All language subtitles for Incredible.Inventions.Series.1.03of10.Nylon.Stocking

Narrator: AROUND THE WORLD,
THE RACE TO WIN WARS

AND EXPLORE THE UNIVERSE

HAS CREATED SOME OF
THE MOST INCREDIBLE PRODUCTS

EVER DESIGNED.

AND WE USE THEM EVERY DAY,

UNAWARE OF THEIR
AMAZING ORIGINS.

ON "INCREDIBLE INVENTIONS"...

THE NYLON STOCKING.

WHY DOES A DAINTY FASHION ITEM
CAUSE RIOTS DURING WORLD WAR
II?

THE L.E.D.

EXACTLY HOW IS THIS TINY LIGHT

HELPING NASA ASTRONAUTS
EXPLORE THE STARS?

THE ROWLETT RUTLAND TOASTER.

WHAT HAS TOAST
AND WORLD WAR II GOT IN COMMON?

WE REVEAL THE AMAZING HISTORY
AND ENGINEERING

BEHIND THESE
INCREDIBLE INVENTIONS.

-- Captions by VITAC --
www.vitac.com

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

THROUGHOUT HISTORY,
HUMANS HAVE DEVELOPED CLOTHING

FOR PRACTICALITY,
WARMTH, AND TO LOOK GOOD.

THOUGH THERE IS ONE
REVOLUTIONARY ITEM

THAT STANDS OUT FOR ITS AFFECT
ON THE U.S. ECONOMY...

...THE NYLON STOCKING.

Gladkowska:
AT THE BEGINNING, STOCKINGS WAS
MADE FROM SILK AND FROM COTTON.

UNTIL THE 18th CENTURY,
IT WAS WORN ONLY BY MEN.

AND ONLY IN THE 19th CENTURY
DID
WOMEN STARTED TO WEAR
STOCKINGS.

EVERYTHING CHANGED IN THE '20s

BECAUSE OF THE REVOLUTION
IN FASHION.

AND BECAUSE OF THAT,

SHOWING LEGS BECAME
SOCIALLY ACCEPTABLE.

Narrator:
HOWEVER, ORIGINALLY, THE FABRIC
IS NOT SO APPEALING, UNTIL
1935,

WHEN WALLACE CAROTHERS,
A CHEMIST AT DuPont LABS,

INTRODUCES A NEW DURABLE
ALTERNATIVE TO SILK --

NYLON.

THIS NEW MATERIAL PROVES
TO BE EXTREMELY USEFUL.

IT'S DURABLE, WATERPROOF,
MOLD-RESISTANT, FAST-DRYING,

AND CAN BE SPUN INTO FIBERS.

DuPont RECOGNIZES
ITS ENORMOUS POTENTIAL

AND DECIDES TO USE IT
AS A CLOTHING FABRIC.

BECAUSE OF ITS ALMOST
TRANSPARENT APPEARANCE

AND HIGH DURABILITY,

NYLON STOCKINGS
BECOME INCREDIBLY POPULAR.

THEY'RE THE FASHION STATEMENT
OF THE 1940s,

WITH 4 MILLION PAIRS
SOLD ON ONE DAY ALONE.

DuPont HELPS CREATE
THE PERFECT PRODUCT

FOR THE NEW NYLON MATERIAL.

THEN, IN THE DARK DAYS
OF WORLD WAR II...

NYLON WAS NEEDED DURING THE
WAR,
PARTICULARLY TO REPLACE SILK,

BECAUSE WHEN THE JAPANESE
ENTERED THE WAR,

THEY TOOK OVER THE SUPPLY LANES

AND TOOK OVER A LOT OF SUPPLY
OF SILK IN SOUTHEAST ASIA.

Narrator:
DuPont SEIZES THE PRODUCTION
OF NYLON STOCKINGS

IN ORDER TO MANUFACTURE ROPE,
AIRPLANE CORDS, AND PARACHUTES.

