Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated:
1
00:00:51,862 --> 00:00:53,586
Narrator:
"Millefiori" is italian
2
00:00:53,586 --> 00:00:55,137
For "A thousand flowers."
3
00:00:55,137 --> 00:00:57,827
It's also an elaborate
Glass-making technique
4
00:00:57,827 --> 00:00:59,758
Developed in 15th-century italy
5
00:00:59,758 --> 00:01:02,586
In which pattern-colored
Glass rods are cut,
6
00:01:02,586 --> 00:01:04,551
Grouped to form floral shapes,
7
00:01:04,551 --> 00:01:06,931
Arranged
Into intricate patterns,
8
00:01:06,931 --> 00:01:08,931
Then encased in clear crystal.
9
00:01:11,896 --> 00:01:14,551
If a picture's worth
A thousand words,
10
00:01:14,551 --> 00:01:16,862
These thousand-flower
Paperweights
11
00:01:16,862 --> 00:01:18,310
Speak for themselves.
12
00:01:18,310 --> 00:01:21,827
Two canadian artists craft
These millefiori masterpieces
13
00:01:21,827 --> 00:01:24,896
Just as the renowned glass
Makers of murano, italy, did
14
00:01:24,896 --> 00:01:26,275
Centuries ago.
15
00:01:26,275 --> 00:01:29,758
A mix containing silica sand,
Soda ash, and lime
16
00:01:29,758 --> 00:01:32,620
Is heated
To 2,400 degrees fahrenheit,
17
00:01:32,620 --> 00:01:35,655
Melting it
Into lead-free liquid crystal.
18
00:01:35,655 --> 00:01:37,413
With a molten-crystal post,
19
00:01:37,413 --> 00:01:41,758
They pick up
A densely colored bar of glass.
20
00:01:41,758 --> 00:01:44,655
They roll and shape
The white color bar
21
00:01:44,655 --> 00:01:47,827
While stabilizing the post
With cold water.
22
00:01:50,206 --> 00:01:51,931
Then with a torch,
23
00:01:51,931 --> 00:01:55,551
They preheat an aluminum mold
Of a flower or other motif.
24
00:01:55,551 --> 00:01:59,310
Preheating the mold helps the
Glass flow into it more easily
25
00:01:59,310 --> 00:02:02,758
And assume the shape
In greater detail.
26
00:02:04,448 --> 00:02:06,724
Once they've molded
The colored glass,
27
00:02:06,724 --> 00:02:10,482
They return to the furnace
To encase it in molten crystal.
28
00:02:10,482 --> 00:02:13,000
Then they repeatedly heat
And shape the crystal
29
00:02:13,000 --> 00:02:16,344
With tools and with steam
On a wad of wet newspaper
30
00:02:16,344 --> 00:02:19,862
Until the crystal encases
The flower-shaped color evenly.
31
00:02:19,862 --> 00:02:21,206
After reheating,
32
00:02:21,206 --> 00:02:24,413
They put some molten crystal
On the end of another rod
33
00:02:24,413 --> 00:02:27,448
And grab the free end
Of the crystal-encased color.
34
00:02:27,448 --> 00:02:30,551
They wait until the glass cools
To a specific consistency.
35
00:02:30,551 --> 00:02:32,793
Then they begin to pull.
36
00:02:32,793 --> 00:02:36,172
They slowly stretch the glass
Into a thin and even rod,
37
00:02:36,172 --> 00:02:37,724
Careful not to twist it,
38
00:02:37,724 --> 00:02:40,206
As that would distort
The flower shape
39
00:02:40,206 --> 00:02:41,896
Of the colored glass inside.
40
00:02:41,896 --> 00:02:45,275
This produces what's called
A murrini cane --
41
00:02:45,275 --> 00:02:49,931
A clear crystal rod with
A colored, flower-shaped center.
42
00:02:49,931 --> 00:02:51,689
Once the murrini solidifies,
43
00:02:51,689 --> 00:02:54,034
They nip it
Into manageable lengths.
