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00:00:01,793 --> 00:00:04,793
--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,793
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:22,620 --> 00:00:24,965
Narrator:
TODAY ON "HOW IT'S MADE"...
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00:00:53,275 --> 00:00:56,275
AUTOMATED MACHINES
CHANGED MANUFACTURING FOREVER
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00:00:56,275 --> 00:00:58,413
WHEN THEY BEGAN
ASSEMBLING PARTS.
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00:00:58,413 --> 00:01:02,862
CNC ASSEMBLY MACHINES HAVE TAKEN
AUTOMATION TO THE NEXT LEVEL.
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00:01:02,862 --> 00:01:07,068
CNC IS AN ACRONYM
FOR COMPUTER NUMERICAL CONTROL.
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00:01:07,068 --> 00:01:09,137
THE MACHINE IS AUTOMATED
BY A COMPUTER
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00:01:09,137 --> 00:01:11,172
RATHER THAN BY MECHANICS.
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00:01:13,241 --> 00:01:15,896
TO DESIGN
A CNC ASSEMBLY MACHINE,
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00:01:15,896 --> 00:01:18,068
ENGINEERS FIRST
ANALYZE THE SEQUENCE
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00:01:18,068 --> 00:01:21,068
OF TASKS REQUIRED
TO ASSEMBLE THE PRODUCT.
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00:01:21,068 --> 00:01:22,862
THEY THEN MATCH EACH TASK
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00:01:22,862 --> 00:01:25,000
TO A PRE-DESIGNED
PROCESSING ENGINE.
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00:01:27,103 --> 00:01:29,275
THE PROCESSING ENGINES
ARE LINKED TOGETHER
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00:01:29,275 --> 00:01:32,793
IN A CUSTOM ASSEMBLY SEQUENCE.
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00:01:32,793 --> 00:01:34,206
EACH ENGINE IS PROGRAMMED
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00:01:34,206 --> 00:01:36,482
TO CONTROL
ITS COMPUTER-GUIDED MOTORS,
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00:01:36,482 --> 00:01:38,206
WHICH PERFORM
THE PRECISE MOTIONS
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00:01:38,206 --> 00:01:41,517
REQUIRED TO EXECUTE A TASK.
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00:01:41,517 --> 00:01:43,137
THE CNC MACHINE'S ENGINES
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00:01:43,137 --> 00:01:45,758
ARE MOUNTED
ON A STURDY BASE FRAME.
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00:01:45,758 --> 00:01:47,000
TO CONSTRUCT IT,
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00:01:47,000 --> 00:01:51,482
WORKERS CUT STEEL TUBES
TO THE REQUIRED LENGTHS.
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00:01:51,482 --> 00:01:54,034
THEY GRIND A JOINT
IN EACH PIECE...
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00:01:57,344 --> 00:01:59,137
...THEN WELD THE PIECES TOGETHER
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00:01:59,137 --> 00:02:02,482
BY MELTING STEEL WELDING WIRE
INTO THE JOINTS.
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00:02:06,517 --> 00:02:09,862
THEY BOLT A STEEL TABLETOP
ONTO THE BASE FRAME.
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00:02:09,862 --> 00:02:13,620
IT HAS CUTOUTS FOR EACH ENGINE.
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00:02:13,620 --> 00:02:15,241
IT'S BEEN GROUND PERFECTLY FLAT.
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00:02:15,241 --> 00:02:17,931
SO THE ENGINES WILL BE LEVEL
WITH EACH OTHER.
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00:02:24,482 --> 00:02:26,517
MEANWHILE,
AN ELECTRICAL TECHNICIAN
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00:02:26,517 --> 00:02:30,000
IS ASSEMBLING THE MACHINE'S
MAIN CONTROL CABINET.
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00:02:30,000 --> 00:02:33,758
IT CONTAINS ONE INDUSTRIAL
COMPUTER FOR EACH ENGINE.
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00:02:33,758 --> 00:02:35,793
A CNC MACHINE HAS ENGINES
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00:02:35,793 --> 00:02:39,310
FOR PERFORMING ROTARY MOVEMENTS,
LINEAR MOVEMENTS,
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00:02:39,310 --> 00:02:41,793
AND FOR PICKING UP
AND PLACING PARTS.
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00:02:43,793 --> 00:02:48,000
THE MOTORS INSIDE EACH ENGINE
HAVE THEIR OWN COMPUTERS.
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00:02:48,000 --> 00:02:49,827
THEY'RE PROGRAMMED
TO PERFORM MOVEMENTS
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00:02:49,827 --> 00:02:52,517
AT SPECIFIC SPEEDS AND FORCES.
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00:02:59,413 --> 00:03:02,034
ONCE THE MAIN CONTROL CABINET
IS ASSEMBLED,
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00:03:02,034 --> 00:03:04,448
WORKERS BOLT IT
TO THE BASE FRAME.