THIS LEADS TO RIOTS BREAKING
OUT
ACROSS THE U.S.

FROM AUGUST 1945 TO MARCH 1946,

ALL FOR THE PRIZED POSSESSION
OF A GOOD PAIR OF STOCKINGS.

WHEN DuPont RESUMES PRODUCTION
OF THE NYLON GARMENT IN 1946,

30 MILLION PAIRS
ARE SHIPPED EVERY MONTH.

A POPULAR ITEM
WORTH FIGHTING FOR,

BORN IN A CHEMIST'S LAB

THAT REVOLUTIONIZED FASHION
ALL OVER THE WORLD,

THE NYLON STOCKING IS,
WITHOUT A DOUBT,

AN INCREDIBLE INVENTION.

THE ADRIAN TIGHTS FACTORY
IN POLAND

HAS BEEN MAKING STOCKINGS
AND TIGHTS SINCE 1984.

WE HAVE STOCKINGS, TIGHTS...

KNEE-HIGHS, AND SOCKS.

Narrator:
THE FACTORY USES THE LATEST
IN MODERN MACHINERY

TO DESIGN AND MANUFACTURE
HIGH-FASHION HOSIERY

IN A WIDE RANGE
OF PATTERNS AND COLORS

TO THE HIGHEST-QUALITY
STANDARD.

IT IS THE SECOND-LARGEST
HOSIERY FACTORY IN POLAND,

PRODUCING ALMOST 1 MILLION
PAIRS
OF TIGHTS AND SOCKS PER MONTH.

WE HAVE PROFESSIONAL
COLLECTION,
MATERNITY COLLECTION,

PLUS-SIZE COLLECTION,

WEDDING,
AND EVEN COLLECTION FOR A MAN.

Narrator: THE PROCESS
OF MANUFACTURING TIGHTS

STARTS BY PLACING YARN
ON THE STANDS OF THE MACHINE.

THE THREADS ARE FED
TO THE CENTER OF THE MACHINE

FROM FOUR DIFFERENT SITES.

THE LEG SECTION OF THE TIGHT
IS MADE INSIDE THE CYLINDER.

UPON A SINGLE ROTATION
OF THE CYLINDER,

FOUR ROWS ARE FORMED AT A TIME.

THE PROCESS OF MANUFACTURING
KNITTED FABRIC

IS FULLY AUTOMATED.

Gladkowska:
USUALLY THE KNITTING MACHINE

CONTAINS
FROM 300 TO 420 NEEDLES.

Narrator:
AFTER APPROXIMATELY 3 MINUTES,

THE FINISHED LEG SECTION
IS TRANSFERRED

FROM PNEUMATIC FEEDER
INTO THE BAG.

ONE KNITTING MACHINE
CAN PRODUCE APPROXIMATELY

150 TO 400 PAIRS OF TIGHTS
A DAY.

TIGHTS ARE CHECKED
BY STRETCHING THEM

ON THE CONTROL MOLD.

THE OPERATOR INSPECTS THE ITEM

AND LOOKS FOR POTENTIAL FAULTS
IN THE FABRIC.

IN EACH PRODUCTION BATCH,
THE PRODUCT PARAMETERS

ARE CONTROLLED BY
THE GAUGING DEVICE.

IT CHECKS LONGITUDINAL
AND LATERAL STRETCHABILITY

OF THE PRODUCT,

AS WELL AS CHECKING
THAT THE SIZE CAN FORM

TO THE COMPANY STANDARDS.

NEXT STEP,
THE TOES OF THE TIGHTS

ARE SEWN TOGETHER.

THE OPERATOR PUTS THE PRODUCTS
AGAINST A TUBE

AND SUCKS THE STOCKING INSIDE
BY USING COMPRESSED AIR.

NEXT, THE MACHINE AUTOMATICALLY
TURNS THE TIGHTS INSIDE OUT.

IT THEN SEWS THE TOES
OF THE TIGHTS TOGETHER.