44
00:02:54,034 --> 00:02:57,344
Then they take murrini
Of different colors and designs,
45
00:02:57,344 --> 00:02:58,931
Cut them into short rods,
46
00:02:58,931 --> 00:03:02,551
And bundle them into a pattern
Called a complex murrini.
47
00:03:02,551 --> 00:03:05,310
They preheat the complex murrini
In a kiln
48
00:03:05,310 --> 00:03:07,689
To prevent
Shock-induced cracking.
49
00:03:07,689 --> 00:03:10,275
They now pick it up
With a hot crystal post
50
00:03:10,275 --> 00:03:12,689
And, after removing
The bundling wires,
51
00:03:12,689 --> 00:03:16,827
Heat and work the group
Of glass rods into one.
52
00:03:16,827 --> 00:03:20,206
They now stretch
This complex murrini
53
00:03:20,206 --> 00:03:23,517
Into what's known
As complex murrini cane.
54
00:03:28,206 --> 00:03:30,241
Once the cane stabilizes,
55
00:03:30,241 --> 00:03:31,896
They cut it
Into yardlong lengths,
56
00:03:31,896 --> 00:03:34,655
Then cool them gradually
In a kiln
57
00:03:34,655 --> 00:03:37,034
To relieve any stresses
In the glass.
58
00:03:37,034 --> 00:03:40,275
Then they slice the lengths
Into pieces 2/10 of an inch --
59
00:03:40,275 --> 00:03:43,931
The size required
For the millefiori paperweights.
60
00:03:45,896 --> 00:03:48,827
Now, using complex
Murrini pieces
61
00:03:48,827 --> 00:03:51,068
Of different colors
And patterns,
62
00:03:51,068 --> 00:03:53,620
They assemble
The paperweight design,
63
00:03:53,620 --> 00:03:55,793
Placing a unique,
Hand-constructed murrini
64
00:03:55,793 --> 00:03:57,344
In the center.
65
00:03:57,344 --> 00:04:00,689
This one is a trillium.
66
00:04:00,689 --> 00:04:03,206
Next, they encircle the setup
67
00:04:03,206 --> 00:04:05,275
With a heat-resistant
Graphite ring.
68
00:04:05,275 --> 00:04:07,689
This holds the pieces
In position.
69
00:04:09,448 --> 00:04:11,758
After a final adjustment,
70
00:04:11,758 --> 00:04:14,551
The artists preheat a white,
Lace-patterned glass base
71
00:04:14,551 --> 00:04:16,034
They prepared earlier.
72
00:04:16,034 --> 00:04:18,448
This base will serve
As a blank canvas
73
00:04:18,448 --> 00:04:20,724
For the colorful
Paperweight pattern.
74
00:04:24,068 --> 00:04:27,068
They push the molten crystal
Onto the base.
75
00:04:27,068 --> 00:04:30,931
The ring contains it
To the base's diameter.
76
00:04:30,931 --> 00:04:33,206
Then they reheat the base,
77
00:04:33,206 --> 00:04:36,068
Making it smooth and free
Of air pockets,
78
00:04:36,068 --> 00:04:39,275
Preheat the complex
Murrini setup,
79
00:04:39,275 --> 00:04:41,000
And stick the base onto it.
80
00:04:41,000 --> 00:04:43,931
Like before,
The ring contains the spread.
81
00:04:43,931 --> 00:04:46,896
Another overall reheating
Softens the glass
82
00:04:46,896 --> 00:04:48,862
And fully fuses
All the components.
83
00:04:48,862 --> 00:04:52,724
This fills crevices
And smoothes the surface.
84
00:04:52,724 --> 00:04:55,241
Now they return to the furnace
85
00:04:55,241 --> 00:04:58,275
To encase this paperweight core
In molten crystal.
86
00:04:58,275 --> 00:05:00,793
Using standard
Glass-making techniques,
87
00:05:00,793 --> 00:05:03,482
They work the crystal
To a bulbous shape.
88
00:05:03,482 --> 00:05:07,103
Then on the bottom,
They form a break-off point.
89
00:05:07,103 --> 00:05:11,310
A sharp tap on the rod
Cracks the glass at that point,
90
00:05:11,310 --> 00:05:13,482
Separating it from the rod.
