinery drops 50 pounds at
A time into a block-shaped mold.
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00:09:46,448 --> 00:09:49,551
A press applies 750 tons
Of pressure,
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00:09:49,551 --> 00:09:52,000
Binding the crystals
Into a block.
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00:09:54,068 --> 00:09:57,551
The farmer simply sets out
Blocks among the cattle,
137
00:09:57,551 --> 00:10:00,551
And the animals lick away
To get their dose of sodium.
138
00:10:15,275 --> 00:10:18,310
A label identifies the type
Of salt block.
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00:10:18,310 --> 00:10:20,620
This one contains iodine
140
00:10:20,620 --> 00:10:24,827
To prevent a thyroid disorder
Called goiter,
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00:10:24,827 --> 00:10:27,275
A tasty and therapeutic
Bovine snack
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00:10:27,275 --> 00:10:31,034
Courtesy of a saltwater lake
And sunshine.
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00:10:41,827 --> 00:10:44,310
Narrator:
The tuba is the largest
Instrument in the brass family
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00:10:44,310 --> 00:10:46,448
And the one
With the lowest pitch.
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00:10:46,448 --> 00:10:49,620
Famous orchestral composers
From stravinsky to gershwin
146
00:10:49,620 --> 00:10:52,034
Have included significant parts
For tuba
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00:10:52,034 --> 00:10:54,655
In some of
Their best-known works.
148
00:10:54,655 --> 00:10:58,620
Some composers have even written
Full concertos for tuba.
149
00:11:02,517 --> 00:11:04,275
Tubas are made of brass,
150
00:11:04,275 --> 00:11:06,862
Sometimes silver-
Or gold-plated.
151
00:11:06,862 --> 00:11:10,827
The instrument consists
Of valves and tubing,
152
00:11:10,827 --> 00:11:13,000
Ending in a flared bell.
153
00:11:13,000 --> 00:11:16,000
The bell flare
Begins as a brass disk
154
00:11:16,000 --> 00:11:19,206
22 inches in diameter.
155
00:11:19,206 --> 00:11:22,344
They use a range of tools
And various mandrels
156
00:11:22,344 --> 00:11:25,862
To work the brass into
A preliminary bell-flare shape.
157
00:11:28,517 --> 00:11:32,586
They use sandpaper to remove
Any marks left by the tools,
158
00:11:32,586 --> 00:11:34,724
Then cut a hole in the center.
159
00:11:41,275 --> 00:11:44,655
To make the conical tail
That leads to the bell flare,
160
00:11:44,655 --> 00:11:47,241
They bend and hammer
A thin brass sheet
161
00:11:47,241 --> 00:11:49,068
Around a tail-shaped mandrel.
162
00:11:51,551 --> 00:11:55,482
To join the seam, they cut
Notches along one edge,
163
00:11:55,482 --> 00:11:58,551
Then hammer them
Over the other edge.
164
00:12:02,137 --> 00:12:05,137
The artisan then melts
Filler metal over the seam
165
00:12:05,137 --> 00:12:07,413
With a high-temperature
Gas torch,
166
00:12:07,413 --> 00:12:10,827
A process known as braising.
167
00:12:12,931 --> 00:12:16,655
Then they use a wooden mallet
To round out the shape.
168
00:12:16,655 --> 00:12:20,655
They use a pressure roller
To flatten out the mallet dents
169
00:12:20,655 --> 00:12:22,827
And further refine the surface.
170
00:12:22,827 --> 00:12:25,827
After notching the wider end
Of the tail,
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00:12:25,827 --> 00:12:28,448
They assemble it
To the bell flare.
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00:12:29,793 --> 00:12:31,034
They dab on flux,
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00:12:31,034 --> 00:12:34,206
A chemical that prepares
The surface for braising,
174
00:12:34,206 --> 00:12:36,034
Then tack the parts together.
175
00:12:42,344 --> 00:12:46,724
They hammer down the notches
And braise the seam all around.
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00:12:46,724 --> 00:12:49,517
This assembly,
Now called the bell,
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00:12:49,517 --> 00:12:51,310
Goes back on the lathe.
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00:12:51,310 --> 00:12:52,931
Using a belt sander,
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00:12:52,931 --> 00:12:56,344
They flatten all the seams
Flush with the surface.
180
00:12:57,862 --> 00:13:01,413
On another mandrel, with
Lubricant assisting the process,
181
00:13:01,413 --> 00:13:03,310
They finalize the bell's shape.
182
00:13:06,931 --> 00:13:10,379
Now they trim the edge
To the correct diameter...
