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Throughout europe in the late 1700s,
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peaked caps were traditionally
worn by industrial workers.
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00:01:00,428 --> 00:01:02,428
Today, they are worn
by professionals
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00:01:02,430 --> 00:01:06,165
such as security personnel,
members of the military,
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00:01:06,167 --> 00:01:09,068
and police officials
that wear uniforms.
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00:01:13,307 --> 00:01:15,874
In the united kingdom,
some police officers
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00:01:15,876 --> 00:01:18,677
still wear
the classic custodian helmet,
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00:01:18,679 --> 00:01:21,313
but now many officers
have chosen to wear
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the lightweight, comfortable,
and practical peaked cap.
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To make these caps,
a hat maker, or a milliner,
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00:01:30,724 --> 00:01:33,759
assembles a number of components
using patterns
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00:01:33,761 --> 00:01:38,397
to cut out the required pieces
of wool, foam, and plastic.
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00:01:38,399 --> 00:01:41,700
A milliner bends a strip
of polypropylene plastic
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00:01:41,702 --> 00:01:44,169
into a circle.
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00:01:44,171 --> 00:01:47,072
She sews the joint
with a high-strength thread,
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00:01:47,074 --> 00:01:51,410
creating the hat band
that will go around the head.
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00:01:51,412 --> 00:01:54,680
She positions a smaller piece
of polypropylene,
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00:01:54,682 --> 00:01:58,617
known as the badge support,
and sews it in place.
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The support will prevent
the weight of a police badge
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00:02:01,455 --> 00:02:03,889
from distorting
the shape of the hat.
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00:02:06,327 --> 00:02:09,595
These crescent-shaped components
are pieces of wool
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glued to thin, flexible foam.
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00:02:13,100 --> 00:02:17,035
She sews the crescents together,
creating a circular piece,
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00:02:17,037 --> 00:02:19,004
which will form the bevel.
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00:02:19,006 --> 00:02:22,174
She uses a specialized,
long-arm sewing machine,
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00:02:22,176 --> 00:02:24,776
which has been customized
to make hats.
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00:02:27,314 --> 00:02:31,416
The seams are carefully ironed
flat to prevent any bulging.
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00:02:31,418 --> 00:02:34,620
If the iron is too hot,
the foam will melt.
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Too cool,
and the wool won't flatten.
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00:02:37,424 --> 00:02:40,826
She aligns two strips
of 100% wool fabric
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and sews them together
at the ends.
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This piece will cover
the plastic stiffener
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00:02:45,833 --> 00:02:49,468
forming the outer band.
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00:02:49,470 --> 00:02:51,703
To ensure the sizing is correct,
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00:02:51,705 --> 00:02:54,873
the milliner places the wool
cover over the stiffener.
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00:03:00,181 --> 00:03:01,613
the stiffener is installed
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00:03:01,615 --> 00:03:05,284
at the end
of the production process.
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00:03:05,286 --> 00:03:09,188
Next, the milliner irons
the seams of the band covers.
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00:03:11,592 --> 00:03:14,393
She finishes the band covers
on a sewing machine
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00:03:14,395 --> 00:03:16,395
known as a flat bed
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00:03:16,397 --> 00:03:19,731
and creates a fold
to hold the plastic stiffener
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00:03:19,733 --> 00:03:22,601
and sews the edges together.
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00:03:22,603 --> 00:03:26,004
Then the band cover is sewed
to the bevel.
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00:03:26,006 --> 00:03:28,740
While it's difficult to attach
two pieces of cloth
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00:03:28,742 --> 00:03:30,209
at different angles,
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00:03:30,211 --> 00:03:35,347
this step creates an even seam
that runs 360 degrees.
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It takes at least six months
of training
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to learn how to make hats.
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00:03:42,223 --> 00:03:45,023
The crown is made
from three materials --
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00:03:45,025 --> 00:03:48,627
a combination of wool and foam,
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00:03:48,629 --> 00:03:51,530
a polyester lining,
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00:03:51,532 --> 00:03:54,266
and a protective-grade
p.V.C. Layer.
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00:03:56,403 --> 00:03:59,371
Once the three materials
have been sewn together,
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00:03:59,373 --> 00:04:03,976
the machinist trims
the perimeter of the crown.