91
00:05:13,482 --> 00:05:15,551
They heat the break-off point
92
00:05:15,551 --> 00:05:19,206
And insert a piece of cane
Bearing the artist's initials.
93
00:05:19,206 --> 00:05:22,310
After a 12-hour controlled
Cooling in the kiln,
94
00:05:22,310 --> 00:05:24,034
They grind the base level.
95
00:05:24,034 --> 00:05:26,172
Then they polish away
The scratches
96
00:05:26,172 --> 00:05:27,724
Left by the grinding wheel.
97
00:05:30,896 --> 00:05:32,758
After a thorough inspection,
98
00:05:32,758 --> 00:05:35,517
These magnificent
Millefiori paperweights
99
00:05:35,517 --> 00:05:37,068
Are ready to be shipped
100
00:05:37,068 --> 00:05:39,931
To art-glass collectors
Worldwide.
101
00:05:51,241 --> 00:05:53,620
Narrator: when the road ahead
Is a sheet of ice,
102
00:05:53,620 --> 00:05:56,103
Rock salt can make the problem
Melt away.
103
00:05:56,103 --> 00:05:58,965
Salt lowers the melting point
Of water to thaw ice
104
00:05:58,965 --> 00:06:00,827
And also prevents its formation.
105
00:06:00,827 --> 00:06:03,827
Salt was first used to de-ice
Highways and walkways
106
00:06:03,827 --> 00:06:05,137
In the 1930s,
107
00:06:05,137 --> 00:06:08,931
But it was only in the 1960s
That its use spread.
108
00:06:12,793 --> 00:06:16,586
Unprocessed rock salt
Actually looks like the ice
109
00:06:16,586 --> 00:06:18,896
It will eventually be used
To melt.
110
00:06:21,655 --> 00:06:25,137
This salt comes
From huge crystalline caverns
111
00:06:25,137 --> 00:06:27,137
A thousand feet
Below the earth's surface
112
00:06:27,137 --> 00:06:28,758
Along the canada/u.S. Border.
113
00:06:28,758 --> 00:06:31,310
That's 2/10 of a mile
Underground.
114
00:06:31,310 --> 00:06:33,344
These massive deposits
Were formed
115
00:06:33,344 --> 00:06:35,310
Hundreds of millions
Of years ago
116
00:06:35,310 --> 00:06:38,517
When saltwater lakes dried up.
117
00:06:41,965 --> 00:06:46,137
The clarity of this rock salt
Is a sign of its purity.
118
00:06:49,034 --> 00:06:53,206
This mineral is 98%
Sodium chloride, or salt.
119
00:06:53,206 --> 00:06:56,000
They extract it in chunks
From the rock's face
120
00:06:56,000 --> 00:06:58,655
By using explosives
And drilling.
121
00:07:00,551 --> 00:07:03,827
Then a loader scoops up
The broken pieces of salt.
122
00:07:03,827 --> 00:07:07,000
This is called
A low-profile loader.
123
00:07:07,000 --> 00:07:11,724
It has a shorter height to fit
Into tight spaces underground.
124
00:07:11,724 --> 00:07:16,827
It transfers the salt
To the primary crusher.
125
00:07:16,827 --> 00:07:18,862
This crusher is
A spiked cylinder
126
00:07:18,862 --> 00:07:21,206
That spins to break the salt
Into pieces
127
00:07:21,206 --> 00:07:24,551
Small enough to be moved
On a conveyor.
128
00:07:24,551 --> 00:07:28,034
The conveyor takes the salt
To a production elevator
129
00:07:28,034 --> 00:07:31,241
Known as a skip.
130
00:07:31,241 --> 00:07:34,000
It takes just a minute
And a half for the skip
131
00:07:34,000 --> 00:07:37,586
To lift its heavy load
Aboveground and up a tower.
132
00:07:41,758 --> 00:07:46,931
When it stops, the bottom opens
To empty the salty cargo.
133
00:07:49,793 --> 00:07:54,793
The salt funnels into two chutes
And lands on vibrating screens.
134
00:07:56,379 --> 00:08:00,965
These screens are essentially
Big automated salt shakers.
