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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Plastic cups and cutlery...
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...Special-effects makeup...
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...Gold...
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...And harps.
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The industry calls it
Single-usage plasticware,
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But that's just a fancy way to
Say throwaway plastic dishes.
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Plastic plates, bowls,
Drinkware, and cutlery
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Come in many styles and colors.
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So for your next party,
You can go disposable
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For everything from champagne
Flutes to parfait glasses.
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Factories make cutlery by
Injecting plastic into molds.
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They make cups, plates,
And bowls
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Using a different process
Called thermoforming.
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Before the forming phase
Can begin,
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An automated system
Loads polystyrene pellets
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Into a machine
Called an extruder,
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Adding pigments
For colored plastic.
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The extruder heats the pellets
Until they melt.
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Then it forces the molten
Plastic through a die
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To shape a hard-plastic sheet
About 8/100ths of an inch thick.
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They use molds to form
This continuous sheet
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Into plastic cups.
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First, the sheet passes through
An oven that's 10 feet long.
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It heats the hard plastic
Until it becomes malleable.
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Then it enters
The thermoforming machine,
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Which simultaneously pushes
And vacuums the sheets
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Into the mold cavities...
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Forming row after row of cups.
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The entire process takes
Just three seconds.
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The cups then travel
To the trimmer,
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Which uses a die
To cut them off the sheet.
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The machine grinds up
The leftover plastic
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And remelts it into new sheets,
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So there's no loss of material
Whatsoever.
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The trimmer feeds the cups
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Directly to a machine
That stacks them...
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Then feeds them to a conveyor
Belt in one long line.
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The conveyor transports them to
A machine called the lip roller.
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It reheats the cups just enough
To make the plastic flexible.
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Then, as we see here
In slow-motion,
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It folds the rim over,
Forming a rounded lip.
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They also make cutlery from
Melted polystyrene pellets,
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As well as from polypropylene --
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A lighter, more flexible, and
Less expensive type of plastic.
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The cutlery molds
Consist of two halves.
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You can see the difference
In this fork mold.
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In one half, the utensil
Cavities are right-side up --
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The fork prongs indented.
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In the other half, the cavities
Are upside down --
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The fork prongs raised.
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A plastic-injection machine
Melts the pellets
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And injects the molten plastic
Into the mold.
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A built-in cooling system
Solidifies the form
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In about 10 seconds.
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The extracted cutlery drops
To a conveyor belt
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That leads directly to the
Automated-packaging equipment.
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For certain customers
Such as fast-food restaurants,
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The factory packages utensils
Individually.
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The automated wrapping machine
Cuts polyethylene film to size,
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Heat-sealing the ends.
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This factory also uses
Polypropylene pellets
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To make straws.
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The black beads are pigments
To color the plastic.
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An extruder --
A different one this time --
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Melts the pellets,
Then forces the molten plastic
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Through a circle-shaped die.
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As the long, continuous straw
Exits the extruder,
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It cools and hardens
In a tank of chilled water.
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As it leaves the tank,
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A knife chops it
Into individual straws.
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They fall onto a conveyor belt
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Which transports them
To the packaging line.
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Just like the forks,
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These straws will also be
Individually wrapped --
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But in paper, not plastic film.
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The wrapper machine feeds them
One-by-one into a paper sleeve.
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Gears mesh the edges together,
Creating a crimped seal.
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The dies on this machine
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Turn ordinary straws
Into flexible ones
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By forming a corrugated section
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That lets you bend the top
Of the straw toward your mouth.
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The machine compresses
The corrugation
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To preserve the shape.
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Back to the plastic cups now.
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This factory can print
Customized designs
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In up to six colors
Applied simultaneously.
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Ultraviolet lamps built
Right into the printing press
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Dry the ink instantly.
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Polystyrene
Is naturally transparent.
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Combining two grades
Of polystyrene
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Creates plasticware
That's semiopaque
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And also highly flexible.
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Narrator:
On "How it's made,"
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We usually stick
To the show's title
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And show you how products
Are manufactured.