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00:04:03,978 --> 00:04:05,777
She marks the side edges
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00:04:05,779 --> 00:04:08,513
and aligns them with the seams
on the bevel.
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00:04:11,285 --> 00:04:13,919
Then she sews the crown
to the bevel.
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00:04:13,921 --> 00:04:17,222
Having spent a great deal
of time perfecting the skills,
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00:04:17,224 --> 00:04:19,524
this milliner
makes it look easy.
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00:04:22,496 --> 00:04:26,131
Finally, the components
begin to resemble a hat.
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00:04:28,435 --> 00:04:31,837
Using a polypropylene template,
the machinist positions
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00:04:31,839 --> 00:04:35,340
and marks
two spots on the bevel.
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00:04:35,342 --> 00:04:39,311
She places two small brass rings
on a special device
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00:04:39,313 --> 00:04:42,381
and aligns the marks
with the device's posts,
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which cut out two holes
through the fabric.
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00:04:46,387 --> 00:04:49,921
Then she places two cup-shaped
rings on the posts,
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00:04:49,923 --> 00:04:51,890
and the machine
punches them down,
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00:04:51,892 --> 00:04:55,427
forming eyelets for ventilation.
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00:04:55,429 --> 00:04:57,596
Next,
the polypropylene stiffener
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is inserted into the hat.
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00:04:59,933 --> 00:05:05,370
Finally, the hat begins
to take on its final shape.
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00:05:05,372 --> 00:05:09,341
The tag containing the hat's
size is sewed on hat band.
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00:05:11,378 --> 00:05:14,913
She places a checkered-pattern
band on the brim of the hat,
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called dicing
or the sillitoe tartan.
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00:05:19,520 --> 00:05:21,720
The milliner inserts
a replica badge
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through holes
in the badge support
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and secures it with a pin.
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This is a replica,
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since we can't show
real police badges on tv.
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Next, the milliner sews
the peak onto the band.
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It took a highly skilled
milliner
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more than half an hour
to sew this hat.
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They might look straightforward,
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00:05:49,316 --> 00:05:52,351
but peaked caps
are surprisingly complex.
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A home water heater stores
and heats water in a tank.
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This is how it works.
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When you turn on a faucet,
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00:06:12,039 --> 00:06:14,740
hot water flows out of the tank
from the top,
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00:06:14,742 --> 00:06:17,909
while cold water flows
into the tank from the bottom.
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00:06:17,911 --> 00:06:21,146
Conventional water heaters
are fueled by natural gas,
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electricity, propane, or oil.
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This company custom-builds
several types of water heaters
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for use with different types
of heat sources,
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such as boilers, heat pumps,
and solar panels.
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00:06:35,662 --> 00:06:38,530
Each work order includes
a picture outlining
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the pipe configuration
and the connecting valves,
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along with a list of the
water heater's specifications.
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00:06:46,540 --> 00:06:48,140
To make a copper tank,
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00:06:48,142 --> 00:06:53,211
a technician cuts a thick sheet
of copper to a specified length.
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00:06:53,213 --> 00:06:56,515
He aligns the end of the sheet
to the gradation on the table
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that corresponds to
the tank's circumference.
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Then he actives the guillotine
blade with a foot pedal.
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00:07:04,591 --> 00:07:08,393
A computer-guided machine
punches holes for the valves.
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00:07:08,395 --> 00:07:10,529
This water heater requires
two valves
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00:07:10,531 --> 00:07:12,497
at each end of the heating coil
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00:07:12,499 --> 00:07:15,434
and one that will connect
the water pipe to the tank.
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00:07:19,540 --> 00:07:21,673
The technician inserts
the copper sheet
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into a mechanical roller.
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00:07:23,911 --> 00:07:25,644
The rollers apply pressure,
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forming the sheet
into an open cylinder.
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00:07:32,486 --> 00:07:35,253
One end of the cylinder
is clamped into a machine
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that welds linear seams.
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00:07:41,395 --> 00:07:43,161
The technician inserts
the other end
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of the cylinder
through the machine
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00:07:45,132 --> 00:07:48,166
and joins it
against the clamped end.