135
00:08:00,965 --> 00:08:04,586
As they pulsate, they shake out
The smaller bits,
136
00:08:04,586 --> 00:08:07,896
While larger chunks move on
To be crushed again.
137
00:08:07,896 --> 00:08:10,517
Then it's on
To more shaking sifters.
138
00:08:10,517 --> 00:08:12,965
These screen out
The very fine particles,
139
00:08:12,965 --> 00:08:15,724
And what's left will be used
As de-icing salt.
140
00:08:19,000 --> 00:08:23,241
There are several sifters
In this room.
141
00:08:23,241 --> 00:08:25,379
They also sift out particles
142
00:08:25,379 --> 00:08:27,689
That are about 4/10 of an inch
In size
143
00:08:27,689 --> 00:08:30,034
To be used
As water-softening product.
144
00:08:30,034 --> 00:08:31,379
And for this purpose,
145
00:08:31,379 --> 00:08:33,896
The darker bits are seen
As undesirable,
146
00:08:33,896 --> 00:08:35,172
So they remove those
147
00:08:35,172 --> 00:08:37,724
With something called
An optical sorter.
148
00:08:37,724 --> 00:08:41,413
The optical sorter bounces light
Off the salt particles,
149
00:08:41,413 --> 00:08:43,034
And a computer
Reads the reflection
150
00:08:43,034 --> 00:08:44,793
To determine
If they're light or dark.
151
00:08:48,482 --> 00:08:51,689
Jets of compressed air
Then target the dark bits
152
00:08:51,689 --> 00:08:53,103
And blast them downward,
153
00:08:53,103 --> 00:08:57,137
While the white particles
Continue forward.
154
00:08:57,137 --> 00:09:00,517
A closer look confirms
155
00:09:00,517 --> 00:09:05,034
That the optical sorter
Has done its job effectively.
156
00:09:05,034 --> 00:09:08,965
The salt meant for water
Softening is pure white,
157
00:09:08,965 --> 00:09:13,344
While a few darker speckles
Is acceptable for road salt.
158
00:09:13,344 --> 00:09:15,275
Outside in the holding area,
159
00:09:15,275 --> 00:09:18,965
The salt accumulates in piles
That look like huge snow drifts.
160
00:09:18,965 --> 00:09:21,344
If the winter is harsh,
161
00:09:21,344 --> 00:09:25,793
Road crews will use it
As fast as it piles up.
162
00:09:25,793 --> 00:09:28,827
When it comes
To bulk purchasing,
163
00:09:28,827 --> 00:09:31,034
Orders don't come
Much bigger than this.
164
00:09:31,034 --> 00:09:32,724
Highway maintenance departments
165
00:09:32,724 --> 00:09:34,965
Buy de-icing salt
By the truckload
166
00:09:34,965 --> 00:09:36,896
And create their own stockpiles
167
00:09:36,896 --> 00:09:39,172
To be prepared
For stormy weather.
168
00:09:39,172 --> 00:09:41,620
But individual consumers,
Of course,
169
00:09:41,620 --> 00:09:44,034
Buy de-icing salt by the bag.
170
00:09:45,206 --> 00:09:46,724
In the packaging department,
171
00:09:46,724 --> 00:09:50,137
Automated trays relay plastic
Bags to grippers overhead,
172
00:09:50,137 --> 00:09:53,965
And the system
Moves them forward.
173
00:09:59,758 --> 00:10:03,793
Suctioning robot arms
Pry each bag open.
174
00:10:05,827 --> 00:10:08,517
A puff of air inflates the bag,
175
00:10:08,517 --> 00:10:11,103
While a nozzle pipes measured
Amounts of the de-icing salt
176
00:10:11,103 --> 00:10:13,931
Into the bag.
177
00:10:13,931 --> 00:10:15,965
Once the bag is full,
178
00:10:15,965 --> 00:10:18,103
The system moves it
Forward again,
179
00:10:18,103 --> 00:10:21,689
And not a grain of salt
Is spilled.
180
00:10:21,689 --> 00:10:23,344
Finally, a heat sealer
181
00:10:23,344 --> 00:10:26,551
Melts the plastic
To close the package.