183
00:13:12,310 --> 00:13:14,275
...Bend it back a bit...
184
00:13:16,758 --> 00:13:20,172
...Polish the perimeter
With the sanding head,
185
00:13:20,172 --> 00:13:24,000
Then use a special tool
To roll the edge over itself.
186
00:13:24,000 --> 00:13:26,827
This forms what's called
The bell bead,
187
00:13:26,827 --> 00:13:28,931
A lip that reinforces the bell
188
00:13:28,931 --> 00:13:32,586
And gives this end of the
Instrument a finished look.
189
00:13:32,586 --> 00:13:34,896
A computer-guided
Engraving machine
190
00:13:34,896 --> 00:13:38,000
Puts the company logo
And model number on the bell.
191
00:13:41,068 --> 00:13:44,413
Each of the tuba's
100 or so tubes
192
00:13:44,413 --> 00:13:47,862
Must be bent
Into a specific shape.
193
00:13:47,862 --> 00:13:51,965
The first step is to fill them
With hot liquid pitch,
194
00:13:51,965 --> 00:13:54,103
Which hardens as it cools.
195
00:13:54,103 --> 00:13:58,241
This keeps the tubes
From collapsing as they're bent.
196
00:13:59,275 --> 00:14:04,137
After bending, the tubes go into
An oven to melt out the pitch.
197
00:14:06,344 --> 00:14:08,517
Certain bent tubes are enlarged
198
00:14:08,517 --> 00:14:11,827
In a machine called
A hydraulic blowout press.
199
00:14:11,827 --> 00:14:14,655
It pumps oil into it
At high pressure.
200
00:14:14,655 --> 00:14:18,034
This blows the tube walls
Outward against the dye,
201
00:14:18,034 --> 00:14:20,586
Forcing it to assume
The new shape.
202
00:14:32,344 --> 00:14:37,344
Certain bent tubes are conical,
Others, cylindrical.
203
00:14:37,344 --> 00:14:39,551
The cylindrical ones go through
204
00:14:39,551 --> 00:14:42,275
What's called
A ball-out operation.
205
00:14:42,275 --> 00:14:46,517
This machine forces steel balls
Of the proper diameter
206
00:14:46,517 --> 00:14:48,034
Through the tube.
207
00:14:48,034 --> 00:14:50,689
This enlarges any spots
That are too narrow.
208
00:15:00,620 --> 00:15:02,689
Before bending, certain tubes
209
00:15:02,689 --> 00:15:06,103
Have to go through a drawing
Machine for resizing.
210
00:15:07,448 --> 00:15:09,344
With lubricant easing the way,
211
00:15:09,344 --> 00:15:12,137
It draws the tube
Between an inner mandrel
212
00:15:12,137 --> 00:15:13,620
And an outer washer.
213
00:15:13,620 --> 00:15:16,724
This forms the tube
To the correct diameters
214
00:15:16,724 --> 00:15:18,172
And wall thickness,
215
00:15:18,172 --> 00:15:21,068
While also stretching it
Lengthwise.
216
00:15:22,689 --> 00:15:24,172
Coming up next,
217
00:15:24,172 --> 00:15:27,517
We'll see where this tube fits
In the finished instrument.
218
00:15:39,655 --> 00:15:43,068
Narrator: tubas come
In different versions.
219
00:15:43,068 --> 00:15:47,000
A b-flat tuba, for example,
Is nearly 18 feet long,
220
00:15:47,000 --> 00:15:50,310
Whereas an f tuba
Is about 11.5 feet long.
221
00:15:50,310 --> 00:15:53,862
Tubas have anywhere
From three to six valves.
222
00:15:53,862 --> 00:15:56,206
Pressing different
Valve combinations
223
00:15:56,206 --> 00:15:57,758
Produces different notes.
224
00:16:02,379 --> 00:16:04,517
To build the valve section,
225
00:16:04,517 --> 00:16:08,827
They insert parts called
Knuckles into the valve cases.
226
00:16:12,896 --> 00:16:16,655
Spacers hold the valve cases
The proper distance apart,
227
00:16:16,655 --> 00:16:19,827
While this alignment plate
Positions the cases
228
00:16:19,827 --> 00:16:21,862
In the correct configuration.
229
00:16:25,206 --> 00:16:29,206
Next, they insert connectors
To later link the valve section
230
00:16:29,206 --> 00:16:31,241
To the rest of the instrument.
231
00:16:31,241 --> 00:16:33,758
After braising
The parts together,
232
00:16:33,758 --> 00:16:37,827
They run a cutter through the
Valve cases to hollow them out.