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00:03:08,620 --> 00:03:11,896
THEN THEY INSTALL STEEL BASES
FOR THE ENGINES.
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00:03:24,000 --> 00:03:27,793
SOME CNC MACHINES
REQUIRE ROBOTIC ARMS.
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00:03:27,793 --> 00:03:29,344
A COMPUTER-GUIDED
MILLING MACHINE
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00:03:29,344 --> 00:03:31,689
CUTS RECTANGULAR BARS
OF ALUMINUM,
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00:03:31,689 --> 00:03:34,931
SHAPING THEM
INTO ROBOTIC ARM COMPONENTS.
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00:03:38,413 --> 00:03:40,241
THIS PRECISION-MEASURING DEVICE
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00:03:40,241 --> 00:03:44,137
ENSURES EACH MILLED PART
MEETS STRICT SPECIFICATIONS.
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00:03:48,724 --> 00:03:50,482
AFTER THE ALUMINUM COMPONENTS
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00:03:50,482 --> 00:03:53,413
RECEIVE
AN ANTI-CORROSION COATING,
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00:03:53,413 --> 00:03:56,310
WORKERS ASSEMBLE THEM
INTO A ROBOTIC ARM.
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00:03:58,344 --> 00:04:00,482
THESE SELF-LUBRICATING
SLEEVE BEARINGS
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00:04:00,482 --> 00:04:03,137
GIVE THE ARM
THE ABILITY TO ROTATE.
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00:04:06,551 --> 00:04:09,275
THEY ADD A SECOND ASSEMBLED ARM
TO CREATE A PAIR
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00:04:09,275 --> 00:04:12,724
THAT WORKS TOGETHER
TO PERFORM AN ASSIGNED TASK.
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00:04:18,758 --> 00:04:21,137
EACH ARM IS CONTROLLED
BY ITS OWN MOTOR,
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00:04:21,137 --> 00:04:24,413
WHICH FOLLOWS THE COMMANDS
OF THE ENGINE'S COMPUTER.
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00:04:26,551 --> 00:04:29,379
THIS COUPLING SECURELY
CONNECTS EACH ROBOTIC ARM
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00:04:29,379 --> 00:04:31,413
TO THE SHAFT OF ITS MOTOR.
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00:04:36,620 --> 00:04:40,275
EACH ENGINE ON THE MACHINE
CAN HAVE UP TO EIGHT MOTORS.
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00:04:40,275 --> 00:04:43,827
THE MOTORS CAN OPERATE
INDEPENDENTLY OR IN UNISON.
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00:04:48,482 --> 00:04:51,827
THIS ENGINE HAS ROBOTIC ARMS
THAT CAN PICK UP, HOLD,
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00:04:51,827 --> 00:04:53,758
AND RELEASE PARTS.
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00:04:59,413 --> 00:05:01,620
TO TEST THE COMPLETED MACHINE,
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00:05:01,620 --> 00:05:03,103
A HIGH-SPEED VIDEO CAMERA
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00:05:03,103 --> 00:05:06,551
CAPTURES IMAGES
AT 1,000 FRAMES PER SECOND.
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00:05:06,551 --> 00:05:10,241
THE QUALITY CONTROL TEAM
SLOWS DOWN THE VIDEO TO ANALYZE
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00:05:10,241 --> 00:05:14,000
AND FINE-TUNE THE ACCURACY
AND EFFICIENCY OF EVERY MOTION.
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00:05:23,172 --> 00:05:26,103
JUST A FEW SIMPLE TAPS
ON THE OPERATOR'S TOUCH SCREEN
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00:05:26,103 --> 00:05:29,137
CAN ADJUST THE ARM
TO MOVE A MILLISECOND FASTER.
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00:05:29,137 --> 00:05:31,586
OR A MILLIMETER FURTHER.
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00:05:31,586 --> 00:05:36,758
CNC MACHINES CAN ASSEMBLE
SMALL PRODUCTS AT HIGH SPEED.
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00:05:36,758 --> 00:05:37,965
THEY ALSO PROVIDE SOMETHING
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00:05:37,965 --> 00:05:40,551
TRADITIONAL ASSEMBLY
EQUIPMENT CAN'T --
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00:05:40,551 --> 00:05:43,103
FLEXIBILITY.
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00:05:43,103 --> 00:05:46,379
A SINGLE MACHINE CAN BE
REPROGRAMMED MULTIPLE TIMES
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00:05:46,379 --> 00:05:48,896
FOR ASSEMBLING
DIFFERENT PRODUCTS.
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00:06:08,241 --> 00:06:10,103
Narrator:
WHEN LIFE GIVES YOU LEMONS,
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00:06:10,103 --> 00:06:11,965
WHY BOTHER MAKING LEMONADE
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00:06:11,965 --> 00:06:15,103
WHEN YOU CAN INDULGE
IN A LUSCIOUS LEMON TART?