182
00:10:26,551 --> 00:10:30,689
It's taken about an hour
For this rock salt
183
00:10:30,689 --> 00:10:34,655
To be mined, crushed,
Sifted, and packaged.
184
00:10:34,655 --> 00:10:37,482
And now they're ready to take it
To the street.
185
00:10:50,482 --> 00:10:52,103
Narrator:
The first nutcrackers
186
00:10:52,103 --> 00:10:54,620
Were plain,
Purely functional devices.
187
00:10:54,620 --> 00:10:56,000
By the 15th century,
188
00:10:56,000 --> 00:10:58,344
European woodcarvers
Began crafting
189
00:10:58,344 --> 00:11:01,413
Beautiful nutcrackers
Shaped like animals and people.
190
00:11:01,413 --> 00:11:03,034
German artisans became known
191
00:11:03,034 --> 00:11:05,862
For their majestic nutcracker
Kings and soldiers,
192
00:11:05,862 --> 00:11:09,586
Just like the one
In tchaikovsky's famous ballet.
193
00:11:11,379 --> 00:11:13,241
This german company
194
00:11:13,241 --> 00:11:16,172
Has been crafting character
Nutcrackers since 1928.
195
00:11:16,172 --> 00:11:18,275
Like porcelain figurines,
196
00:11:18,275 --> 00:11:21,689
These nutcrackers sell
As limited-edition collectibles.
197
00:11:21,689 --> 00:11:23,620
At hundreds of dollars each,
198
00:11:23,620 --> 00:11:27,000
People don't actually use them
For the intended purpose.
199
00:11:30,620 --> 00:11:33,137
But they can and do
Perform the job.
200
00:11:33,137 --> 00:11:34,931
You simply manipulate a lever
201
00:11:34,931 --> 00:11:38,137
To open, then close the mouth
To crack the nutshell.
202
00:11:38,137 --> 00:11:41,793
On the factory floor, they use
A multiblade circular saw
203
00:11:41,793 --> 00:11:44,379
To cut all the body parts
Out of linden wood.
204
00:11:44,379 --> 00:11:48,172
Linden is ideal because it's
Lightweight, easy to carve,
205
00:11:48,172 --> 00:11:51,379
And its color is pale enough
To mimic skin.
206
00:11:54,724 --> 00:11:57,620
These blocks are on their way
To becoming nutcracker torsos.
207
00:12:01,206 --> 00:12:03,724
First, they go through a planer.
208
00:12:03,724 --> 00:12:06,103
It trims the four sides
Of each block,
209
00:12:06,103 --> 00:12:07,896
Forming an octagonal shape...
210
00:12:19,827 --> 00:12:23,413
...From square to octagonal
And next to round.
211
00:12:23,413 --> 00:12:26,448
But first, workers
Use a circular saw
212
00:12:26,448 --> 00:12:29,000
To cut the blocks
Into torso-length pieces.
213
00:12:31,586 --> 00:12:34,172
A conveyor feeds the pieces
One by one
214
00:12:34,172 --> 00:12:36,862
Into an automatic,
Multi-station lathe.
215
00:12:36,862 --> 00:12:39,172
The first station
Rounds out the octagon,
216
00:12:39,172 --> 00:12:42,137
Then forms
The basic torso shape.
217
00:12:43,206 --> 00:12:45,793
The second station
Finalizes the shape.
218
00:12:45,793 --> 00:12:48,862
Then the next four stations
Sand the wood smooth
219
00:12:48,862 --> 00:12:51,758
So that the wood stain
They'll apply later on
220
00:12:51,758 --> 00:12:54,275
Will penetrate well and evenly.
221
00:12:54,275 --> 00:12:57,310
Then the torsos go
Three at a time
222
00:12:57,310 --> 00:13:00,103
Into a vertical router.
223
00:13:00,103 --> 00:13:03,413
It cuts a notch in each one
224
00:13:03,413 --> 00:13:07,275
For the lever that opens and
Closes the nutcracker's mouth.
225
00:13:12,896 --> 00:13:15,034
Next stop is a drilling machine,
226
00:13:15,034 --> 00:13:18,344
Which simultaneously drills
All the holes required
227
00:13:18,344 --> 00:13:22,448
To attach the body parts,
As well as the lever's axle.