THEN, THE PRODUCT IS
AUTOMATICALLY TURNED OUTSIDE IN

AND DISCHARGED BY
THE AUTOMATIC FEEDER.

DURING AN 8-HOUR SHIFT,

A SINGLE MACHINE
SEWS TOGETHER

APPROXIMATELY
4,000 PAIRS OF TIGHTS.

ONCE THE TOES OF THE TIGHTS
ARE SEWN,

THE SINGLE LEG
IS SLICED APART AT THE TOP...

...AND THEN MADE INTO PAIRS
BY SEWING TWO UPPERS TOGETHER

WHILE, AT THE SAME TIME,
SEWING AN ADDITIONAL PIECE

OF COTTON-KNITTED FABRIC
CALLED A GUSSET,

WHICH IMPROVES THE COMFORT
OF THE TIGHTS

ALONG THE MIDSECTION.

HERE, THE ELASTIC CROCHET TAPE
IS ALSO SEWN ON.

FINISHED TIGHTS
ARE PACKED INTO BAGS

AND PLACED IN THE DYER,

A MACHINE THAT DYES THE TIGHTS
THE SELECTED COLOR.

DEPENDING
ON THE COLOR INTENSITY,

THE DYING PROCESS TAKES
BETWEEN 4 AND 8 HOURS.

SEVERAL
RANDOMLY-SELECTED SAMPLES

FROM EACH BATCH
ARE TAKEN TO THE LAB,

WHERE THEY ARE TESTED
FOR CONFORMITY

TO THE COLOR STANDARD
IN DIFFERENT TYPES OF LIGHTING.

AFTER THE RESIDUAL MOISTURE
HAS BEEN REMOVED,

THE PROCESS OF STABILIZATION,
OR IRONING, STARTS.

THE OPERATOR PLACES THE TIGHTS
ON METAL MOLDS,

WHICH IS THEN TRANSFERRED INTO
A HIGH-PRESSURE CHAMBER.

WHEN THE PRODUCT LEAVES
THE HIGH-PRESSURE CHAMBER,

IT PASSES TO THE DRYING CHAMBER

WITH A SYSTEM
OF INFRARED RADIATORS.

THE DRYING TEMPERATURE

IS APPROXIMATELY
200 DEGREES FAHRENHEIT.

AFTER THE STABILIZATION
PROCESS,

TIGHTS ARE CHECKED
AND FINISHED MANUALLY,

FOR EXAMPLE BY THREADING
ON ALL THE METAL STRINGS.

NEXT, THE PRODUCT IS FOLDED
AND PACKED IN THE FILM POUCH

THAT PROVIDES ADDITIONAL
PROTECTION FROM DAMAGE.

THE POUCHES ARE THEN PLACED IN
DECORATED CARDBOARD ENVELOPES,

WHICH ARE LABELED WITH BAR
CODES

AND INFORMATION ABOUT THE
MODEL,
COLOR, AND SIZE.

FINISHED AND TESTED TIGHTS
ARE PACKED IN BULK CARTONS

AND SHIPPED TO CUSTOMERS.

NYLON STOCKINGS CERTAINLY HAD
A GREAT IMPACT ON FASHION

AND WORLD WAR II,

JUST AS L.E.D. LIGHTS PLAY
A ROLE IN SPACE EXPLORATION,

BUT EXACTLY HOW
MAY SURPRISE YOU.

Narrator: A LIGHT BEHIND
THE LATEST FLAT-SCREEN TV

REMINDS YOU THAT
YOU'VE LEFT A DEVICE ON.

L.E.D.s,
OR LIGHT-EMITTING DIODES,

ARE THE TINY LITTLE LAMPS
THAT ARE LIGHTING UP OUR WORLD.

THESE TINY BRIGHT DOTS
HAVE BECOME

A FAMILIAR PART
OF OUR EVERYDAY LIVES.

BUT THEIR CONNECTION
TO PIONEERING SPACE TRAVEL

IS NOT WIDELY KNOWN.