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00:07:48,168 --> 00:07:50,569
The machine is programmed
to weld a seam
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00:07:50,571 --> 00:07:54,105
to the length
of the connected ends.
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00:07:54,107 --> 00:07:56,608
The technician monitors
the welding arm
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00:07:56,610 --> 00:08:00,145
through a u.V. Lens
to protect his eyes.
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00:08:00,147 --> 00:08:02,280
The machine stops automatically
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00:08:02,282 --> 00:08:06,251
when it reaches
the programmed seam length.
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00:08:06,253 --> 00:08:08,320
This process closes the cylinder
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00:08:08,322 --> 00:08:10,755
with a strong,
pressure-resistant seam,
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00:08:10,757 --> 00:08:14,993
creating the water-heater
tank's structural component.
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00:08:14,995 --> 00:08:18,530
Another technician places
the tank's top on a press.
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00:08:18,532 --> 00:08:21,533
The press punches a hole
for a threaded pipe fitting.
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00:08:21,535 --> 00:08:24,269
The fitting connects the pipe
to the hot water.
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00:08:24,271 --> 00:08:25,904
Using a different press,
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00:08:25,906 --> 00:08:27,606
the technician makes
another hole
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00:08:27,608 --> 00:08:30,008
into the cylinder
for a threaded fitting.
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00:08:30,010 --> 00:08:32,244
This fitting connects to
an electrical element
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00:08:32,246 --> 00:08:35,680
that heats water
in conjunction with a boiler.
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00:08:35,682 --> 00:08:38,450
Another technician makes
the tank's heating coil
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00:08:38,452 --> 00:08:42,354
by running a straight copper
tube through three rollers.
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00:08:42,356 --> 00:08:44,589
The tube is bent under pressure,
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00:08:44,591 --> 00:08:47,792
forming it into a coiled shape.
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00:08:47,794 --> 00:08:50,762
The heat from the boiler,
pump, or solar panel
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00:08:50,764 --> 00:08:52,597
flows through the heating coil,
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00:08:52,599 --> 00:08:54,833
heating the water stored
in the tank.
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00:08:59,373 --> 00:09:02,641
Since the copper-tube wall
is too thin to weld,
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00:09:02,643 --> 00:09:06,778
a technician uses a fusing
technique known as brazing.
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00:09:06,780 --> 00:09:09,915
This metal-joining process
brazes a flow fitting
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00:09:09,917 --> 00:09:11,550
on one end of the heating coil
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00:09:11,552 --> 00:09:13,752
and a return fitting
on the other.
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00:09:16,557 --> 00:09:20,225
Next, the heating coil
is placed in the tank.
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00:09:20,227 --> 00:09:23,995
The fittings protrude through
a hole at the top and bottom.
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00:09:23,997 --> 00:09:26,765
The technician secures each one
with a nut,
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00:09:26,767 --> 00:09:29,568
then tightens the nuts
with an impact wrench.
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00:09:31,538 --> 00:09:35,540
Like the dome top, the bottom
component's edges are grooved,
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00:09:35,542 --> 00:09:37,442
allowing the tank
to fit perfectly
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00:09:37,444 --> 00:09:39,311
into the cylinder base.
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00:09:42,549 --> 00:09:45,584
Once the top and bottom
components are installed,
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00:09:45,586 --> 00:09:47,719
the tank goes back
to the brazing station
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00:09:47,721 --> 00:09:49,454
for final assembly.
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00:09:52,359 --> 00:09:54,993
A welder brazes
the top and bottom components
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00:09:54,995 --> 00:09:56,294
to the cylinder,
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00:09:56,296 --> 00:09:58,697
then he brazes
a feed fitting to a hole
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00:09:58,699 --> 00:10:00,532
near the bottom of the tank.
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00:10:00,534 --> 00:10:02,968
This location is where
cold water enters
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00:10:02,970 --> 00:10:04,703
the tank to be heated.
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00:10:08,308 --> 00:10:12,344
Next, a technician conducts
a quality-control test.
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00:10:12,346 --> 00:10:16,114
He blocks the three fittings,
fills the cylinder with air,
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00:10:16,116 --> 00:10:19,551
then submerges the tank in water
to check for air bubbles,
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00:10:19,553 --> 00:10:21,252
which would indicate a leak.