228
00:13:22,448 --> 00:13:25,241
Now they dress the torso
In a coat,
229
00:13:25,241 --> 00:13:29,517
Which they create simply by
Staining the wood a dark color.
230
00:13:29,517 --> 00:13:30,931
Once the stain dries,
231
00:13:30,931 --> 00:13:34,448
They spray on two coats
Of semigloss lacquer.
232
00:13:34,448 --> 00:13:37,758
Every nutcracker stands
On a wooden base,
233
00:13:37,758 --> 00:13:40,206
Under which they burn
The company's logo.
234
00:13:40,206 --> 00:13:44,482
It's a mark of authenticity
For collectors.
235
00:13:44,482 --> 00:13:47,896
The automatic lathe also shapes
The other body parts,
236
00:13:47,896 --> 00:13:49,241
Including the head.
237
00:13:49,241 --> 00:13:51,379
Workers attach a nose,
238
00:13:51,379 --> 00:13:54,586
Then, using a router,
Cut holes for the eyes.
239
00:13:54,586 --> 00:13:57,931
Then they lightly spray on
A touch of red paint
240
00:13:57,931 --> 00:14:01,068
To simulate a sun-kissed nose
And rosy cheeks.
241
00:14:03,379 --> 00:14:05,551
Then, with a steady hand,
242
00:14:05,551 --> 00:14:08,000
They paint the whites
Of the eyes...
243
00:14:11,413 --> 00:14:13,344
...And the eyebrows.
244
00:14:15,965 --> 00:14:17,482
Once the paint dries,
245
00:14:17,482 --> 00:14:20,724
They apply some glue
To the center of each eye,
246
00:14:20,724 --> 00:14:24,068
Then affix an iris and pupil
Made of enameled tin.
247
00:14:26,448 --> 00:14:29,413
Now they align the head
With the torso
248
00:14:29,413 --> 00:14:31,965
And screw the parts together.
249
00:14:33,344 --> 00:14:36,103
After decorating the coat
With buttons and a buckle,
250
00:14:36,103 --> 00:14:39,344
They glue a strip of rabbit-fur
Hair to the head...
251
00:14:42,758 --> 00:14:44,275
...A rabbit-fur beard
252
00:14:44,275 --> 00:14:46,965
To camouflage the notch
For the lever,
253
00:14:46,965 --> 00:14:49,793
Then they mount the torso
Onto the legs,
254
00:14:49,793 --> 00:14:53,517
Which wear painted-on boots
And stand on the base.
255
00:14:53,517 --> 00:14:57,034
Then this nutcracker
Percussionist gets his drum,
256
00:14:57,034 --> 00:15:00,310
Along with arms and drumsticks.
257
00:15:04,655 --> 00:15:07,689
They top him off with a hat
Made of spray-painted wood.
258
00:15:12,379 --> 00:15:14,206
Most of the nutcracker's parts
259
00:15:14,206 --> 00:15:17,000
Join together
With wooden dowels.
260
00:15:17,000 --> 00:15:20,344
A large dowel running
Across the notch in the torso
261
00:15:20,344 --> 00:15:23,448
Is the axle
On which the lever rotates.
262
00:15:30,206 --> 00:15:32,758
This extensive cast
Of nutcracker characters
263
00:15:32,758 --> 00:15:34,586
Comes in various sizes,
264
00:15:34,586 --> 00:15:38,206
And you can even special-order
A life-sized version.
265
00:15:50,689 --> 00:15:54,172
Narrator: car doors have come a
Long way over the last century.
266
00:15:54,172 --> 00:15:57,000
They're lighter
For improved fuel efficiency
267
00:15:57,000 --> 00:16:00,413
And stronger to better withstand
The force of an impact.
268
00:16:00,413 --> 00:16:03,413
They also contain a lot
Of electronic gadgetry,
269
00:16:03,413 --> 00:16:05,379
Like speakers and power windows,
270
00:16:05,379 --> 00:16:07,931
All of which enhance
The daily commute.