L.E.D.s ARE DEVELOPED
IN DALLAS, TEXAS,

IN THE EARLY 1960s

AND EMIT LIGHT
THROUGH A PHENOMENON

CALLED ELECTROLUMINESCENCE,

WHICH DESCRIBES LIGHT
BEING PRODUCED BY A MATERIAL

AS AN ELECTRIC CURRENT
OR FIELD PASSES THROUGH IT.

THIS SCIENTIFIC BEHAVIOR
IS FIRST DISCOVERED IN ENGLAND

OVER 100 YEARS AGO
BY HENRY JOSEPH ROUND.

BUT IT'S NOT UNTIL
THE INTRODUCTION OF THE L.E.D.

IN 1962

THAT ELECTROLUMINESCENCE
FINDS ITS COMMERCIAL USE.

THE FIRST L.E.D.s
ONLY EMIT INFRARED LIGHT

THAT'S NOT VISIBLE
TO THE HUMAN EYE.

THINK OF THE LITTLE L.E.D.

ON THE FRONT
OF A REMOTE CONTROL.

BUT RESEARCH HAS FOUND
THAT USING DIFFERENT MATERIALS

AND COMPOUNDS
CHANGES THE LIGHT FREQUENCY,

WHICH IN TURN TRANSLATES
TO DIFFERENT COLORS

EMITTING FROM THE L.E.D.

SOON, THE RACE IS ON
TO DEVELOP SEMICONDUCTORS

MADE FROM A VARIETY
OF EXOTIC-SOUNDING
COMBINATIONS.

PRETTY COLORS IS WHERE
THE CONNECTION WITH SPACE
TRAVEL

COMES IN.

SPACE IS VAST
AND SPACE TRAVEL LENGTHY.

FOR INSTANCE, IT TOOK NEARLY
3 DAYS FOR THE APOLLO MISSIONS

TO REACH OUR NEAREST
COSMIC NEIGHBOR, THE MOON.

MARS, OUR NEXT NEAREST WORLD,

HAS AN ESTIMATED TRAVEL TIME
OF NEARLY 2 YEARS.

SO HOW DO YOU KEEP YOUR CREW
FIT
AND HEALTHY

FOR THIS LENGTH OF TIME?

FRESH FOOD

AND A DEVELOPMENT
OF THOSE LITTLE L.E.D.s

THAT YOU COME IN CONTACT WITH
EVERY DAY

ARE BEING USED BY NASA
TO ENABLE FUTURE MARS EXPLORERS

TO GROW FOOD IN
THE UNFORGIVING VACUUM OF
SPACE.

Gazard: THE BEST POSSIBLE USE
FOR L.E.D.s IN SPACE

IS TO ACTUALLY GROW FOOD.

YOU CAN PROVIDE
A CONTINUAL SOURCE OF LIGHT.

YOU CAN PROVIDE IT CHEAPLY.

THE COMPONENTS ARE ACTUALLY
VERY EFFICIENT

AND VERY RELIABLE.

AND YOU CAN TUNE THEM TO
PRODUCE
EXACTLY THE COLORS YOU WANT.

Narrator: BUT WHY IS
A CONSTANT SOURCE OF LIGHT

SO IMPORTANT
FOR HEALTHY PLANT GROWTH?

AS YOU PROBABLY KNOW,
A PLANT GROWS

BY A PROCESS
CALLED PHOTOSYNTHESIS.

PLANTS CONTAIN A PIGMENT
CALLED CHLOROPHYLL

THAT USUALLY GIVES A PLANT
ITS CHARACTERISTIC GREEN COLOR.

CHLOROPHYLL CAPTURES
THE SUN'S ENERGY

AND USES IT TO MAKE SUGARS
OUT OF CARBON DIOXIDE

FROM THE AIR AND WATER.

THE SUGARS FUEL THE PLANT'S
ROOTS, STEMS, AND LEAVES

SO THE PLANT CAN GROW.

