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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
Today on "How it's made,"
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Macarons...
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Pine-needle baskets...
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And micrometers.
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Meringue cookies with
A flavored filling,
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Macarons were first produced
In the eighth century
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In venetian monasteries.
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In 1533,
The recipe came to france
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With the pastry chefs brought
By the italian noblewoman
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Who arrived to marry the king.
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Macarons have been
Considered french ever since.
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Macarons are as much a treat
For the eyes as for the mouth,
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With colorful meringue shells
Sandwiching a flavorful filling.
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To prepare what's known as
Italian meringue for the shells,
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The bakers combine
Sugar and water.
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They heat the mixture
To precisely
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222 degrees fahrenheit,
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Slightly above
The boiling point.
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In a mixing bowl,
The bakers combine egg whites
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With dehydrated egg whites.
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Using a combination of liquid
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And dried egg whites reduces
The amount of moisture
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In the meringue mixture.
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When there's less moisture,
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It's easier to control
The baking.
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Workers mix the egg whites
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00:02:06,103 --> 00:02:09,241
For about 8 to 10 minutes
To make an emulsion,
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00:02:09,241 --> 00:02:13,793
Then add the boiling water
And sugar.
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The combination mixes
Until the temperature
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Drops to 104 degrees fahrenheit.
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No thermometer is necessary.
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Bakers can tell by
The stiff texture
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Of what is now meringue.
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The next step is to flavor
And color the meringue.
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Workers weigh very precise
Quantities of almond powder...
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...Then icing sugar.
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They transfer these ingredients
To the mixer...
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...And blend them thoroughly.
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The baker adds
The blended almond powder
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And icing sugar to a mixture
Of egg whites
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And, in this case,
Red food coloring
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Because these will be
Raspberry macarons.
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They resume mixing for another
Two or three minutes
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Until everything
Is thoroughly blended.
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Then the baker
Adds this mixture
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To the meringue
To color and flavor it.
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Five more minutes of blending,
And the meringue is ready.
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It's time to form
The meringue shells.
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A worker pours the meringue
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Into the feed vat
Of the depositer.
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The depositer dispenses
5-gram disks of meringue,
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60 disks per lined baking sheet.
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Using a micrometer,
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A worker measures
Each disk to make sure
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It's between 1.69
And 1.77 inches in diameter.
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Meringue expands with baking,
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So this ensures each disk
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Will bake into a shell
That's the correct size.
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Then, fans blow air
To dry out the tops.
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Evaporating
The moisture prevents
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The top of the disks from rising
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As they bake in the oven
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For 15 to 20 minutes
At 249 degrees fahrenheit.
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When they come out of the oven,
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The baked shells
Are set out to cool.
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Meanwhile, the bakers
Prepare the filling,
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Mixing chocolate with
Piping-hot 35% cream.
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As the chocolate melts,
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They blend
The ingredients thoroughly.
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Then the baker refrigerates
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The filling for 12 hours
At 48 degrees fahrenheit.
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When the filling comes
Out of the fridge,
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It's firm but malleable enough
To be scooped up
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And put in a pastry bag.
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With filling and shells
Now ready,
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The baker can begin
Assembling the macarons.
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They squeeze about 5 grams
Of filling onto each shell...
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...Then place
Another shell on top,
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Pressing gently to spread
The filling outward.
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The macarons fit perfectly
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Into the slots of
Plastic retail trays,
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Thanks to the careful measuring
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Of the meringue disks
Prior to baking.
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The trays pass through a machine
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Which seals them in
A pocket of plastic film
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To keep out moisture.
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Then, each tray is packaged
In a retail box.
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This colorful selection features
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Five flavors of macarons --
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Raspberry, blueberry, lemon,
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Cherry, and exotic fruits.
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Narrator:
When indigenous north americans
Needed containers,
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They looked no further
Than the pine needles
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That littered the forest floor.
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They wove the needles
Into sturdy baskets
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For their daily use.
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The making of these
Coniferous containers
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Continues today,
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Ensuring that it doesn't
Become a lost art.