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00:10:27,461 --> 00:10:29,794
a stainless-steel water heater
is constructed
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00:10:29,796 --> 00:10:31,262
just like a copper heater,
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00:10:31,264 --> 00:10:33,798
except that they don't require
any brazing.
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00:10:37,270 --> 00:10:41,206
A robot sprays the tanks with
expandable polyurethane foam
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00:10:41,208 --> 00:10:42,974
for insulation.
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00:10:42,976 --> 00:10:45,577
The customer selects
the degree of insulation,
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00:10:45,579 --> 00:10:49,247
one to four inches thick.
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00:10:49,249 --> 00:10:53,418
The foam takes just five minutes
to cure.
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00:10:53,420 --> 00:10:56,921
As the tank stores hot water,
the insulation reduces
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00:10:56,923 --> 00:11:00,025
the amount of heat
the tank loses over time.
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00:11:13,807 --> 00:11:15,373
Electrically powered vehicles
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may seem like
a 21st-century phenomenon,
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00:11:18,378 --> 00:11:21,679
but they were actually
first invented in the 1880s.
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00:11:21,681 --> 00:11:23,982
During that time,
they were very popular,
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00:11:23,984 --> 00:11:27,552
until combustion-engine vehicles
became the new normal.
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00:11:27,554 --> 00:11:29,454
Today,
these electrically powered
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00:11:29,456 --> 00:11:34,259
alternative-fuel vehicles
are making a comeback.
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This manufacturer produces
a wide range of electric boats.
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00:11:38,231 --> 00:11:41,132
Thanks to powerful batteries,
some of these vehicles
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00:11:41,134 --> 00:11:45,570
can travel
over 35 miles per hour.
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00:11:45,572 --> 00:11:48,907
Craftspeople apply
a gel-coat skin to a mold,
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00:11:48,909 --> 00:11:51,309
using a product
derived from vinyl.
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00:11:53,346 --> 00:11:56,381
Then they layer on
a dry fiberglass fabric
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00:11:56,383 --> 00:12:00,318
and vacuum-bag
the entire assembly.
189
00:12:00,320 --> 00:12:03,054
The vacuum suction
draws in liquid resin,
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00:12:03,056 --> 00:12:05,356
infusing the material.
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00:12:05,358 --> 00:12:08,359
A craftsman marks a dry spot
as a test point
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00:12:08,361 --> 00:12:11,463
to monitor and ensure
complete saturation.
193
00:12:14,367 --> 00:12:17,535
The infusion process
takes about two hours.
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00:12:17,537 --> 00:12:21,372
Once complete, the assembly
will cure for four to six hours,
195
00:12:21,374 --> 00:12:25,143
depending on the general
humidity and temperature levels.
196
00:12:25,145 --> 00:12:28,813
Once cured, the assembly
is removed from the mold.
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00:12:28,815 --> 00:12:31,049
Despite the structure's
light weight,
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00:12:31,051 --> 00:12:35,220
this deck is incredibly
strong, rigid, and durable.
199
00:12:38,225 --> 00:12:42,627
The fiberglass decks and hulls
make up the boat's shells.
200
00:12:44,931 --> 00:12:48,233
A craftswoman applies
a high-strength marine glue
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00:12:48,235 --> 00:12:52,070
to a recessed area of the deck.
202
00:12:52,072 --> 00:12:55,707
She installs an anti-skid
deck insertion.
203
00:12:55,709 --> 00:13:01,012
This material is a composite
designed to resemble wood.
204
00:13:01,014 --> 00:13:03,681
Unlike real wood,
this composite material
205
00:13:03,683 --> 00:13:06,017
will last the lifetime
of the boat
206
00:13:06,019 --> 00:13:10,488
and won't require
any additional maintenance.
207
00:13:10,490 --> 00:13:14,325
The craftswoman uses a roller
to apply pressure evenly
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00:13:14,327 --> 00:13:16,561
across the entire
decking surface.
209
00:13:16,563 --> 00:13:20,331
This step will eliminate
any unwanted air pockets.
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00:13:20,333 --> 00:13:22,767
Next, a mirror-image
decking section
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00:13:22,769 --> 00:13:25,570
is applied to the other side.