AND LIGHT IS A KEY INGREDIENT
TO MAKE THIS HAPPEN.

IN 2014,
THE INTERNATIONAL SPACE STATION

BEGINS EXPERIMENTING
WITH GROWING PLANTS

USING NASA'S VEGGIE GROW
SYSTEM.

THE VEGGIE GROW IS COMPRISED
OF AN ARRAY OF L.E.D. LIGHTS

WITH PILLOWS THAT CONTAIN
THE SEEDS, FERTILIZERS,

CLAY, AND WATER
THAT LEAD TO HEALTHY LETTUCE

BEING GROWN HIGH ABOVE
THE EARTH'S ATMOSPHERE.

BUT NASA'S EXPERTISE
WITH TUNINGS AND L.E.D. COLOR

DOESN'T STOP AT GROWING PLANTS.

NASA HAS FOUND A USE
FOR THAT NASTY RED LIGHT, TOO.

IT'S CALLED RED-LIGHT THERAPY

AND IS BEING USED
TO AID THE RECOVERY

OF A WIDE VARIETY
OF CONDITIONS

BY AIDING THE BODY'S ABILITY
TO REPAIR ITSELF.

RED-LIGHT THERAPY
CAN HELP REPAIR TISSUES

IN A MUCH QUICKER LEVEL
BY STIMULATING THE CIRCULATION

AND, IN TURN, WILL INCREASE

THE CHEMICAL MESSENGERS
CALLED CYTOKINES

TO STIMULATE THE FIBROBLASTS,

WHICH ARE CELLS THAT
CAN HELP PRODUCE COLLAGEN

AND HENCE REPAIR TISSUE
QUICKER.

Narrator: THE APPLICATION
OF THIS RED-LIGHT TECHNOLOGY

IS USED IN AREAS AS DIVERSE AS
PAIN RELIEF IN CANCER PATIENTS

TO THE TREATMENT
OF SPORTS INJURIES,

ANTI-AGING REGIMES.

SO, THE NEXT TIME
YOU USE YOUR REMOTE,

TURN YOUR CAR HEADLIGHTS ON,
OR WATCH YOUR FLAT-SCREEN TV,

THE SAME TECHNOLOGY
ILLUMINATING YOUR WORLD

MAY ONE DAY BE HEALING A WOUND

OR GROWING FOOD ON A SPACE SHIP
AS IT HURDLES TOWARD MARS.

THE L.E.D. --
TRULY AN INCREDIBLE INVENTION.

COMING UP, A SPECIAL EXPERIMENT

THAT PUTS THE L.E.D. LIGHT
TO THE TEST.

Narrator: SO, HOW EFFICIENT
IS AN L.E.D. LIGHT?

WELL, WE ARE GOING TO
PUT IT TO THE TEST.

THE EXPERIMENT -- WE ARE GOING
TO TAKE A GLORIOUS, ZESTY LEMON

AND TURN IT INTO
A NATURAL BATTERY

WITH ENOUGH ELECTRIC JUICE TO
LIGHT UP OUR LOW-VOLTAGE L.E.D.

TO BEGIN,
WE WILL NEED A LEMON --

ACTUALLY, MAYBE A FEW --

ELECTRIC WIRES
WITH CROCODILE CLIPS,

COPPER PIECES,
ZINC-COATED NAILS,

AND FINALLY OUR LITTLE L.E.D.

NEXT, WE GENTLY CRUSH
AND ROLL THE LEMONS

TO RELEASE THE JUICE INSIDE.

THEN, A WIRE IS CONNECTED
TO A PIECE OF COPPER

AND ANOTHER
TO A ZINC-COATED NAIL.

THE COPPER AND NAIL

ARE THEN PUSHED INTO
EACH END OF THE LEMON.

THIS PROCESS IS REPEATED

UNTIL WE HAVE THREE
FRUITY LEMON BATTERY CELLS.

NOW THE TECHNICAL BIT.