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Pine-needle baskets
Are beautiful examples
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Of resourcefulness.
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They prove that something
Substantial can be made
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From needles
That would otherwise
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Just end up on the ground
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And be trampled on.
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The norway red pine
In the northern united states
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Sheds needles in the fall.
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Just before they drop,
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They can be easily
Plucked from the branches.
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This forager also
Collects needles
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That have fallen to the ground.
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He tosses some pinecones
Into the bag too.
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Back in the studio,
A craftsperson immerses
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The needles in boiling water
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And simmers them
For five minutes.
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This softens the needles
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So that they're flexible
Enough to work with.
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She selects a pinecone
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And boils it for 15
Or 20 minutes.
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This causes the scales
To close up,
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And the cone shrinks.
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Here are the pinecones
Before and after boiling.
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The shrunken cone will serve
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As a handle for a basket lid.
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After winding waxed linen thread
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Around the cone's base,
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The craftsperson loops thread
Around the strands
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To hold them firmly together.
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She now coils a bundle
Of pine needles around the cone
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And sews them to it.
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She sets the cone aside for now.
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Next, for an effect
That is simply decorative,
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The craftsperson coils
Pine needles
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Around a colorful piece of stone
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That's been sealed in acrylic.
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Holes around the edge
Of the acrylic envelope
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Make it easier to stitch
The pine-needle coil
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00:08:16,344 --> 00:08:18,068
To the decorative center.
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The craftsperson gives
Each stitch a gentle tug
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To pull the coils snuggly
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00:08:28,379 --> 00:08:32,758
So that it encompasses
The acrylic edge.
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This decorative center
Is now ready to be used
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00:08:35,241 --> 00:08:39,620
As a starting point
For a basket or a lid.
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Using another technique,
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She crafts a basket center
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Using only softened pine needles
And thread.
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This will be a bit trickier.
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Using pliers,
She pulls off the sheaths
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That hold the groupings
Of needles together.
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Without the sheaths in the way,
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It will be easier
To work with the needles.
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00:09:02,551 --> 00:09:04,758
The craftsperson
Now takes a bundle
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00:09:04,758 --> 00:09:06,965
That's almost the thickness
Of a pencil
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00:09:06,965 --> 00:09:09,379
And forms a small loop.
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She ties a knot
At the cross point.
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She stitches the bundle
All the way around,
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Creating a spiral
With a threaded pattern
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That radiates outward,
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Like spokes on a wheel.
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The craftsperson continually
Tucks more pine needles
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Into the tail of the spiral
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To make it thicker
And more even.
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She then weaves a basket base
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From the center spiral outward.
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She stitches each coil of pine
Needles to the one before it.
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00:09:45,172 --> 00:09:48,379
And she aligns the stitching
To create a decorative pattern
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That adds to the appeal
Of the basket.
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The craftsperson
Now tucks in pine needles
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With the black sheaths still on,
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To add even more
Visual interest.
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She artfully arranges them
Around the basket base
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And stitches them to it.
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From start to finish,
It takes about 12 hours
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To craft the entire basket.
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After completing the lid
With the decorative stone,
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The craftsperson tests the fit.
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For an alternative
Embellishment,
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She weaves red dogwood twigs
Into a pine-needle basket.
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It's another way to be creative
With the materials
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That nature offers up
In abundance.
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Each one of these pine-needle
Baskets is an original,
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Handcrafted by an artisan.
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And that makes them
Worth holding on to.
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Narrator:
A micrometer is a handheld
Precision-measuring tool
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Typically used in manufacturing.
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A toolmaker producing parts
For factory equipment
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00:11:16,827 --> 00:11:19,517
Or a machinist making parts
For a product
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Would use a micrometer
To take precision measurements
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00:11:22,620 --> 00:11:25,034
To make sure
The part dimensions confirm
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00:11:25,034 --> 00:11:28,896
To engineering specifications.
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00:11:28,896 --> 00:11:30,862
Micrometers
Come in different types
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00:11:30,862 --> 00:11:32,965
And ranges of measurement.