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But this next segment is about
Special-effects makeup --
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The kind that makeup artists use
On theater and movie actors.
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So in this case,
We'll show you how it's made,
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But we'll also show you
How it's applied.
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Watch as this
Special-effects-makeup artist
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Works his magic
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To transform this 28-year-old
Woman into a senior citizen.
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After gelling her hair flat,
He glued on a bald cap
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Using a theatrical adhesive
Called spirit gum.
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He protects her eyebrows
And eyelashes
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With petroleum jelly,
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Then covers her face
In alginate,
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A material generally used
To take dental impressions.
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Then he applies
Wet plaster bandages.
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After 25 minutes, the materials
Harden into a mask.
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Now he lines it with plaster.
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In a half-hour,
The plaster hardens
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Into a perfect replica
Of the woman's face.
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Like putting non-stick spray
On a baking pan,
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He coats the model
In a release agent.
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Then, using professional-grade
Plasticine,
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He begins to sculpt
An elderly face.
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He smoothes out the wrinkles
With strong rubbing alcohol
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So they'll look realistic.
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He uses a bumpy rubber pad
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To give the skin
An aged orange-peel texture.
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The finished sculpture
Sits in water for 2 to 3 hours.
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This activates
The release agent,
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Detaching the plasticine
From the plaster underneath.
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The artist carefully cuts
The sculpture into sections.
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The number of pieces varies
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With the size and complexity
Of the mask.
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Now he can start producing
The mold he'll use
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To cast the elderly woman's
Face mask.
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First, he takes a thin plaster
Impression of each piece.
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Then he coats the impression
In plaster
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To make the positive half
Of the mold.
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Once it hardens, he applies
The plasticine piece
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To space the depth
Of the mold cavity.
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Then he coats that in plaster
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To create the negative half
Of the mold.
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When it hardens,
He applies release agent
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To both mold cavities,
Pours in hot gelatin,
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Then closes the mold.
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In a half-hour,
The gelatin hardens
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Into a flexible replica
Of that particular piece
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Of the plasticine sculpture.
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He implants synthetic hairs
To create eyebrows.
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Now, using surgical glue,
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He begins to apply the pieces,
Called prosthetics.
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He starts with the largest
Facepiece first.
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It includes the nose, cheeks,
Neck, and upper lip.
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He cuts a hole in the chin area
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So that he can apply
The chinpiece.
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Now the lower lip.
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He cuts off the excess,
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Then glues the edges
Of the chinpiece
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To the large facepiece.
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Now for the forehead --
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Again, he applies glue
Along the edges
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To connect it to the rest.
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To age the eyes,
He uses contact lenses.
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They create a ring
Around the iris --
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A typical feature
Of elderly eyes.
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Using tweezers,
He applies eye bags,
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Again gluing the edges
To the rest of the mask.
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And finally,
Some wrinkly eyelids.
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With the mask fully assembled,
It's makeup time.
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Using a toothbrush,
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The artist sprays it unevenly
Over the mask,
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Then smudges it
With his fingers.
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This technique creates
A realistic look
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Because the human face --
Aged skin especially --
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Has color variations.
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Using a very thin brush,
He accentuates some wrinkles
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By creating depth
With a darker color.
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Now some freckles
And age spots...
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...And a gray wig.
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And finally,
Just a bit of lip color
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Because lips dull with age.
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All this takes
An experienced makeup artist
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About a month of work.
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And such expertise
Doesn't come cheap.
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A major transformation like this
For stage or screen
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Can cost up to $10,000.
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Narrator: gold is the softest
And most malleable metal.
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It can be pressed
Extremely thin,
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Crafted into various shapes,
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Even drawn out to form
A fine wire,
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And all without breaking.
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Gold isn't affected by water
Or oxygen, as many metals are,
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00:11:03,965 --> 00:11:06,517
So it doesn't rust or tarnish.
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Most gold comes
From lode deposits,
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Also called vein deposits --
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Concentrations of gold and other
Metals in the cracks of rocks.