WE CONNECT THE WIRES
ATTACHED TO THE COPPER

TO THE WIRES
LINKED TO THE ZINC NAILS

TO FORM A CHAIN.

WE THEN CONNECT
A CROCODILE-CLIP WIRE

FROM THE LAST REMAINING
COPPER HEAD

AND ANOTHER CROCODILE-CLIP WIRE
ON THE ZINC-COATED NAIL

AT THE OTHER END OF THE CHAIN.

CONNECT THE ZINC NAIL
TO THE NEGATIVE TERMINAL

ON THE L.E.D.

AND THE COPPER NAIL
TO THE POSITIVE TERMINAL,

AND LET THERE BE LIGHT.

AND THE SCIENCE?

THE ENERGY TO POWER THE LIGHT
DOES NOT COME FROM THE LEMON

BUT RATHER A CHEMICAL CHANGE
IN THE ZINC

AS THE SURFACE
OF THE GALVANIZED NAIL

STARTS TO DISSOLVE
FROM THE JUICE INSIDE THE
LEMON.

THIS IS CALLED OXIDATION.

AND THE ENERGY RELEASED
PRODUCES ELECTRICITY.

THE METAL PROVIDES THE POWER,

AND THE LEMON MERELY
PROVIDES AN ENVIRONMENT

WHERE THIS CAN HAPPEN.

DOES A FRUITY FUTURE AWAIT US?

PROBABLY NOT, AS IT WOULD
TAKE OVER 6 MILLION LEMON CELLS

TO CREATE THE SAME POWER
AS AN AVERAGE CAR BATTERY,

WHICH DEMONSTRATES
HOW ENERGY-EFFICIENT

THIS LITTLE LIGHT IS.

THE ROWLETT RUTLAND TOASTER --

IT'S A HUMBLE KITCHEN APPLIANCE
WITH A MILITARY CONNECTION.

BUT BEFORE WE EXPLAIN HOW,

LET'S UNDERSTAND THE HISTORY
BEHIND MAKING TOAST.

IT'S THOUGHT THE EGYPTIANS
DEVELOPED THE BASIC FORMULA

FOR THE TYPE OF BREAD
WE KNOW AND LOVE

ABOUT 3,000 YEARS AGO.

BUT THEY ENCOUNTERED
THE SAME PROBLEM

THAT WE STILL HAVE --

HOW TO STOP BREAD
FROM QUICKLY GOING STALE.

Hurd: HISTORICALLY,
WHEN PEOPLE MADE BREAD AT HOME,

WHEN YOU MAKE BREAD AT HOME
TODAY,

YOU'LL NOTICE YOUR BREAD
WILL GO STALER A LOT QUICKER

THAN THE STUFF YOU'LL BUY
IN A SUPERMARKET

PURELY BECAUSE
THE STUFF IN THE SUPERMARKET

IS PUMPED FULL OF SUGARS
BUT ALSO PRESERVATIVES.

THE ONLY WAY THAT
BREAD TASTES GOOD

WHEN IT'S STALE IS
IF YOU WHACK IT IN THE TOASTER.

AND, REALLY,
THERE IS NOTHING BETTER

THAN STALE BREAD FOR THE
TOASTER

BECAUSE IT'S LOST
ALL THAT MOISTURE ANYWAY.

IT BECOMES EVEN CRISPIER

AND EVEN TOASTIER
AND EVEN TASTIER.

Narrator: BEFORE TOASTERS,
TOASTING ISN'T AN EXACT
SCIENCE.

BUT NOW, THERE IS REAL SCIENC

BEHIND WHAT MAKES
A PERFECT PLATFORM

FOR YOUR HOT, BUTTERY TREAT.

Hurd: SCIENTIFICALLY,
WHEN WE TOAST BREAD,

WE HAVE WHAT'S KNOWN
AS THE MAILLARD REACTION.

THAT'S WHEN AMINO ACIDS
INTERACT WITH REDUCING SUGARS,

AND THEY KIND OF HAVE
A BIT OF A PARTY.