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00:11:32,965 --> 00:11:34,620
This model is
Designed to measure
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00:11:34,620 --> 00:11:37,172
The outside diameter
Of an object.
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The graduations are in
Imperial units up to 1 inch.
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00:11:40,896 --> 00:11:43,586
The micrometer's frame starts
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00:11:43,586 --> 00:11:45,413
Out as a forged-steel part
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00:11:45,413 --> 00:11:48,896
That needs to be machined
To the final shape.
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00:11:48,896 --> 00:11:53,068
Workers secure the part
On a mechanical milling machine.
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00:11:53,068 --> 00:11:56,793
The machine first
Squares the ends...
203
00:11:59,551 --> 00:12:02,068
...Then slices the part
Down the middle,
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00:12:02,068 --> 00:12:06,620
Dividing it into frames
For two micrometers.
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00:12:06,620 --> 00:12:09,965
A computer-guided mill
Profiles the frame.
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00:12:09,965 --> 00:12:15,310
This is the forged frame
Before this step and after.
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00:12:15,310 --> 00:12:18,103
Another computer-guided mill
Reduces the inside
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00:12:18,103 --> 00:12:22,862
And outside diameters
Of the frame's hollow stem.
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00:12:22,862 --> 00:12:26,344
Workers insert a nut
In the stem,
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00:12:26,344 --> 00:12:28,000
Then dip a piece of solder
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00:12:28,000 --> 00:12:30,586
Into a soldering chemical
Called flux
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00:12:30,586 --> 00:12:34,103
And insert it through
A hole in the stem.
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00:12:34,103 --> 00:12:36,965
They hold the stem
Inside a soldering coil.
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00:12:36,965 --> 00:12:39,931
The heat instantly
Melts the solder,
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00:12:39,931 --> 00:12:42,620
Fusing the nut to the stem.
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00:12:42,620 --> 00:12:46,241
Workers remove excess solder
With a wire brush.
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00:12:50,689 --> 00:12:54,793
Then, they grind the stem
To finalize the diameter.
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00:12:57,896 --> 00:12:59,413
Here's what the stem looks like
219
00:12:59,413 --> 00:13:03,724
Before this last grinding
And after.
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00:13:03,724 --> 00:13:06,068
Next, on the opposite end
Of the frame,
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00:13:06,068 --> 00:13:07,793
They mill a notch.
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00:13:07,793 --> 00:13:09,655
This is for the lock nut
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00:13:09,655 --> 00:13:11,862
That locks the micrometer
Against the object
224
00:13:11,862 --> 00:13:13,586
While you read the measurement.
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00:13:19,034 --> 00:13:21,758
Workers now sandblast
The entire frame.
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00:13:21,758 --> 00:13:26,275
This removes all traces of metal
Dust and machining lubricant,
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00:13:26,275 --> 00:13:28,689
Leaving the surface pristine,
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00:13:28,689 --> 00:13:31,620
A requirement
For the next step --
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00:13:31,620 --> 00:13:34,827
Electroplating the frame
With chrome.
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00:13:34,827 --> 00:13:36,689
They complete
The micrometer's frame
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00:13:36,689 --> 00:13:39,068
By laser-marking the brand name
232
00:13:39,068 --> 00:13:41,068
And a reference chart
Of measurements
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00:13:41,068 --> 00:13:46,034
In fractions of an inch
And the decimal equivalents.
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00:13:46,034 --> 00:13:48,275
This machine shapes
A long steel rod
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00:13:48,275 --> 00:13:50,517
Into the micrometer's
Inside shell,
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00:13:50,517 --> 00:13:53,206
Which, in conjunction
With the outside shell,
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00:13:53,206 --> 00:13:56,034
Displays
The measurement reading.
238
00:13:56,034 --> 00:13:58,758
The machine first drills
Through the rod
239
00:13:58,758 --> 00:14:01,586
To form a hollow cylinder.
240
00:14:01,586 --> 00:14:03,586
Next, it reams the inside
241
00:14:03,586 --> 00:14:08,034
And grinds the outside
To the required diameter.