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00:11:19,655 --> 00:11:22,655
Lode deposits require
Hard-rock mining,
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00:11:22,655 --> 00:11:24,517
Using drilling and blasting
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00:11:24,517 --> 00:11:27,310
To remove gold-bearing rock
Called ore.
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00:11:32,413 --> 00:11:36,862
Miners descend more than
1,600 feet underground.
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There they drill holes
For explosives
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00:11:41,551 --> 00:11:44,344
Using what's called
A long hole air drill.
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00:11:49,275 --> 00:11:52,344
They drill
In a specific pattern
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Set out in a plan prepared
By the mine's engineers.
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00:11:59,000 --> 00:12:03,000
The engineers know exactly where
Those veins of gold are
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00:12:03,000 --> 00:12:05,413
Thanks to the mining company's
Geologists,
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00:12:05,413 --> 00:12:09,379
Who've studied ore samples.
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00:12:09,379 --> 00:12:11,620
The company collects
These samples
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00:12:11,620 --> 00:12:14,896
By drilling deep into the rock
At 50-foot intervals.
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00:12:14,896 --> 00:12:18,827
These diamond-drill cores,
As they're called,
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00:12:18,827 --> 00:12:23,793
Are up to 330 feet long and
Measure 1.5 inches in diameter.
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00:12:25,586 --> 00:12:28,000
Gold in its natural state
Isn't pure.
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00:12:28,000 --> 00:12:31,206
It's usually intertwined
With silver or other metals.
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00:12:31,206 --> 00:12:34,379
So the mined ore has to be
Processed afterward
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00:12:34,379 --> 00:12:36,793
To isolate and extract the gold.
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00:12:36,793 --> 00:12:42,137
A ton of ore yields only about
2/10ths of an ounce of gold.
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00:12:45,275 --> 00:12:48,586
After blasting the rock apart
With explosives,
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00:12:48,586 --> 00:12:50,793
Miners use what's called
A muck machine
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00:12:50,793 --> 00:12:54,586
To transfer the ore to cars
Headed to the main shaft
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00:12:54,586 --> 00:12:57,000
And then aboveground
To the mill.
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00:12:58,862 --> 00:13:02,068
There, a crusher reduces
The large chunks
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00:13:02,068 --> 00:13:05,655
Into smaller rocks about
The size of road gravel.
220
00:13:05,655 --> 00:13:09,482
A mill then pulverizes them
To the texture of beach sand.
221
00:13:09,482 --> 00:13:13,206
The factory adds
A water and cyanide solution,
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00:13:13,206 --> 00:13:16,379
Then another mill grinds it
Further into a mud-like pulp.
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00:13:16,379 --> 00:13:19,482
The pulp flows into
Large settling tanks.
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00:13:19,482 --> 00:13:23,172
The wet solids are heavier
And sink to the bottom.
225
00:13:23,172 --> 00:13:26,000
The water at the top
Drains to another area.
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00:13:26,000 --> 00:13:29,344
They transfer the wet solids
To an agitation tank
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00:13:29,344 --> 00:13:30,551
And blow in air.
228
00:13:30,551 --> 00:13:33,000
The oxygen sets off
A chemical reaction
229
00:13:33,000 --> 00:13:36,068
Between the cyanide
And the gold trapped in the ore,
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00:13:36,068 --> 00:13:37,931
Triggering the gold to dissolve
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00:13:37,931 --> 00:13:41,379
And leach
Into the surrounding water.
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00:13:41,379 --> 00:13:45,862
Drum filters then separate
The water from the solids.
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00:13:45,862 --> 00:13:49,517
This water now joins the water
That was separated earlier.
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00:13:49,517 --> 00:13:53,034
They pour in zinc powder to
Solidify the dissolved gold
235
00:13:53,034 --> 00:13:56,724
And form pieces containing
Both zinc and gold.
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00:13:56,724 --> 00:13:58,379
To smelt it into bars,
237
00:13:58,379 --> 00:14:01,034
They first have to mix
Several chemicals --
238
00:14:01,034 --> 00:14:03,517
Manganese dioxide...