AND YOU GET
ALL THESE BEAUTIFUL, LIKE,

TASTES AND FLAVORS COMING OUT.

YOU'RE GETTING THE SWEETNESS
FROM THAT CHEMICAL REACTION.

Narrator:
IT'S AN ITEM FOUND IN KITCHENS
ALL ACROSS THE U.S.

BUT HOW IS IT MADE?

FIND OUT WHEN WE RETURN.

Narrator: SO, WHAT IS THE
MILITARY LINK WITH THE TOASTER?

ROWLETT RUTLAND'S FOUNDER,
TED RUTLAND,

STARTED MAKING TOASTERS
USING THE SAME TOOLS

THAT HAD BEEN MAKING COMPONENTS
FOR TANKS DURING WORLD WAR II.

AS AN ADDED BONUS,
THERE WAS A SURPLUS

OF A PARTICULAR MATERIAL
AFTER THE WAR.

Bob: THE FIRST TOASTERS
HAVE A LARGE AMOUNT

OF ALUMINIUM IN THEM
BECAUSE, AFTER THE WAR,

THERE WAS A SURPLUS
OF HIGH-QUALITY ALUMINIUM,

WHICH WAS TO MAKE AIRPLANES.

AND SO, EVERYTHING THAT WAS
MADE
OF ALUMINIUM BECAME QUITE
CHEAP.

Narrator:
RUTLAND TOASTERS HAVE BEEN THE
POWER BEHIND THE PERFECT TOAST

SINCE 1947.

AND THEY ARE STILL
GOING STRONG TODAY.

THEY ARE ALSO THE PROUD MAKERS
OF THE KING OF ALL TOASTERS,

A 6-FOOT LONG, 34-SLOT MONSTER

WHICH HOLDS THE CURRENT RECORD

FOR THE LONGEST TOASTER
IN THE WORLD.

SO, HOW ARE THESE
SHINY MARVELS MADE?

THE MANUFACTURER
OF THE TOASTER'S CASE

IS THE FIRST STAGE
IN THE PROCESS.

A SHEET OF STAINLESS STEAL
IS PLACED IN THE CNC MACHINE.

THE TOASTER'S SIDES
AND AIR VENTS ARE PUNCHED OUT

TO LEAVE ALL FOUR SIDES
AS ONE CONTINUOUS STEEL STRIP.

NEXT, THE TOASTER

HAS ITS CORNERS FORMED
BY THE STEEL STRIP

IN A MACHINE
CALLED A PRESS BREAK.

IN PRESS BREAK FORMING,

THE SHEET IS POSITIONED
OVER THE DYE BLOCK.

AND THE DYE BLOCK
PRESSES THE SHEET

TO FORM THE CORNER SHAPE.

THE STEEL SHEET IS NOW STARTING
TO RESEMBLE THE ACTUAL TOASTER.

BUT THE SIDES STILL
NEED TO BE CONNECTED.

AND THIS WORKER USES AN AIR GUN

TO RIVET THE SIDES TOGETHER.

THE TOASTER CASE
IS NOW POWDER COATED

TO GIVE IT A TOUGH
AND SMOOTH FINISH.

WHILE THE TOASTER CASE
IS BEING FINISHED,

THE ASSEMBLY OF
THE INTERNAL WORKINGS,

CALLED THE INNER SCREEN,
BEGINS.

TO START, A METAL SCREEN
WITH A HEAT SHIELD

AND BOTH END PANELS
ARE RIVETED TOGETHER.

THE TOASTER'S GUARD WIRES

ARE THEN SLID INTO POSITION

AND THE REMAINING SCREEN
LINED UP OVER THE WIRES

WITH ANOTHER HEAT SHIELD
RIVETED TOGETHER

TO FORM A METAL BOX.

THE FINGER BAR,
WHICH THE TOAST RESTS ON,

AND A RETAINING STRIP
ARE THEN FIXED ON

TO THE BOTTOM
OF THE INNER ASSEMBLY.