212
00:13:25,572 --> 00:13:29,340
A specialist installs
the electrical-wiring harness.
213
00:13:29,342 --> 00:13:32,443
To avoid corrosion,
marine-grade wiring is stored
214
00:13:32,445 --> 00:13:34,712
in a sealed environment
under the deck.
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00:13:38,385 --> 00:13:40,418
Since the decking
is lightweight,
216
00:13:40,420 --> 00:13:44,055
it only takes two people to lift
and install it on the hull.
217
00:13:46,193 --> 00:13:49,127
The lip of the deck
fits snugly into place.
218
00:13:52,299 --> 00:13:57,135
The most powerful boat models
require lithium-ion batteries.
219
00:13:57,137 --> 00:14:00,238
These boats are built
with military-grade foam.
220
00:14:00,240 --> 00:14:02,674
The density of the foam
adds structure,
221
00:14:02,676 --> 00:14:06,411
causing the boat
to become unsinkable.
222
00:14:06,413 --> 00:14:09,080
Using a hoist, technicians
install the deck
223
00:14:09,082 --> 00:14:12,283
of a large, powerful
electric boat.
224
00:14:12,285 --> 00:14:15,053
The deck lip slides
over the top of the hull.
225
00:14:17,257 --> 00:14:18,890
Depending on the boat model,
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00:14:18,892 --> 00:14:21,726
the manufacturer uses
either lithium-ion
227
00:14:21,728 --> 00:14:25,830
or lead-acid batteries
as a power source.
228
00:14:25,832 --> 00:14:29,033
A specialist installs a series
of marine-grade
229
00:14:29,035 --> 00:14:32,070
dc31 lead-acid batteries.
230
00:14:32,072 --> 00:14:34,739
At 6 volts, 225 amps,
231
00:14:34,741 --> 00:14:37,508
they're similar to batteries
used in cars.
232
00:14:37,510 --> 00:14:41,913
By contrast, the 7.7-kilowatt
lithium-ion batteries
233
00:14:41,915 --> 00:14:44,515
pack a charge of 48 volts.
234
00:14:44,517 --> 00:14:47,952
The batteries are installed
under the seats.
235
00:14:47,954 --> 00:14:51,322
To create a watertight seal
between the deck to the hull,
236
00:14:51,324 --> 00:14:53,324
a craftsman installs
a rubber bumper
237
00:14:53,326 --> 00:14:55,827
around the perimeter
of the boat.
238
00:14:55,829 --> 00:14:58,263
Holes have been pre-drilled
to avoid cracking
239
00:14:58,265 --> 00:15:00,398
when installation is complete.
240
00:15:03,503 --> 00:15:05,770
This manufacturer sources
their motors
241
00:15:05,772 --> 00:15:08,006
from an outside
electric-motor company,
242
00:15:08,008 --> 00:15:12,410
which also builds motors
for cars.
243
00:15:12,412 --> 00:15:16,347
The fin, made of aluminum
encased in marine-grade rubber,
244
00:15:16,349 --> 00:15:20,485
is installed on the bottom
of the motor.
245
00:15:20,487 --> 00:15:23,821
The propeller attaches
to the motor with a zinc nut.
246
00:15:25,959 --> 00:15:28,526
Two circuit boards located
on board
247
00:15:28,528 --> 00:15:30,995
will send instructions
to the motor.
248
00:15:30,997 --> 00:15:34,165
A waterproof cover is placed
on top of the circuit boards
249
00:15:34,167 --> 00:15:36,034
for added protection.
250
00:15:36,036 --> 00:15:40,204
Locknuts with nylon washers will
prevent unnecessary vibrations
251
00:15:40,206 --> 00:15:42,106
while the motor is on.
252
00:15:42,108 --> 00:15:43,942
With the steering cables
installed,
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00:15:43,944 --> 00:15:46,377
the entire unit pivots
right and left,
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00:15:46,379 --> 00:15:49,314
allowing the pilot
on deck to steer.
255
00:15:49,316 --> 00:15:51,115
The powerful motor is equivalent
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00:15:51,117 --> 00:15:53,985
to a 10-horsepower
combustion engine,
257
00:15:53,987 --> 00:15:55,853
and because it sits
in the water,
258
00:15:55,855 --> 00:15:58,222
it stays cool and quiet.