271
00:16:12,000 --> 00:16:14,068
A car door is one
Of the first things
272
00:16:14,068 --> 00:16:16,448
Many people reach for
As they start their day,
273
00:16:16,448 --> 00:16:20,068
So let's unlock the mystery
Of how it's made.
274
00:16:20,068 --> 00:16:22,620
It all starts with carbon steel,
275
00:16:22,620 --> 00:16:25,241
An alloy that's strong,
Yet malleable.
276
00:16:26,551 --> 00:16:29,931
Machinery uncoils
And straightens it.
277
00:16:29,931 --> 00:16:32,310
A large blade slices it
To the desired length,
278
00:16:32,310 --> 00:16:34,655
Producing sheets called blanks.
279
00:16:34,655 --> 00:16:36,758
Then it's over
To a powerful press.
280
00:16:36,758 --> 00:16:38,965
This particular one
Is a trial press,
281
00:16:38,965 --> 00:16:41,344
Which offers a better view
Of the process
282
00:16:41,344 --> 00:16:43,103
Than the one
On the production line.
283
00:16:43,103 --> 00:16:45,620
The press forces the blank
Into a die,
284
00:16:45,620 --> 00:16:48,206
Giving it the basic shape
Of two car doors.
285
00:16:48,206 --> 00:16:50,586
It's a design
That's been engineered
286
00:16:50,586 --> 00:16:54,137
For both aerodynamics
And strength.
287
00:16:54,137 --> 00:16:56,482
Back on the production line,
288
00:16:56,482 --> 00:16:59,655
The main press is
Churning out car doors.
289
00:16:59,655 --> 00:17:01,482
An automated device with fingers
290
00:17:01,482 --> 00:17:03,517
Then grips
The newly shaped steel
291
00:17:03,517 --> 00:17:06,034
And transfers it
To a punch cutter.
292
00:17:06,034 --> 00:17:07,448
It separates the two doors
293
00:17:07,448 --> 00:17:12,103
And trims the excess metal
From the edges.
294
00:17:12,103 --> 00:17:14,689
With the outer door panels
Now complete,
295
00:17:14,689 --> 00:17:18,482
A handler inspects them
For bumps, dents, or scratches.
296
00:17:18,482 --> 00:17:21,689
He approves only those
That are absolutely flawless.
297
00:17:21,689 --> 00:17:24,379
The next worker arranges
The window frame,
298
00:17:24,379 --> 00:17:26,655
A reinforcing plate
For the hinge,
299
00:17:26,655 --> 00:17:28,241
And the inner door panel,
300
00:17:28,241 --> 00:17:30,551
All on a special
Clamping fixture.
301
00:17:30,551 --> 00:17:33,931
Its fingers grip the parts
To hold them in position
302
00:17:33,931 --> 00:17:35,448
As the fixture rotates
303
00:17:35,448 --> 00:17:38,517
And two robots move in
To weld them together.
304
00:17:40,620 --> 00:17:42,068
At the next station,
305
00:17:42,068 --> 00:17:46,206
The worker arranges steel bars
And tubes on a robotic platform.
306
00:17:46,206 --> 00:17:47,758
They add strength to the door
307
00:17:47,758 --> 00:17:50,931
So it will better withstand
Any impact.
308
00:17:50,931 --> 00:17:54,793
He places the inner door panel
Over the bars and tubes.
309
00:17:54,793 --> 00:17:58,655
The robotic platform
Angles the parts for welding.
310
00:18:01,758 --> 00:18:04,034
Another robot applies adhesive
311
00:18:04,034 --> 00:18:05,724
To the rim
Of the outer door panel.
312
00:18:05,724 --> 00:18:10,344
More robots dab adhesive
At strategic locations.
313
00:18:13,482 --> 00:18:16,965
Those dabs match up to the tubes
And bars on the inner panel
314
00:18:16,965 --> 00:18:20,586
As they mate it
To the outer one.
315
00:18:20,586 --> 00:18:24,172
A special press then folds
The lip of the outer panel
316
00:18:24,172 --> 00:18:25,586
Over the inner one.
317
00:18:25,586 --> 00:18:29,379
This hemming gives the assembled
Car door a neater edge.