242
00:14:08,034 --> 00:14:10,965
The same machine
Also shapes a steel rod
243
00:14:10,965 --> 00:14:13,689
Into the micrometer's
Outside shell.
244
00:14:13,689 --> 00:14:17,655
It carves a diamond pattern
Onto it called a knurl.
245
00:14:17,655 --> 00:14:22,793
This textures the surface,
Making it easier to grip.
246
00:14:22,793 --> 00:14:24,379
Then the machines reams
247
00:14:24,379 --> 00:14:27,000
The inside
To the required diameter.
248
00:14:29,896 --> 00:14:32,310
After sandblasting both shells,
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00:14:32,310 --> 00:14:34,310
Workers hang them on a rack,
250
00:14:34,310 --> 00:14:37,620
Then dip the rack into
A tank of chromic acid.
251
00:14:37,620 --> 00:14:39,379
Copper prongs on the rack
252
00:14:39,379 --> 00:14:42,275
Deliver a positive
Electrical current to the shells
253
00:14:42,275 --> 00:14:44,172
While the chromic acid
Is charged
254
00:14:44,172 --> 00:14:45,413
With a negative current.
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00:14:45,413 --> 00:14:47,827
This magnetically draws
A chrome layer
256
00:14:47,827 --> 00:14:50,310
Onto the surface of the shells.
257
00:14:53,241 --> 00:14:56,793
Then a computer-guided laser
Marks the brand name
258
00:14:56,793 --> 00:14:58,689
And the graduations
On the inside
259
00:14:58,689 --> 00:15:02,034
And outside shells.
260
00:15:02,034 --> 00:15:05,172
This computer-guided mill
Shapes a steel rod
261
00:15:05,172 --> 00:15:07,517
Into the micrometer's
Key measuring component,
262
00:15:07,517 --> 00:15:09,827
The spindle.
263
00:15:09,827 --> 00:15:13,275
The machine first
Profiles the outside.
264
00:15:13,275 --> 00:15:15,793
Then it drills a hole
1/2 inch deep
265
00:15:15,793 --> 00:15:18,689
And reams it
To the correct diameter.
266
00:15:21,172 --> 00:15:23,413
It's critical that
The spindle not wear down
267
00:15:23,413 --> 00:15:24,862
With long-term use,
268
00:15:24,862 --> 00:15:28,862
As this would effect the
Micrometer's measuring accuracy.
269
00:15:28,862 --> 00:15:31,379
To prevent this,
They harden the steel through
270
00:15:31,379 --> 00:15:33,103
A heat-treatment process.
271
00:15:33,103 --> 00:15:35,793
First, workers put the spindles
272
00:15:35,793 --> 00:15:40,413
In a furnace at a temperature
Of 1,526 degrees fahrenheit.
273
00:15:40,413 --> 00:15:43,793
After an hour, they submerge
The spindles in oil,
274
00:15:43,793 --> 00:15:47,206
Then freeze them overnight
To stabilize the steel.
275
00:15:47,206 --> 00:15:50,137
The next day,
Workers temper the steel
276
00:15:50,137 --> 00:15:52,931
By putting the spindles back
In the furnace for an hour,
277
00:15:52,931 --> 00:15:56,137
This time at
A lower temperature.
278
00:15:56,137 --> 00:15:58,000
Once the spindles cool,
279
00:15:58,000 --> 00:16:01,241
A machining tool
Grinds threads into them.
280
00:16:01,241 --> 00:16:03,862
The precision of that
Threading determines
281
00:16:03,862 --> 00:16:06,793
The micrometer's
Measurement accuracy.
282
00:16:17,137 --> 00:16:18,862
Narrator: to use a micrometer,
283
00:16:18,862 --> 00:16:20,517
You place the object
You're measuring
284
00:16:20,517 --> 00:16:25,206
Against the stationary end
Of the frame called the anvil.
285
00:16:25,206 --> 00:16:27,896
Then you rotate the spindle
On the opposite end
286
00:16:27,896 --> 00:16:30,379
Until it's seated
Against the object.
287
00:16:30,379 --> 00:16:32,517
You turn the nut
To lock that position
288
00:16:32,517 --> 00:16:36,655
And read the measurement.