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00:06:15,103 --> 00:06:17,586
NOT TOO SOUR, NOT TOO SWEET,
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00:06:17,586 --> 00:06:19,586
A LEMON TART
IS A DELECTABLE DESSERT
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00:06:19,586 --> 00:06:21,103
THAT YOU CAN MAKE YOURSELF.
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00:06:21,103 --> 00:06:23,620
OR EVEN BETTER,
LEAVE IT TO THE BAKING PROS
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00:06:23,620 --> 00:06:25,275
AND BUY READY-MADE.
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00:06:30,724 --> 00:06:34,103
THIS THAW-AND-SERVE LEMON TART
HAS A SHORTBREAD SHELL
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00:06:34,103 --> 00:06:37,413
AND CREAMY LEMON FILLING
TOPPED WITH BUTTERCREAM.
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00:06:41,724 --> 00:06:44,724
EACH BATCH OF DOUGH PRODUCED
IN THIS INDUSTRIAL MIXER
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00:06:44,724 --> 00:06:48,068
YIELDS 449 TART SHELLS.
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00:06:48,068 --> 00:06:51,068
THE FIRST STEP IS TO LIGHTLY
BLEND MARGARINE, SUGAR,
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00:06:51,068 --> 00:06:53,000
AND SALT FOR 2 OR 3 MINUTES.
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00:06:55,344 --> 00:06:57,551
NEXT, ADD PASTEURIZED EGGS
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00:06:57,551 --> 00:07:01,275
AND MIX FOR ABOUT 2 MINUTES
AT SLOW SPEED.
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00:07:01,275 --> 00:07:05,000
FAST MIXING MAKES THE DOUGH
TOO TIGHT, CAUSING IT TO CRACK.
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00:07:07,068 --> 00:07:10,724
THEY ADD WHITE FLOUR
WHILE CONTINUING TO MIX SLOWLY
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00:07:10,724 --> 00:07:14,758
UNTIL THE INGREDIENTS
ARE WELL-BLENDED.
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00:07:14,758 --> 00:07:16,793
ONCE THE DOUGH IS READY, WORKERS
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00:07:16,793 --> 00:07:21,241
PUT IT THROUGH WHAT IS ACTUALLY
A HAMBURGER FORMING MACHINE.
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00:07:21,241 --> 00:07:24,379
IT EXTRUDES 1/4-POUND
DOUGH PATTIES.
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00:07:24,379 --> 00:07:26,034
WORKERS PLACE THEM IN THE MIDDLE
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00:07:26,034 --> 00:07:29,241
OF A NONSTICK ALUMINUM TART PAN
THREE AT A TIME.
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00:07:31,379 --> 00:07:35,413
THEY MOUNT THE PAN ON A PRESS,
COVERING IT WITH PLASTIC.
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00:07:35,413 --> 00:07:37,103
A DIE STRIKES THE PAN,
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00:07:37,103 --> 00:07:39,724
FLATTENING AND SPREADING
THE DOUGH EVENLY.
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00:07:42,206 --> 00:07:43,931
THE PANS GO INTO THE OVEN,
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00:07:43,931 --> 00:07:46,758
WHERE THEY ROTATE
FOR 23 TO 24 MINUTES
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00:07:46,758 --> 00:07:49,310
AT 350 DEGREES FAHRENHEIT.
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00:07:52,620 --> 00:07:56,793
THE DOUGH BAKES
INTO A SHORTBREAD TART SHELL.
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00:07:56,793 --> 00:07:58,379
LEMON JUICE AND LEMON OIL
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00:07:58,379 --> 00:08:01,206
ARE THE KEY INGREDIENTS
IN THE CREAMY FILLING.
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00:08:03,931 --> 00:08:07,448
FIRST, WORKERS MELT MARGARINE
ON A STOVE...
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00:08:15,275 --> 00:08:18,448
...THEN MIX IN SUGAR,
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00:08:18,448 --> 00:08:20,172
LEMON POWDER...
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00:08:24,172 --> 00:08:26,724
...AND FOOD STARCH
TO THICKEN THE MIX.
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00:08:28,758 --> 00:08:32,172
THEY BLEND FOR 2 MINUTES,
THEN ADD EGGS.
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00:08:35,482 --> 00:08:37,931
AFTER ANOTHER 5 TO 8 MINUTES
OF MIXING,
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00:08:37,931 --> 00:08:41,517
THEY POUR IN BOILED
LEMON JUICE AND LEMON OIL.
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00:08:41,517 --> 00:08:47,275
BOILING THESE ACIDIC INGREDIENTS
PREVENTS THE FATS FROM CURDLING.
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00:08:47,275 --> 00:08:48,620
THE FILLING IS READY.
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00:08:48,620 --> 00:08:50,655
SO THEY MOVE THE BOWL
FROM THE MIXER
122
00:08:50,655 --> 00:08:52,724
OVER TO THE DEPOSITING LINE.
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00:08:55,413 --> 00:08:59,793
A PUMP TRANSFERS THE CONTENTS
TO A HOPPER FEEDING A DEPOSITOR.