THEN, THE HEATING ELEMENTS
ARE INSERTED INTO THE TOASTER.

THE ELEMENT IS A CRITICAL PART
OF THE TOASTER.

THE TOASTER MUST PROVIDE HEAT
BUT NOT MELT WHILE IN USE.

SO MICRO-WIRES
WRAPPED AROUND MICA SHEETS

ARE THE FOUNDATION
OF THE HEAT SOURCE.

MICA IS
A NATURAL SILICON MINERAL

AND HAS FANTASTIC
HEAT-RESISTANT PROPERTIES.

THE ELECTRICAL PROPERTIES
OF THE FOUR ELEMENTS

USED IN THE TOASTER DEPEND
ON WHERE THEY ARE POSITIONED.

400-WATT ELEMENTS
AT THE END OF THE TOASTER.

THAT'S ONLY GOING TO TOAST
ONE SIDE OF THE BREAD.

SO IT'S SLIGHTLY LOWER IN VALUE

THAN THE MIDDLE ELEMENTS,
WHICH ARE 500-WATT.

FINISHING WITH A 400
AT THIS END, AS WELL.

THEY'RE ALL IN.

THEN WE'RE GOING
TO LINK THEM TOGETHER

WITH THESE COPPER LINKS.

Narrator:
THE INNER SCREEN IS NOW
FINISHED

AND CAN BE FIXED
INTO THE TOASTER CASE,

WHICH HAS NOW HAD A TIMER
AND ELECTRIC WIRES FITTED.

A POLISHED METAL COVER
IS CAREFULLY PLACED

ON TOP OF THE TOASTER

AND THEN SCREWED INTO PLACE.

THE TOASTER IS THEN FLIPPED
OVER

AND A HANDLE CONNECTED
TO THE FINGER BAR

TO ALLOW THE USER
TO MANUALLY POP THE TOAST UP.

THE TOASTER WIRES
ARE THEN CONNECTED

TO THE HEATING ELEMENTS.

THE NEXT STAGE IS
FOR THE TOASTER TO BE
INSPECTED.

TO BEGIN, IT IS CAREFULLY
CHECKED FOR SCRATCHES,

DENTS, AND TO MAKE SURE ALL
NOBS
AND RIVETS ARE IN PLACE

AND THE TIMER AND FINGER BAR
OPERATE SUCCESSFULLY.

THE TOASTER IS THEN GIVEN
AN ELECTRICAL CHECK

TO MAKE SURE THAT ALL THE WIRES
AND ELEMENTS

ARE FUNCTIONING CORRECTLY.

THE TOASTER IS NEARLY READY.

IN THE PACKAGING AREA,

A BOTTOM PLATE CRUMB DRAWER
AND FEET

ARE SECURED
TO THE UNDERSIDE OF THE
TOASTER.

THE TOASTER IS THEN
WRAPPED AND BOXED,

READY TO BE SENT OUT
TO TOAST LOVERS

ALL OVER THE WORLD.

IT'S JUST A DESIGN WHICH
YOU CAN'T REALLY IMPROVE ON.

YOU KNOW, IT WORKS,
IT MAKES PERFECT TOAST.

YOU CAN'T MAKE IT
ANY DIFFERENTLY.

IT'S JUST, IF IT AIN'T BROKE,
DON'T FIX IT, YOU KNOW.

Narrator: SO THERE YOU HAVE IT,

A GLANCE THROUGH
THE HIDDEN HISTORY

AND SUPER SCIENCE

OF SOME AMAZING PRODUCTS
WE USE EVERY DAY...

...THE NYLON STOCKING,
THE L.E.D.,

AND THE ROWLETT RUTLAND
TOASTER.

THEY MAY SEEM
COMMON AND ORDINARY,

HOWEVER, THESE PRODUCTS
HELPED CHANGE THE WORLD

ONE INCREDIBLE INVENTION
AT A TIME.