289
00:16:36,655 --> 00:16:40,413
The spindle for this model
Has 40 threads per inch.
290
00:16:40,413 --> 00:16:43,413
So turning it one revolution
In either direction
291
00:16:43,413 --> 00:16:46,655
Moves it 25/1,000 inch.
292
00:16:46,655 --> 00:16:48,620
If the steel
Hadn't been hardened,
293
00:16:48,620 --> 00:16:51,068
Those threads would
Wear down over time,
294
00:16:51,068 --> 00:16:53,586
Causing inaccurate measurements.
295
00:16:53,586 --> 00:16:55,517
For the same reason,
296
00:16:55,517 --> 00:16:57,448
This disk they now
Prepare to solder
297
00:16:57,448 --> 00:16:59,103
Onto the face of the spindle
298
00:16:59,103 --> 00:17:01,517
Is made of tungsten carbide,
299
00:17:01,517 --> 00:17:04,413
The hardest type of steel.
300
00:17:04,413 --> 00:17:06,689
After fluxing the face
Of the spindle,
301
00:17:06,689 --> 00:17:08,655
Topping it with
The disk of solder,
302
00:17:08,655 --> 00:17:12,620
And positioning the fluxed
Carbide disk on top of that,
303
00:17:12,620 --> 00:17:16,241
Workers place the spindle inside
The hot soldering machine
304
00:17:16,241 --> 00:17:19,344
To fuse the carbide
To the face of the spindle.
305
00:17:23,758 --> 00:17:27,206
They grind the diameter
Of the carbide disk to reduce it
306
00:17:27,206 --> 00:17:31,000
To the same diameter
As the spindle.
307
00:17:31,000 --> 00:17:32,275
After this grinding,
308
00:17:32,275 --> 00:17:33,896
The disk becomes integrated
309
00:17:33,896 --> 00:17:37,689
With the rest of the spindle.
310
00:17:37,689 --> 00:17:41,586
They grind the face
Of the carbide disk flat.
311
00:17:41,586 --> 00:17:44,103
Then this lapping machine
Polishes the face
312
00:17:44,103 --> 00:17:45,586
To perfect the flatness
313
00:17:45,586 --> 00:17:49,310
And produces a mirror finish.
314
00:17:49,310 --> 00:17:51,448
They perform
A quality-control check
315
00:17:51,448 --> 00:17:54,965
With an optical parallel
Made of sapphire.
316
00:17:54,965 --> 00:17:57,931
It projects bands of light
Which detect flatness
317
00:17:57,931 --> 00:18:01,793
To a degree the human eye
Can't perceive.
318
00:18:01,793 --> 00:18:06,137
This second test reflects light
Off the mirror-finish face.
319
00:18:06,137 --> 00:18:07,965
When rotating the spindle,
320
00:18:07,965 --> 00:18:10,551
The light should stand still.
321
00:18:10,551 --> 00:18:12,068
This indicates the face
322
00:18:12,068 --> 00:18:15,206
Is perfectly perpendicular
To the diameter.
323
00:18:15,206 --> 00:18:17,551
The micrometer's anvil,
324
00:18:17,551 --> 00:18:19,586
The fixed surface
Opposite the spindle
325
00:18:19,586 --> 00:18:22,172
Against which you place
The object you're measuring,
326
00:18:22,172 --> 00:18:24,586
Is also machined from carbide.
327
00:18:26,827 --> 00:18:28,724
To assemble the micrometer,
328
00:18:28,724 --> 00:18:30,344
A worker places a spring
329
00:18:30,344 --> 00:18:33,586
In a recessed area
Of the frame stem,
330
00:18:33,586 --> 00:18:36,586
Then the inside shell
Onto the stem.
331
00:18:36,586 --> 00:18:38,172
The spring applies
Enough tension
332
00:18:38,172 --> 00:18:40,827
To hold the shell in place.
333
00:18:40,827 --> 00:18:43,586
The inside of the stem
Will have female threads
334
00:18:43,586 --> 00:18:47,517
To match male threads
On the spindle.