239
00:14:03,517 --> 00:14:06,551
Fluoride...
240
00:14:06,551 --> 00:14:08,275
Silica flour...
241
00:14:10,551 --> 00:14:12,862
...Borax...
242
00:14:12,862 --> 00:14:15,482
And sodium nitrate.
243
00:14:15,482 --> 00:14:17,448
This chemical mix, called flux,
244
00:14:17,448 --> 00:14:20,413
Will separate the gold
From the impurities.
245
00:14:20,413 --> 00:14:23,241
They pour it into the smelter,
246
00:14:23,241 --> 00:14:28,206
Whose temperature is a fiery
2,910 degrees fahrenheit.
247
00:14:32,896 --> 00:14:35,241
They rotate the smelter
248
00:14:35,241 --> 00:14:39,034
So that the contents
Heat evenly over 2 1/2 hours.
249
00:14:39,034 --> 00:14:42,586
The heavier gold eventually
Sinks to the bottom,
250
00:14:42,586 --> 00:14:45,482
While the impurities,
Called slag,
251
00:14:45,482 --> 00:14:47,206
Float to the surface.
252
00:14:47,206 --> 00:14:48,827
They pour out the slag,
253
00:14:48,827 --> 00:14:52,103
Taking a sample to make sure
It contains no gold.
254
00:14:52,103 --> 00:14:56,827
If it does, it goes back in
Until it's gold-free.
255
00:14:56,827 --> 00:14:59,620
By now, the gold
Has cooled slightly,
256
00:14:59,620 --> 00:15:03,034
So they reheat it
To 2,910 degrees fahrenheit,
257
00:15:03,034 --> 00:15:06,413
Then cast it
Into bar-shaped molds.
258
00:15:06,413 --> 00:15:09,758
The gold takes about
Four minutes to solidify.
259
00:15:09,758 --> 00:15:12,379
It's put in a basin
Of cold water,
260
00:15:12,379 --> 00:15:14,965
Where it will cool completely
After an hour.
261
00:15:14,965 --> 00:15:17,379
They extract the gold bars
From the molds
262
00:15:17,379 --> 00:15:19,241
And clean off any slag residue.
263
00:15:21,517 --> 00:15:24,034
Gold bars are
Also called ingots.
264
00:15:24,034 --> 00:15:28,103
At this stage,
The gold is 80% pure.
265
00:15:28,103 --> 00:15:31,482
The united states mint
Will refine it to 99.9% --
266
00:15:31,482 --> 00:15:33,482
The international gold standard.
267
00:15:44,379 --> 00:15:46,724
Narrator:
Harps come in many sizes.
268
00:15:46,724 --> 00:15:49,172
The type that
Classical musicians play
269
00:15:49,172 --> 00:15:52,068
Is known as the orchestral,
Or concert, harp.
270
00:15:52,068 --> 00:15:55,827
It produces more tones than
Any other stringed instrument.
271
00:15:55,827 --> 00:15:57,620
The player plucks the harp
272
00:15:57,620 --> 00:16:01,034
With the thumb and first three
Fingers of each hand,
273
00:16:01,034 --> 00:16:04,137
While at the same time
Operating foot pedals.
274
00:16:10,206 --> 00:16:13,827
The harp is one of the oldest
String instruments,
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00:16:13,827 --> 00:16:17,620
Originating in the middle east
As early as 3000 b.C.
276
00:16:17,620 --> 00:16:21,379
Harps begin appearing
In europe in the 700s.
277
00:16:21,379 --> 00:16:24,068
They initially had
A curved pillar.
278
00:16:24,068 --> 00:16:28,172
By about 1500, this evolved
Into a sturdier straight pillar
279
00:16:28,172 --> 00:16:32,034
That could support more tension.