124
00:09:04,862 --> 00:09:06,379
THE DEPOSITOR IS PRE-SET
125
00:09:06,379 --> 00:09:10,344
TO SQUIRT 22 OUNCES
OF LEMON FILLING IN EACH TART.
126
00:09:17,655 --> 00:09:21,000
THE FILLED TARTS
GO INTO THE OVEN FOR 11 MINUTES.
127
00:09:26,482 --> 00:09:28,689
THE LEMON TARTS
COME OUT OF THE OVEN,
128
00:09:28,689 --> 00:09:31,379
COOL AT ROOM TEMPERATURE
FOR 2 TO 3 HOURS,
129
00:09:31,379 --> 00:09:35,413
THEN GO INTO A FREEZER
OVERNIGHT.
130
00:09:35,413 --> 00:09:38,137
THE NEXT DAY, WORKERS
REMOVE THE FROZEN TARTS
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00:09:38,137 --> 00:09:39,896
FROM THE PANS.
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00:09:51,482 --> 00:09:53,827
THEY GENTLY REMOVE
ANY SPECKS OF BROWNING,
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00:09:53,827 --> 00:09:57,827
THEN SPRAY ON A LIGHT LAYER
OF GLAZE MADE FROM APRICOTS.
134
00:09:57,827 --> 00:10:00,206
THIS ADDS A HINT OF SWEETNESS.
135
00:10:00,206 --> 00:10:03,000
THE GLAZE ALSO PREVENTS
THE FILLING FROM CRACKING
136
00:10:03,000 --> 00:10:04,793
WHEN IT'S THAWED FOR SERVING.
137
00:10:08,275 --> 00:10:12,586
NEXT, THEY PUT THE TART
IN AN AUTOMATED CAKE SLICER.
138
00:10:12,586 --> 00:10:14,103
THE TURNTABLE ROTATES
139
00:10:14,103 --> 00:10:16,758
AS THE TART
IS CUT INTO 12 SLICES
140
00:10:16,758 --> 00:10:20,206
WITH PAPERS
IN BETWEEN EACH ONE.
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00:10:20,206 --> 00:10:21,448
THIS IS FOR RESTAURANTS
142
00:10:21,448 --> 00:10:24,137
WHO SERVE THE DESSERT
BY THE SLICE.
143
00:10:26,482 --> 00:10:28,241
WORKERS EMBELLISH EACH SLICE
144
00:10:28,241 --> 00:10:30,344
WITH A FLOWER
MADE OF BUTTERCREAM,
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00:10:30,344 --> 00:10:33,344
A DECADENT MIXTURE OF BUTTER,
EGG WHITES, AND SUGAR.
146
00:10:38,000 --> 00:10:39,310
THEY COMPLETE EACH FLOWER
147
00:10:39,310 --> 00:10:41,793
WITH A DOT OF LEMON FILLING
IN THE CENTER.
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00:10:43,965 --> 00:10:47,827
THIS LEMON TART IS FINISHED.
149
00:10:47,827 --> 00:10:50,103
THEY WRAP IT
IN A CARDBOARD CAKE BAND
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00:10:50,103 --> 00:10:53,793
PRINTED WITH THE BRAND NAME.
151
00:10:53,793 --> 00:10:56,482
THEY SEAL THE TART
IN PLASTIC FILM,
152
00:10:56,482 --> 00:10:59,000
INSERT IT INTO A RETAIL BOX,
153
00:10:59,000 --> 00:11:02,724
AND SHIP IT FROZEN
TO A STORE OR RESTAURANT.
154
00:11:02,724 --> 00:11:04,586
TO SERVE THIS TASTY DESSERT,
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00:11:04,586 --> 00:11:06,482
YOU SIMPLY DEFROST
AT ROOM TEMPERATURE
156
00:11:06,482 --> 00:11:08,137
FOR ABOUT A HALF HOUR.
157
00:11:23,551 --> 00:11:26,965
Narrator: TOY SOLDIERS
AREN'T JUST FOR CHILDREN.
158
00:11:26,965 --> 00:11:30,275
THEY'RE A HOBBY FOR GROWN-UPS
THAT DATES BACK OVER A CENTURY.
159
00:11:32,413 --> 00:11:35,172
THE SCIENCE-FICTION NOVELIST
H.G. WELLS
160
00:11:35,172 --> 00:11:36,724
PUBLISHED THE FIRST SET OF RULES
161
00:11:36,724 --> 00:11:39,931
FOR TOY SOLIDER WAR GAMES
IN 1913.
162
00:11:44,206 --> 00:11:45,793
THE GAME IS ON.
163
00:11:45,793 --> 00:11:47,965
IT'S TIME TO RALLY THE TROOPS.
164
00:11:47,965 --> 00:11:51,206
THESE MINI SOLDIERS ARE MADE
OF EITHER METAL OR PLASTIC
165
00:11:51,206 --> 00:11:55,172
AND HAND-PAINTED
BY THE GAME PLAYERS.