259
00:15:58,224 --> 00:16:01,459
Finally, a craftswoman places
the boat's sun canopy
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00:16:01,461 --> 00:16:02,827
over the framework.
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00:16:02,829 --> 00:16:05,330
This will allow customers
to add solar panels
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00:16:05,332 --> 00:16:07,031
for charging the boat.
263
00:16:07,033 --> 00:16:09,500
Also, a customer can choose
the colors
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00:16:09,502 --> 00:16:12,236
for both their canopies
and upholstery.
265
00:16:12,238 --> 00:16:14,339
There's no denying
that electric boats
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00:16:14,341 --> 00:16:16,607
are the future of fun
on the water.
267
00:16:29,189 --> 00:16:30,755
Modern fencing is a sport
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00:16:30,757 --> 00:16:34,993
consisting of three disciplines,
one of which is foil fencing.
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00:16:34,995 --> 00:16:37,362
While in play,
a lightweight foil sword
270
00:16:37,364 --> 00:16:39,597
is used to score points.
271
00:16:39,599 --> 00:16:42,367
Points can be scored
when the tip of a player's sword
272
00:16:42,369 --> 00:16:47,138
makes contact onto
their opponent's torso.
273
00:16:47,140 --> 00:16:49,407
A fencing foil is
a piece of equipment
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00:16:49,409 --> 00:16:52,310
that should only be used
by trained professionals.
275
00:16:52,312 --> 00:16:55,646
This sword doesn't have
a sharp edge or pointed tip.
276
00:16:55,648 --> 00:16:58,616
It's all about scoring hits.
277
00:16:58,618 --> 00:17:02,820
Fencing foils are made
out of thin steel bars.
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00:17:02,822 --> 00:17:05,823
The steel is a low-carbon,
nickel-rich alloy
279
00:17:05,825 --> 00:17:08,292
that's strong yet flexible.
280
00:17:08,294 --> 00:17:13,164
An automated saw cuts the bars
to a length of 35 inches.
281
00:17:13,166 --> 00:17:19,003
The bar will be stretched and
shortened as it's transformed.
282
00:17:19,005 --> 00:17:22,840
A forge heats and hammers
the hilt end to a round shape,
283
00:17:22,842 --> 00:17:26,444
leaving the rest of the rod
rectangular.
284
00:17:26,446 --> 00:17:30,081
Here you can see the difference
in the rod's shape.
285
00:17:30,083 --> 00:17:33,484
Another forging machine
softens the end of the rod
286
00:17:33,486 --> 00:17:36,854
and pushes the blade
through a series of hammers.
287
00:17:36,856 --> 00:17:39,657
This tapers the blade
and stretches the steel,
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00:17:39,659 --> 00:17:41,626
doubling it in size.
289
00:17:44,097 --> 00:17:47,365
An operator clamps
the tapered blade in a jig
290
00:17:47,367 --> 00:17:50,334
to hold it straight
while the steel cools.
291
00:17:52,906 --> 00:17:57,175
Then the operator slices
the hilt end to length.
292
00:17:57,177 --> 00:18:02,413
The excess steel will be
recycled into new swords.
293
00:18:02,415 --> 00:18:06,784
Next, the blades are heated
in a 932-degree oven.
294
00:18:06,786 --> 00:18:08,553
This step removes stresses
295
00:18:08,555 --> 00:18:10,521
and makes the metal
less brittle.
296
00:18:13,193 --> 00:18:14,826
After a second heating,
297
00:18:14,828 --> 00:18:17,795
the blades soak in oil
to cool and harden.
298
00:18:19,666 --> 00:18:22,800
The exposure to intense heat
causes a rusty scale
299
00:18:22,802 --> 00:18:27,305
to form on the blade,
so technicians clean it off.
300
00:18:27,307 --> 00:18:31,008
A sword maker clamps the blades
in a disc grinder.
301
00:18:31,010 --> 00:18:35,279
The grinder carves a fine groove
from the hilt to the tip.
302
00:18:35,281 --> 00:18:39,951
The groove will house a wire
for the electric scoring system.