280
00:16:32,034 --> 00:16:34,482
As music became
More sophisticated,
281
00:16:34,482 --> 00:16:36,931
They added a second row
Of strings
282
00:16:36,931 --> 00:16:39,448
As well as pitch-raising
Mechanisms,
283
00:16:39,448 --> 00:16:42,827
Enabling the orchestral harp
To produce more notes.
284
00:16:52,482 --> 00:16:54,310
This harp is a cross
285
00:16:54,310 --> 00:16:57,172
Between a classical harp
And a celtic harp.
286
00:16:57,172 --> 00:17:00,862
There's the pillar in the front,
The sound box in the back,
287
00:17:00,862 --> 00:17:03,344
And the neck
Running across the top.
288
00:17:03,344 --> 00:17:07,275
The sides of the sound box
Are called the ribs.
289
00:17:07,275 --> 00:17:10,000
They're made from pieces
Of solid poplar,
290
00:17:10,000 --> 00:17:11,655
3/10ths of an inch thick.
291
00:17:11,655 --> 00:17:15,379
The instrument maker traces a
Rib-shaped template on the wood
292
00:17:15,379 --> 00:17:18,965
And then cuts out the shape
Using a band saw.
293
00:17:22,172 --> 00:17:24,689
He clamps them
Onto his worktable
294
00:17:24,689 --> 00:17:27,206
And, with a plane,
Makes them symmetrical.
295
00:17:30,206 --> 00:17:32,655
Now he draws three lines
Across each rib
296
00:17:32,655 --> 00:17:35,620
To mark where he'll cut slots.
297
00:17:35,620 --> 00:17:40,379
You'll see what those slots
Are for later on.
298
00:17:40,379 --> 00:17:44,344
Next he glues on a notched strip
Of wood called a lining
299
00:17:44,344 --> 00:17:46,310
To the curved side of the rib.
300
00:17:46,310 --> 00:17:49,103
The lining enlarges
The glueable surface,
301
00:17:49,103 --> 00:17:51,724
Making it easier
To assemble the side
302
00:17:51,724 --> 00:17:53,827
To the back of the sound box.
303
00:17:53,827 --> 00:17:58,241
The notches enable the lining
To bend to the curved shape.
304
00:18:03,103 --> 00:18:04,758
Now he glues on the lining
305
00:18:04,758 --> 00:18:06,965
That will connect
The straight side of the rib
306
00:18:06,965 --> 00:18:10,758
To the front of the sound box.
307
00:18:10,758 --> 00:18:13,379
He shaves off some wood
With a small plane,
308
00:18:13,379 --> 00:18:15,551
Then rounds off a corner.
309
00:18:23,793 --> 00:18:26,586
He planes the back lining
As well,
310
00:18:26,586 --> 00:18:29,137
Removing a corner to flatten it.
311
00:18:29,137 --> 00:18:32,896
Trimming the linings reduces the
Final weight of the instrument.
312
00:18:37,413 --> 00:18:40,689
Now he cuts off the ends
Of the linings on both sides
313
00:18:40,689 --> 00:18:43,827
To be able to slide into place
The adjoining parts,
314
00:18:43,827 --> 00:18:46,379
The bottom plate,
And the top plate.
315
00:18:46,379 --> 00:18:50,206
They're made of russian plywood,
Which is a piece of plywood
316
00:18:50,206 --> 00:18:52,620
Sandwiched between sheets
Of birchwood
317
00:18:52,620 --> 00:18:55,344
1/10th of an inch thick.
318
00:18:55,344 --> 00:18:59,137
He glues the top plate
Into place, then clamps it.
319
00:18:59,137 --> 00:19:02,068
He does the same
With the bottom plate.
320
00:19:04,448 --> 00:19:06,517
He closes the back
Of the sound box
321
00:19:06,517 --> 00:19:08,793
With what's called
The back plate.
322
00:19:08,793 --> 00:19:11,241
It's also cut
From russian plywood.
323
00:19:11,241 --> 00:19:12,827
He glues it onto the lining,
324
00:19:12,827 --> 00:19:15,758
Applying pressure with
Tight rubber strapping.