166
00:11:55,172 --> 00:11:58,172
NO DETAIL IS OVERLOOKED
IN MAKING THESE WAR FIGURES
167
00:11:58,172 --> 00:12:01,068
TRUE TO THE HISTORICAL PERIOD
OF THE GAME.
168
00:12:03,241 --> 00:12:06,689
PLAYERS MOVE THE FIGURES
AROUND TABLETOP SCENERY
169
00:12:06,689 --> 00:12:09,103
LIKE CHESSMEN ON A CHESS BOARD.
170
00:12:09,103 --> 00:12:13,206
AND LIKE CHESS,
THIS IS A GAME OF STRATEGY.
171
00:12:13,206 --> 00:12:16,862
IT'S A WAY TO ENGAGE
IN THE TACTICAL ELEMENTS OF WAR
172
00:12:16,862 --> 00:12:21,068
WITHOUT THE VIOLENCE
OF A REAL BATTLE.
173
00:12:21,068 --> 00:12:22,793
MAKING MINIATURE WAR FIGURINES
174
00:12:22,793 --> 00:12:26,379
STARTS WITH THE CONSTRUCTION
OF A MODEL.
175
00:12:26,379 --> 00:12:29,034
WITH ONLY ONE HAND
AND HIS PROSTHESIS,
176
00:12:29,034 --> 00:12:32,034
A MODELER EXPERTLY BENDS
TIN COPPER WIRE
177
00:12:32,034 --> 00:12:34,206
INTO A FRAMEWORK FOR THE MODEL.
178
00:12:36,241 --> 00:12:39,275
EACH SOLDIER NEEDS TO BE
1.1 INCHES IN LENGTH.
179
00:12:39,275 --> 00:12:42,517
SO HE SHAPES AND TRIMS THE WIRE
ACCORDINGLY.
180
00:12:45,103 --> 00:12:47,551
ONCE HE COMPLETES
THE WIRE SKELETON,
181
00:12:47,551 --> 00:12:50,689
HE STICKS THE LEG PRONGS
INTO A CORK.
182
00:12:50,689 --> 00:12:53,793
THIS ENABLES HIM TO GET
A FIRM GRIP ON THE SKELETON
183
00:12:53,793 --> 00:12:56,620
AS HE BUILDS UP THE FIGURE
WITH EPOXY PUTTY.
184
00:13:00,103 --> 00:13:02,586
HE SCULPTS A BASE LAYER
USING A DENTAL TOOL
185
00:13:02,586 --> 00:13:07,034
THAT'S USUALLY USED
FOR SCRAPING PLAQUE.
186
00:13:07,034 --> 00:13:09,034
AFTER THE BASE LAYER CURES,
187
00:13:09,034 --> 00:13:13,034
HE BUILDS UP THE CHEST
AND CALF AREAS.
188
00:13:13,034 --> 00:13:18,206
AFTER MORE CURING TIME,
HE SCULPTS THE SOLDIER'S TUNIC.
189
00:13:18,206 --> 00:13:20,586
USING A TOOL WITH A FINE POINT,
190
00:13:20,586 --> 00:13:24,344
HE PITS THE SURFACE TO SIMULATE
MEDIEVAL CHAIN MAIL ARMOR.
191
00:13:26,379 --> 00:13:28,034
WITH SKILLFUL ARTISTRY,
192
00:13:28,034 --> 00:13:30,551
THE MINIATURE SOLDIER
TAKES SHAPE.
193
00:13:34,103 --> 00:13:37,241
HE INSERTS A WIRE
INTO A DRILLED SHOULDER SOCKET
194
00:13:37,241 --> 00:13:40,344
AND APPLIES PUTTY
TO CREATE A MUSCULAR EFFECT.
195
00:13:45,000 --> 00:13:48,586
HE BUILDS UP THE SLEEVE AND
PIERCES IT ALL THE WAY AROUND
196
00:13:48,586 --> 00:13:52,068
TO CONTINUE
THE CHAIN MAIL EFFECT.
197
00:13:52,068 --> 00:13:54,689
HE CARVES THE ROUNDED RIM
OF THE HAT.
198
00:13:56,827 --> 00:14:01,793
THIS SMALL-SCALE SOLDIER
IS IN FIGHTING FORM.
199
00:14:01,793 --> 00:14:04,275
HE'S USED TO MAKE A MOLD
FOR TIN SOLDIERS
200
00:14:04,275 --> 00:14:06,413
THAT WILL LOOK JUST LIKE HIM.
201
00:14:09,310 --> 00:14:11,241
MEANWHILE,
ANOTHER MEMBER OF THE TEAM
202
00:14:11,241 --> 00:14:16,034
SCULPTS EPOXY PUTTY MODELS
THAT ARE THREE TIMES LARGER.