335
00:18:47,517 --> 00:18:50,275
This adjusting nut
On the end of the stem
336
00:18:50,275 --> 00:18:51,862
Controls the thread engagement
337
00:18:51,862 --> 00:18:53,206
Between the two,
338
00:18:53,206 --> 00:18:56,241
Enabling the spindle to move
More tightly or loosely.
339
00:18:57,586 --> 00:19:00,310
The next step is cutting
Those female threads
340
00:19:00,310 --> 00:19:02,862
Into the inside of the stem.
341
00:19:02,862 --> 00:19:07,206
First, a worker reams the stem
To the required diameter,
342
00:19:07,206 --> 00:19:11,310
Then switch the reaming tool
On the lathe for a tapping tool.
343
00:19:11,310 --> 00:19:13,931
Tapping is the term
For cutting threads.
344
00:19:13,931 --> 00:19:16,172
They put the stem
Back on the lathe
345
00:19:16,172 --> 00:19:19,620
And tap
40 female threads per inch.
346
00:19:19,620 --> 00:19:23,241
Now, workers can assemble
The spindle to the stem.
347
00:19:23,241 --> 00:19:24,482
They mount the spindle
348
00:19:24,482 --> 00:19:26,724
On an automatic lapping machine.
349
00:19:26,724 --> 00:19:29,862
Then a worker slides the stem
Over the spindle,
350
00:19:29,862 --> 00:19:32,275
Going back and forth
Multiple times
351
00:19:32,275 --> 00:19:35,137
To fit both sets
Of threads together.
352
00:19:35,137 --> 00:19:38,000
They lubricate the threads
With instrument oil
353
00:19:38,000 --> 00:19:42,241
So they'll glide smoothly
Against each other.
354
00:19:42,241 --> 00:19:44,689
After assembling the lock nut
In its notch,
355
00:19:44,689 --> 00:19:47,655
The worker cleans
The spindle face with alcohol
356
00:19:47,655 --> 00:19:51,896
And glues the anvil to it
Temporarily.
357
00:19:51,896 --> 00:19:53,482
Then they rotate the spindle
358
00:19:53,482 --> 00:19:56,620
Until the anvil reaches
Its adhesive-coated position
359
00:19:56,620 --> 00:19:59,620
At the opposite end
Of the frame.
360
00:19:59,620 --> 00:20:01,206
When the adhesive sets,
361
00:20:01,206 --> 00:20:05,206
The worker separates
The spindle and anvil.
362
00:20:05,206 --> 00:20:07,965
Using an optical parallel,
They check the spindle
363
00:20:07,965 --> 00:20:09,896
And anvil faces to make sure
364
00:20:09,896 --> 00:20:14,413
They're perfectly
Parallel to each other.
365
00:20:14,413 --> 00:20:16,241
The worker completes
The assembly
366
00:20:16,241 --> 00:20:19,275
By fitting the outside shell
To the frame.
367
00:20:19,275 --> 00:20:23,827
It covers the end of the spindle
That's protruding from the stem.
368
00:20:23,827 --> 00:20:26,379
A steel ratchet
Locks it into position.
369
00:20:29,413 --> 00:20:31,931
A final round of
Quality-control testing
370
00:20:31,931 --> 00:20:34,103
Ensures the device
Works smoothly
371
00:20:34,103 --> 00:20:36,965
And measures accurately.
372
00:20:36,965 --> 00:20:38,758
In this test, they measure
373
00:20:38,758 --> 00:20:44,034
Four different-sized
Measuring blocks.
374
00:20:44,034 --> 00:20:47,310
In this one, they bring out
Those optical parallels again
375
00:20:47,310 --> 00:20:50,000
To check flatness
And parallelism.
376
00:20:52,862 --> 00:20:55,586
They also perform
A cosmetic inspection
377
00:20:55,586 --> 00:20:58,793
And check that the graduations
Are all legible
378
00:20:58,793 --> 00:21:01,724
Because, of course,
No one wants a micrometer
379
00:21:01,724 --> 00:21:03,241
That doesn't measure up.
29396
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