233
00:16:39,275 --> 00:16:42,793
Here, you can see what
The case interiors look like
234
00:16:42,793 --> 00:16:44,827
Before cutting and after.
235
00:16:44,827 --> 00:16:48,551
Now they begin soldering
On the valve section's tubing,
236
00:16:48,551 --> 00:16:51,206
Working from
The valve cases outward.
237
00:16:58,000 --> 00:17:02,275
The tuba's frame section is made
Up of several u-shaped parts.
238
00:17:02,275 --> 00:17:05,448
Workers assemble them
With connecting rings.
239
00:17:11,448 --> 00:17:15,931
They insert a support brace
Inside this frame piece...
240
00:17:20,068 --> 00:17:21,620
...Then position tabs
241
00:17:21,620 --> 00:17:25,068
Onto which they'll later mount
The valve section.
242
00:17:25,068 --> 00:17:29,034
They clamp the tabs in place,
Then solder them on.
243
00:17:40,275 --> 00:17:44,724
Then they attach
The bell section to the frame.
244
00:17:44,724 --> 00:17:48,448
Before adding the valve section,
They give a preliminary buffing
245
00:17:48,448 --> 00:17:50,620
To what they've assembled
So far.
246
00:18:04,965 --> 00:18:07,482
They brush some
Liquid polishing compound
247
00:18:07,482 --> 00:18:10,758
Into the places that they
Couldn't access with the wheel
248
00:18:10,758 --> 00:18:13,000
And buff those areas with a rag.
249
00:18:23,206 --> 00:18:25,448
Then a final overall buffing
250
00:18:25,448 --> 00:18:28,724
Until the brass reflects
Like a mirror.
251
00:18:37,344 --> 00:18:41,241
Meanwhile, the valve-section
Assembly continues.
252
00:18:41,241 --> 00:18:45,344
First, they close off the bottom
Of each valve case
253
00:18:45,344 --> 00:18:47,172
With a screw-on cap...
254
00:18:49,310 --> 00:18:51,172
...Then drop in a spring
255
00:18:51,172 --> 00:18:54,448
To provide resistance
For the valve piston.
256
00:18:55,551 --> 00:18:57,517
Then the piston.
257
00:19:01,586 --> 00:19:07,551
A felt to cushion it, a top cap,
Another cushioning felt,
258
00:19:07,551 --> 00:19:10,172
And, finally, the finger button.
259
00:19:13,379 --> 00:19:16,827
A little oil ensures all
The buttons move smoothly.
260
00:19:16,827 --> 00:19:19,379
The felts inside
Prevent the pistons
261
00:19:19,379 --> 00:19:23,000
From making a clanging sound
As they move up and down.
262
00:19:26,793 --> 00:19:29,172
Now for the tuba's
Tuning slides.
263
00:19:29,172 --> 00:19:32,172
A coat of grease
Helps them move in and out
264
00:19:32,172 --> 00:19:36,896
To increase or decrease the
Overall length of the tubing.
265
00:19:36,896 --> 00:19:40,068
Shortening tunes
The instrument higher.
266
00:19:40,068 --> 00:19:42,206
Lengthening tunes it lower.
267
00:19:42,206 --> 00:19:45,241
Now they screw
The finished valve section
268
00:19:45,241 --> 00:19:48,206
To the assembled frame
And bell sections
269
00:19:48,206 --> 00:19:50,793
And insert
The main tuning slide.
270
00:19:54,413 --> 00:19:59,862
Finally, the tuba's mouthpipe,
Made not of brass like the rest,
271
00:19:59,862 --> 00:20:01,448
But of nickel silver.
272
00:20:04,448 --> 00:20:07,862
They spray the entire instrument
With cleaning solution
273
00:20:07,862 --> 00:20:10,793
To remove any grease residue
And fingerprints.
274
00:20:13,896 --> 00:20:15,344
Prior to assembly,
275
00:20:15,344 --> 00:20:19,448
Each section was cleaned
And coated with a clear lacquer
276
00:20:19,448 --> 00:20:22,793
To ensure the tuba will always
Look as good as it sounds.
277
00:20:24,517 --> 00:20:28,379
[ "Ride of the valkyries"
Plays ]
278
00:20:28,379 --> 00:20:31,344
--captions by vitac--
Www.Vitac.Com
279
00:20:31,344 --> 00:20:34,344
Captions paid for by
Discovery communications
280
00:20:41,172 --> 00:20:43,517
If you have any comments
About the show,
281
00:20:43,517 --> 00:20:46,413
Or if you'd like to suggest
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282
00:20:46,413 --> 00:20:48,275
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