203
00:14:16,034 --> 00:14:17,413
THESE MODELS ARE USED
204
00:14:17,413 --> 00:14:21,275
TO MASS-PRODUCE
PLASTIC WAR FIGURES.
205
00:14:21,275 --> 00:14:23,965
GOING LARGE FIRST
AND THEN SCALING DOWN
206
00:14:23,965 --> 00:14:27,275
IS THE ONLY WAY
TO TRANSFER ALL THE DETAILS.
207
00:14:31,068 --> 00:14:32,758
AS HE CARVES HAIR DETAILS
208
00:14:32,758 --> 00:14:35,413
INTO THE HEAD
OF THIS FRENCH CAVALRY FIGURE,
209
00:14:35,413 --> 00:14:39,241
HE'S CAREFUL TO NOT LEAVE
ANY PROTRUDING BITS.
210
00:14:39,241 --> 00:14:42,793
OTHERWISE, PLASTIC COULD SNAG
ON MOLDS MADE FROM THEM,
211
00:14:42,793 --> 00:14:46,103
JEOPARDIZING THE PRODUCTION
OF THE PLASTIC VERSIONS.
212
00:14:49,965 --> 00:14:52,310
WITH CURING TIME BETWEEN LAYERS,
213
00:14:52,310 --> 00:14:56,034
IT TAKES ABOUT A WEEK TO SCULPT
THIS FRENCH CAVALRY MODEL.
214
00:15:00,827 --> 00:15:02,206
THEY'RE READY TO MAKE MOLDS
215
00:15:02,206 --> 00:15:05,172
FROM THE SMALLER SCALE
MODELS NOW.
216
00:15:05,172 --> 00:15:07,655
THE MOLD MAKER
ARRANGES THE EPOXY MODELS
217
00:15:07,655 --> 00:15:09,896
ON A SILICONE RUBBER DISK.
218
00:15:13,310 --> 00:15:16,068
HE PRESSES EACH ONE
INTO THE RUBBER.
219
00:15:16,068 --> 00:15:19,241
THE ENDS LEAVE LITTLE DENTS.
220
00:15:19,241 --> 00:15:21,827
HE REMOVES THE MODEL
AND SLICES IT INTO THE RUBBER
221
00:15:21,827 --> 00:15:24,241
WITH A SURGICAL SCALPEL,
222
00:15:24,241 --> 00:15:28,758
CUTTING HOLES WHERE THE FIGURES
HAVE LEFT THE INDENTATIONS.
223
00:15:28,758 --> 00:15:31,206
HE REMOVES THE SILICONE CUTOUTS,
224
00:15:31,206 --> 00:15:35,172
THEN CARVES A NARROW CHANNEL
TO CONNECT THE TWO SLOTS.
225
00:15:38,862 --> 00:15:42,103
HE INSERTS THE MODEL
INTO THE NICHE.
226
00:15:42,103 --> 00:15:44,689
HE REPEATS THIS PROCESS
WITH THE OTHER SOLDIERS
227
00:15:44,689 --> 00:15:46,310
ON THE DISK,
228
00:15:46,310 --> 00:15:49,586
THEN PLACES THE DISK
IN A PREHEATED STEEL VESSEL.
229
00:15:51,896 --> 00:15:53,758
HE PUTS A LID ON THE VESSEL
230
00:15:53,758 --> 00:15:58,034
AND TRANSFERS IT
TO A VULCANIZING PRESS.
231
00:15:58,034 --> 00:16:02,862
IN THE PRESS, HEATED PLATES
SQUEEZE IT USING PRESSURE.
232
00:16:02,862 --> 00:16:05,206
THIS SOFTENS THE RUBBER INSIDE,
233
00:16:05,206 --> 00:16:08,655
MELTING AROUND THE FIGURES,
PICKING UP THE CONTOURS.
234
00:16:12,827 --> 00:16:16,379
THIS TRANSFERS THE DISK
INTO A MOLD.
235
00:16:19,241 --> 00:16:21,862
COMING UP NEXT, THE MINIATURES
236
00:16:21,862 --> 00:16:24,517
EMERGE FROM THE MOLD SHELL
BATTLE-READY.
237
00:16:37,551 --> 00:16:39,413
Narrator:
IN THE AGE OF VIDEO GAMES,
238
00:16:39,413 --> 00:16:42,931
TABLETOP WAR GAMES
STILL HAVE PLENTY OF FANS.
239
00:16:42,931 --> 00:16:44,965
THE CHALLENGE BEGINS
WITH THE ACQUISITION
240
00:16:44,965 --> 00:16:47,758
OF SMALL ARMIES OF MINIATURES.
241
00:16:47,758 --> 00:16:49,689
PLAYERS HAND-PAINT THE SOLDIERS
242
00:16:49,689 --> 00:16:52,862
AND BUILD ELABORATE BACKDROPS
WITH SCENERY.
243
00:16:52,862 --> 00:16:54,724
THEN THE GAMES BEGIN.