318
00:18:33,482 --> 00:18:36,482
With the inner and outer panels
Now joined,
319
00:18:36,482 --> 00:18:39,448
The car door undergoes
Rustproofing, paint,
320
00:18:39,448 --> 00:18:41,724
And other protective treatments.
321
00:18:41,724 --> 00:18:43,931
Now, over on the assembly line,
322
00:18:43,931 --> 00:18:46,551
A worker fits the handle
Into its niche
323
00:18:46,551 --> 00:18:50,724
And bolts it to the door
From the other side.
324
00:18:50,724 --> 00:18:54,793
Chrome trim
Is clipped into place.
325
00:18:54,793 --> 00:18:56,137
Moving down the line,
326
00:18:56,137 --> 00:18:58,620
A worker installs
A small, fixed window
327
00:18:58,620 --> 00:19:00,655
In the groove of the frame.
328
00:19:00,655 --> 00:19:03,896
He uses a plastic protector
To prevent scratches
329
00:19:03,896 --> 00:19:07,379
As he slides the larger window
Into its slot in the door
330
00:19:07,379 --> 00:19:10,793
And links it to a power-lifting
Mechanism inside.
331
00:19:16,103 --> 00:19:19,793
He separates the two windows
With a metal divider.
332
00:19:19,793 --> 00:19:21,241
At the next station,
333
00:19:21,241 --> 00:19:24,379
This car door gets
An automated side-view mirror.
334
00:19:25,965 --> 00:19:29,000
They're now ready for the inner
Panel and its workings.
335
00:19:29,000 --> 00:19:31,379
The employee wires
The panel to the door
336
00:19:31,379 --> 00:19:34,172
And snaps it into place.
337
00:19:34,172 --> 00:19:37,862
He tests the power windows,
And they close to a tight seal,
338
00:19:37,862 --> 00:19:40,517
Indicating
A successful installation.
339
00:19:40,517 --> 00:19:44,068
A special elevator now lowers
The completed car doors
340
00:19:44,068 --> 00:19:47,103
6 1/2 yards
To the next station.
341
00:19:47,103 --> 00:19:49,413
A worker unloads each door
342
00:19:49,413 --> 00:19:51,448
With the help
Of a pneumatic arm.
343
00:19:51,448 --> 00:19:54,034
This device shoulders
The weight of the part
344
00:19:54,034 --> 00:19:56,931
And correctly positions the door
For installation.
345
00:20:00,827 --> 00:20:04,586
He drives bolts into hinges
To attach the door to the car.
346
00:20:04,586 --> 00:20:05,862
On the door side,
347
00:20:05,862 --> 00:20:08,241
The heavy-duty
Reinforcement plate
348
00:20:08,241 --> 00:20:10,931
Surrounds the hinges
And supports them.
349
00:20:10,931 --> 00:20:12,310
The whole weight of the door
350
00:20:12,310 --> 00:20:15,551
Will hang on this plate
As it swings open and shut.
351
00:20:17,413 --> 00:20:19,517
With all the panels installed,
352
00:20:19,517 --> 00:20:21,448
It's time
For the final adjustments.
353
00:20:21,448 --> 00:20:23,482
They call this finessing.
354
00:20:23,482 --> 00:20:25,344
They examine each panel
355
00:20:25,344 --> 00:20:28,689
To confirm that it's flush
To the rest of the car body,
356
00:20:28,689 --> 00:20:32,310
And they tweak the installation
Job where needed.
357
00:20:32,310 --> 00:20:35,758
Finally, they're satisfied
The assembly is airtight,
358
00:20:35,758 --> 00:20:39,758
So it's time to close the door
On this production.
359
00:20:39,758 --> 00:20:42,758
--captions by vitac--
Www.Vitac.Com
360
00:20:42,758 --> 00:20:45,758
Captions paid for by
Discovery communications
361
00:20:51,379 --> 00:20:53,896
If you have any comments
About the show,
362
00:20:53,896 --> 00:20:56,517
Or if you'd like to suggest
Topics for future shows,
363
00:20:56,517 --> 00:20:58,379
Drop us a line at...
28948
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.