325
00:19:15,758 --> 00:19:18,206
When the glue dries
After about an hour
326
00:19:18,206 --> 00:19:19,931
And the strapping comes off,
327
00:19:19,931 --> 00:19:22,517
He marks the location
Of the sound holes,
328
00:19:22,517 --> 00:19:25,551
The holes from which sound
Exits the instrument.
329
00:19:25,551 --> 00:19:29,068
He constructs the top plate
On the front of the sound box
330
00:19:29,068 --> 00:19:30,482
From solid spruce.
331
00:19:30,482 --> 00:19:34,068
He lays the pieces down
From widest to narrowest,
332
00:19:34,068 --> 00:19:37,379
Then glues on a reinforcement
Strip made of solid maple.
333
00:19:37,379 --> 00:19:39,620
The strings pass
Through the strip
334
00:19:39,620 --> 00:19:41,241
And another on the inside.
335
00:19:41,241 --> 00:19:44,448
They prevent the tension
From rupturing the top plate.
336
00:19:44,448 --> 00:19:46,655
He attaches a solid poplar frame
337
00:19:46,655 --> 00:19:50,241
To strengthen where
The top plate and the ribs join.
338
00:19:50,241 --> 00:19:52,793
After sanding
With fine sandpaper,
339
00:19:52,793 --> 00:19:55,206
He coats the sound box
In varnish.
340
00:19:55,206 --> 00:19:57,620
Remember those slots
In the ribs?
341
00:19:57,620 --> 00:20:01,172
They now hold bracings
To prevent the ribs from bowing
342
00:20:01,172 --> 00:20:03,724
Under the tension
Of the strings.
343
00:20:03,724 --> 00:20:07,413
Using a band saw, the instrument
Maker cuts the neck
344
00:20:07,413 --> 00:20:11,103
From a board of russian plywood
About an inch thick.
345
00:20:11,103 --> 00:20:13,689
He makes a slot for gluing
The pillar,
346
00:20:13,689 --> 00:20:15,517
Also made of russian plywood.
347
00:20:15,517 --> 00:20:18,620
Once the varnish on the neck
And pillar are dry,
348
00:20:18,620 --> 00:20:21,103
He hammers in pins
For the strings.
349
00:20:21,103 --> 00:20:23,482
This type of harp
Has 34 strings.
350
00:20:23,482 --> 00:20:27,103
Brass bridge pins space them
Evenly apart.
351
00:20:27,103 --> 00:20:30,724
Steel zither pins adjust
The tension for tuning.
352
00:20:30,724 --> 00:20:35,448
He uses a wooden guide to hammer
The pins to a uniform depth.
353
00:20:35,448 --> 00:20:39,724
The three finished pieces fit
Together with dowels and slots.
354
00:20:39,724 --> 00:20:41,862
He secures the joints with glue
355
00:20:41,862 --> 00:20:44,482
And a long screw
Through the pillar.
356
00:20:44,482 --> 00:20:47,137
Strength is critical.
357
00:20:47,137 --> 00:20:52,034
This harp has to withstand
790 pounds of string tension.
358
00:20:52,034 --> 00:20:54,448
Reaching through
The sound holes,
359
00:20:54,448 --> 00:20:57,482
He threads the strings through
The reinforcement strips
360
00:20:57,482 --> 00:20:59,034
To the pins outside.
361
00:20:59,034 --> 00:21:02,482
These are nylon strings.
362
00:21:02,482 --> 00:21:04,655
Harps can
Also have steel strings.
363
00:21:04,655 --> 00:21:08,413
He winds them around the zither
Pins with a special key.
364
00:21:08,413 --> 00:21:10,724
The last step
Is to tune the harp
365
00:21:10,724 --> 00:21:13,482
With the help
Of an electronic tuner.
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00:21:22,448 --> 00:21:24,689
If you have any comments
About the show
367
00:21:24,689 --> 00:21:27,655
Or if you'd like to suggest
Topics for future shows,
368
00:21:27,655 --> 00:21:29,862
Drop us a line at...
29534
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