244
00:16:59,896 --> 00:17:01,896
AS PRODUCTION CONTINUES,
245
00:17:01,896 --> 00:17:06,827
THE MOLD-MAKER CARVES CHANNELS
INTO THE SILICONE DISK.
246
00:17:06,827 --> 00:17:08,793
HE LINKS THE CHANNELS
TO THE IMPRESSIONS
247
00:17:08,793 --> 00:17:11,517
OF MINIATURE SOLDIERS
AND MILITARY MACHINERY
248
00:17:11,517 --> 00:17:13,689
THAT HAVE BEEN CREATED
BY THE MODELS.
249
00:17:16,517 --> 00:17:20,000
THE CHANNELS ALLOW MOLTEN METAL
TO FLOW INTO THE IMPRESSIONS
250
00:17:20,000 --> 00:17:22,310
IN ORDER TO CAST COPIES.
251
00:17:24,517 --> 00:17:25,896
IN THE STOREROOM,
252
00:17:25,896 --> 00:17:28,862
THERE ARE THOUSANDS
OF SILICONE MOLDS,
253
00:17:28,862 --> 00:17:32,758
EACH DEPICTING
DIFFERENT CHARACTERS AND PROPS.
254
00:17:32,758 --> 00:17:34,275
WHEN THE ORDER COMES IN,
255
00:17:34,275 --> 00:17:36,551
AN APPRENTICE
MAKES THE SELECTION.
256
00:17:39,758 --> 00:17:43,724
NEXT, AN OPERATOR PUTS THE MOLD
IN A CASTING MACHINE.
257
00:17:46,517 --> 00:17:48,310
AS THE MOLD SPINS
IN THE MACHINE,
258
00:17:48,310 --> 00:17:51,413
HE ADDS MOLTEN TIN
THROUGH AN OPENING IN THE LID.
259
00:17:51,413 --> 00:17:54,551
THE SPINNING
THROWS THE LIQUID TIN
260
00:17:54,551 --> 00:17:56,379
INTO THE MOLD CREVICES.
261
00:17:58,793 --> 00:18:01,448
AFTER THE CASTING SOLIDIFIES
AND COOLS,
262
00:18:01,448 --> 00:18:04,103
HE EXTRACTS
THE LITTLE TIN SOLDIERS.
263
00:18:08,000 --> 00:18:10,413
THESE TIN WAR FIGURES
ARE ON THEIR WAY
264
00:18:10,413 --> 00:18:12,724
TO THE GAMING FRONT LINES.
265
00:18:14,931 --> 00:18:18,068
MAKING PLASTIC WAR FIGURES
STARTS WITH AN EPOXY RESIN
266
00:18:18,068 --> 00:18:20,620
FOR A PATTERN.
267
00:18:20,620 --> 00:18:22,827
THEY ADD A HARDENER
AND BLEND THE BATCH
268
00:18:22,827 --> 00:18:26,241
TO THE CONSISTENCY
OF PANCAKE BATTER.
269
00:18:26,241 --> 00:18:28,689
THEY TRANSFER IT
TO A LARGER BUCKET
270
00:18:28,689 --> 00:18:30,793
AND PLACE IT
IN A VACUUM CHAMBER,
271
00:18:30,793 --> 00:18:32,482
WHICH PULLS OUT THE AIR.
272
00:18:32,482 --> 00:18:36,655
IN THE PROCESS,
THE EPOXY SWELLS.
273
00:18:36,655 --> 00:18:39,103
ONCE THE EPOXY MIXTURE DEFLATES,
274
00:18:39,103 --> 00:18:41,827
A TEAM BRUSHES IT
ONTO SCULPTED MILITARY MODELS
275
00:18:41,827 --> 00:18:44,103
ARRANGED IN A STEEL BOX.
276
00:18:46,517 --> 00:18:50,655
AFTER FILLING ALL THE CREVICES,
THEY DISPENSE MORE EPOXY.
277
00:18:50,655 --> 00:18:53,000
A CHUTE ENSURES A GENTLE FLOW,
278
00:18:53,000 --> 00:18:56,482
PREVENTING THE BUILDUP
OF MORE BUBBLES.
279
00:18:56,482 --> 00:18:58,793
THEY REPEAT THIS ON THE OTHER
SIDE OF THE MODELS
280
00:18:58,793 --> 00:19:00,862
TO CREATE A TWO-PART PATTERN.
281
00:19:02,827 --> 00:19:04,620
ONCE THE EPOXY HARDENS,
282
00:19:04,620 --> 00:19:06,172
THEY MILL THE OUTSIDE
OF THE PATTERN
283
00:19:06,172 --> 00:19:08,965
TO PRE-DETERMINED MEASUREMENTS.
284
00:19:08,965 --> 00:19:12,724
AN EMPLOYEE THEN OPENS IT
AND DISCARDS THE MODELS.
285
00:19:12,724 --> 00:19:15,655
HE INSPECTS THE IMPRESSIONS
THEY'VE LEFT.