303
00:18:39,953 --> 00:18:41,352
The blade is cleaned to remove
304
00:18:41,354 --> 00:18:44,055
any remaining
surface imperfections.
305
00:18:44,057 --> 00:18:46,624
A spinning belt
coated with an abrasive
306
00:18:46,626 --> 00:18:50,394
grinds all four sides
of the blade.
307
00:18:50,396 --> 00:18:52,163
Then the sword is polished
308
00:18:52,165 --> 00:18:55,099
using a buffing wheel
and polishing compound.
309
00:18:58,238 --> 00:19:01,639
You can see the difference this
makes in the blade on the right.
310
00:19:04,544 --> 00:19:07,278
The craftsman hammers the blade
against an anvil
311
00:19:07,280 --> 00:19:10,481
to straighten out any kinks.
312
00:19:10,483 --> 00:19:12,517
Then he inspects the blade.
313
00:19:14,487 --> 00:19:16,954
If needed, the craftsman will
make adjustments
314
00:19:16,956 --> 00:19:20,358
to the blade with a hammer.
315
00:19:20,360 --> 00:19:23,461
Now it's time to work
on the hilt end of the blade.
316
00:19:23,463 --> 00:19:27,298
Another craftsman locks the end
of the blade in a threading die,
317
00:19:27,300 --> 00:19:28,766
applies lubricant,
318
00:19:28,768 --> 00:19:31,769
and activates
the automated system.
319
00:19:31,771 --> 00:19:35,573
The system turns the sword
in the die, carving out threads.
320
00:19:35,575 --> 00:19:38,009
Then the threaded hilt
is cut to length.
321
00:19:41,381 --> 00:19:44,649
At the next station,
a computerized laser engraves
322
00:19:44,651 --> 00:19:48,452
the company logo into the steel.
323
00:19:48,454 --> 00:19:50,454
After the sensor barrel
is installed
324
00:19:50,456 --> 00:19:51,923
on the end of the sword
325
00:19:51,925 --> 00:19:55,193
and the electrical scoring wire
is placed in the groove,
326
00:19:55,195 --> 00:19:59,530
the technician applies glue
to keep the wire secure.
327
00:19:59,532 --> 00:20:01,499
The sword blade is placed
in a rack
328
00:20:01,501 --> 00:20:04,569
that holds it
in a bow-like bend.
329
00:20:04,571 --> 00:20:06,304
This step will give
the glued wire
330
00:20:06,306 --> 00:20:08,005
the flexibility it needs
331
00:20:08,007 --> 00:20:11,342
to bend with the rest
of the sword while in use.
332
00:20:11,344 --> 00:20:14,545
After the blade has cured,
a pressure sensor spring
333
00:20:14,547 --> 00:20:18,382
is inserted into the barrel
and capped with a sensor button.
334
00:20:20,453 --> 00:20:24,222
The technician uses screws
to hold the components together.
335
00:20:26,492 --> 00:20:27,892
To assemble the hilt,
336
00:20:27,894 --> 00:20:31,095
the scoring wire is threaded
through a hole in the guard
337
00:20:31,097 --> 00:20:34,832
so it can easily slide
into place.
338
00:20:34,834 --> 00:20:37,868
Then the sensor wire
is connected to a socket.
339
00:20:40,473 --> 00:20:43,541
The wiring assembly is covered
with a plastic pad
340
00:20:43,543 --> 00:20:45,876
that allows the socket
to protrude.
341
00:20:48,414 --> 00:20:50,314
Finally, the pistol-grip handle
342
00:20:50,316 --> 00:20:54,685
is screwed into
the threaded end of the blade.
343
00:20:54,687 --> 00:20:59,290
This fencing foil is now ready
for testing.
344
00:20:59,292 --> 00:21:02,960
The technician plugs the fencing
foil into testing equipment,
345
00:21:02,962 --> 00:21:05,997
then he places a one-pound
weight on the sensor button
346
00:21:05,999 --> 00:21:09,867
and checks to see
if it responds.
347
00:21:09,869 --> 00:21:11,669
And the results are in.
348
00:21:11,671 --> 00:21:15,906
This fencing foil is now ready
to stand up to its competition.
28466
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