286
00:19:15,655 --> 00:19:19,482
THEY USE THIS PATTERN TO MAKE
A SMALLER-SCALE MOLD FROM STEEL.
287
00:19:22,862 --> 00:19:26,034
USING AN AUTOMATED SAW,
THEY CARVE SMALLER PIECES
288
00:19:26,034 --> 00:19:28,517
FROM A BLOCK
OF NICKEL CHROME STEEL.
289
00:19:31,896 --> 00:19:34,827
AN AUTOMATED MILLING TOOL
MACHINES THE SMALLER BLOCKS
290
00:19:34,827 --> 00:19:36,758
SO THE TWO OF THEM
WILL FIT TOGETHER
291
00:19:36,758 --> 00:19:39,000
TO CREATE ONE MOLD SET.
292
00:19:41,586 --> 00:19:43,862
A CARRIAGE SHUNTS THE BLOCK
BACK AND FORTH
293
00:19:43,862 --> 00:19:45,517
BETWEEN AN ABRASIVE WHEEL
294
00:19:45,517 --> 00:19:49,000
TO GRIND THE SURFACE
TO PRECISE MEASUREMENTS.
295
00:19:52,655 --> 00:19:54,586
A MOLD-MAKER
FOLLOWS THE IMPRESSIONS
296
00:19:54,586 --> 00:19:56,931
IN THE EPOXY PATTERN
WITH A STYLUS,
297
00:19:56,931 --> 00:19:59,000
WHICH MOVES
A NEEDLE-LIKE CUTTER.
298
00:20:01,413 --> 00:20:04,517
THE CUTTER ETCHES A TEMPLATE
INTO THE STEEL BLOCK
299
00:20:04,517 --> 00:20:05,793
THAT'S THREE TIMES SMALLER
300
00:20:05,793 --> 00:20:07,793
THAN THE ONE
IN THE EPOXY PATTERN.
301
00:20:12,034 --> 00:20:15,620
USING A WAND THAT GENERATES
HIGH-FREQUENCY VIBRATIONS,
302
00:20:15,620 --> 00:20:20,000
HE POLISHES THE ETCHINGS
IN THE STEEL MOLD.
303
00:20:20,000 --> 00:20:21,413
IT'S A GENTLE POLISH
304
00:20:21,413 --> 00:20:24,448
THAT DOESN'T DAMAGE ANY OF
THE ETCHING IN THE MOLD BLOCK.
305
00:20:28,758 --> 00:20:30,413
THEY DRILL CHANNELS IN THE STEEL
306
00:20:30,413 --> 00:20:33,896
TO ALLOW PLASTIC TO FLOW
TO THE IMPRESSIONS.
307
00:20:33,896 --> 00:20:37,620
THEY ALSO INSERT
WATER-COOLING PIPES.
308
00:20:37,620 --> 00:20:42,206
THEY'RE READY TO MASS-PRODUCE
PLASTIC WAR FIGURES.
309
00:20:42,206 --> 00:20:44,137
THE MACHINE MELTS PLASTIC
310
00:20:44,137 --> 00:20:47,413
AND INJECTS IT UNDER PRESSURE
INTO THE MOLD SET.
311
00:20:47,413 --> 00:20:49,689
THE PLASTIC HARDENS,
AND THE MACHINE
312
00:20:49,689 --> 00:20:53,517
EJECTS THE LITTLE SOLDIERS
CONNECTED BY RUNNERS.
313
00:20:53,517 --> 00:20:56,724
THIS PARTICULAR PRODUCTION
INCLUDES MINIATURE RIFLES
314
00:20:56,724 --> 00:20:59,655
AND OTHER
MILITARY PARAPHERNALIA.
315
00:20:59,655 --> 00:21:03,551
THEY PACK THE PLASTIC SOLDIERS,
THEIR HORSES, AND THEIR GUNS
316
00:21:03,551 --> 00:21:05,689
INTO BOXES FOR RETAIL
317
00:21:05,689 --> 00:21:08,000
ALONG WITH INSTRUCTIONS
FOR PAINTING.
318
00:21:13,172 --> 00:21:15,379
AFTER PAINTING,
THE PLASTIC SOLDIERS
319
00:21:15,379 --> 00:21:18,862
AND THEIR TIN COMRADES
ARE IN TIP-TOP MILITARY FORM
320
00:21:18,862 --> 00:21:22,000
AND READY FOR BATTLE.
321
00:21:22,000 --> 00:21:23,517
THERE WILL BE CASUALTIES.
322
00:21:23,517 --> 00:21:27,827
BUT OF COURSE,
IT'S ALL JUST FOR FUN.
323
00:21:27,827 --> 00:21:30,965
THESE MINIATURE WAR FIGURES
ARE SURVIVORS.
324
00:21:30,965 --> 00:21:34,137
THEY WILL LIVE ON
TO FIGHT MANY MORE BATTLES.
25492
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