All language subtitles for S06E05 - Air Filters; Billiard Cues; Ice Sculptures; Suits (576p AMZN WEB-DL x265 Garshasp)_track4_[eng]

Narrator:
Today on "How it's made"...

Air filters...

...Billiard cues...

...Ice sculptures...

...And suits.

Pollutants in the air

Can make it tough for you
To breathe and function.

But pollutants can also affect
Your car's performance.

It's the reason an air filter
Is standard equipment

On internal combustion engines.

The filter keeps dirt
And particles out of the engine

So it runs smoothly
And gives good mileage.

Trapping dust and grime
Is a dirty job,

And it takes its toll.

Air filters get clogged and
Have to be replaced regularly.

So we need a steady supply.

To make an air filter,

An automated spool
Unwinds thick paper

And feeds it
Between two rollers.

Bumps on the rollers press
Indentations into the paper.

The short, vertical ones
Are spacers

To help air flow
Through the filter.

The long, horizontal lines
Are the pre-fold creases.

The rollers fold the paper
Along those lines

As they push it out
The other side.

An automated counter
Keeps track of the folds,

Because each filter needs
To have approximately 75 pleats.

Now a conveyor belt moves
The paper to a circular blade.

A steel bar
Holds the paper pack down

While the blade slides
On a motorized rail,

Slicing the paper
At the correct number of folds.

The paper pack
Rolls down the conveyor belt,

Heading to the next station.

In the meantime,

A robotic arm sprays liquid wax
Onto the aluminum molds

That will be used to shape the
Tops and bottoms of the filters.

The carousel turns, positioning
Another set for spraying.

The wax will ensure
That nothing sticks to the molds

During the next steps.

Now chrome-plated steel screens
Fall into a positioning tray.

A robot picks them up
With magnets two at a time.

It places them on
The bottom mold for the filter.

A platen, or plate,
Bearing two top molds

Flips forward on the carousel.

The carousel turns,
And remember the paper packs?

A worker places one
In each of those two top molds.

Now a robot dispenses
A liquid polyurethane mixture

Around the screen
In the bottom mold.

Then the automated platen
Flips back

So that the top molds
With the paper packs face down.

An air cylinder pushes a platen
Holding the bottom molds up

To meet the top ones,

And heat triggers
This chemical reaction.

The polyurethane swells

And covers the screen
And the paper pack,

Forming a solid,
Flexible plastic layer.

A robot with grippers peels the
New air filter out of the mold

And sets it on a cooling rack.

Because of the wax
Sprayed onto the molds,

The robots
Don't have to work hard

To pull the air filters out.

Like well-greased cookie sheets,

Nothing gets stuck
To the bottom.

After they're cool,
The rack tips up,

And the air filters
Tumble down a slide

To a worker
Who collects each one.

With a band saw, she trims
The excess polyurethane,

Or flash, from the rim.

Now all that's left
Is the packaging.

On another assembly line,

A robot prepares to make
A radial seal type of filter.

It sprays the no-stick wax

Onto the brims of molds that
Look like inverted top hats.

A small wheel turns

And delivers the molds
To a larger assembly wheel.

Another robot
Picks up plastic caps

And places them
Inside the molds.

Then a pneumatic pusher
Raises the caps,

And nozzles dispense a
Hot glue bead onto their edges.

Another pneumatic pusher tool

Forces round packs of pleated
Paper out of cylindrical holders

And into the molds.

The big wheel keeps on turning,
Positioning the molds

To receive more packs, or tubes,
Of filter paper.

The wheel pushes
The paper-filled molds

Onto a conveyor belt.

And down the line,
A robot pumps a polyurethane mix

Into the bottom mold
For the filter.

A worker presses the
Paper-filled top mold onto it.

Heat triggers
The chemical reaction

That expands the polyurethane,

Encasing the bottom
Of the filter paper

And forming a gasket

That will fit snugly
Near an engine intake.

The radial air filter
Is now completely assembled,

And it's taken just 20 minutes.

The filters are ready to work

Under the hood
Of today's automobiles.

Narrator: the game of billiards
Has been popular

For several hundred years,

Dating back as early
As the 15th century.

Then players used a mace
To strike the ball.

When the mace's large head

Made it tough
To shoot along the rail,

Players started using
Its slimmer tail end.

This led to the invention
Of the cue stick

So players didn't have to worry
About switching back and forth.

Pick a cue, but be selective,

Because choosing a stick
That feels right for you

Pays off when you're behind
The eight ball.

To make the butt,
Or bottom section, of a cue,

They start with a block
Of expensive bird's-eye maple.

The wood spins on a lathe.

A doughnut-shaped blade
Moves on rails

And cuts around
The circumference,

Turning the block
Into a cylinder.

As it cuts,
The shavings are vacuumed away.

Now a square-tipped steel cutter

Carves into one end of the wood.

It makes a groove
That will be used

To attach the butt's forearm
To its lower part.

He slides a black plastic ring
Around the rim

And glues it down.

It's decorative,

But it will also give the cue
Some stability.

Next, he brushes glue on top
Of it to attach another ring,

This one made of
A nickel/silver alloy.

He screws the forearm into
The lower part of the butt.

Glue oozes out of the joint
As the screws tighten.

The forearm is now bonded
To the lower part of the cue,

Making one butt piece.

Then they employ
A vertical cnc lathe.

Computerized cutters
Move up on rails,

Precisely tapering each butt
Piece to the desired diameter.

After that, another computerized
Tool called a cnc inlay cutter

Chisels geometric designs
Into the cue's forearm.

The same type of cutter

Carves matching designs
From ebony wood.

A worker removes the ebony
Cutouts and inspects them.

He handles them cautiously

Because the thin strips of wood
Are fragile and break easily.

With a stick, he slathers
A thick epoxy mixture

Into the cue stick's
Carved-out design.

The ingredients
Of this high-strength glue

Are a trade secret.

Next, he presses one
Of the ebony cutouts

Into the glue-filled cavity.

He fits a synthetic ivory cutout
Inside of the ebony one,

Pressing it down into the glue
With big tweezers.

He continues to build the design
With another piece of ebony.

These intricate inlays
Give the cue some attitude.

A cue stick's good looks
Can affect a player's mind-set

And give him or her
A competitive edge.

This glue may look a bit messy
Now, but when it dries,

The ample amounts
Will keep the inlay tight,

Preventing air and moisture from
Getting in and doing damage.

He inserts little pieces
Of synthetic stone

As a final touch...

And then presses all the pieces
Down with a wood dowel.

Next, a computerized drill
Bores a hole

In the exact center
Of the joint section.

A second drilling
Makes a thread inside the hole.

He screws a steel joint pin
Dappled with glue

Into the thread
Created by the drill,

Twisting it tightly
With a special tool.

When the joint
Is fully entrenched,

He unscrews the tool.

And now the butt can be screwed
To the shaft for the game

And then taken apart
For transport.

An automated paint gun

Sprays clear varnish
Onto the cue sticks.

A motorized stamping machine

Inks the logo
Onto the cue's butt piece.

And a worker applies glue as
The cue stick turns on a lathe.

This is in preparation
For the wrap.

Then the turning cue pulls linen
Thread from a spool,

Wrapping itself with the
Lower section with glue on it.

This linen wrap will make
The cue easier to grip

And will absorb moisture.

They roll the cue stick
Up against

A high-speed cloth buffing wheel
To give it a shine.

Now these cue sticks are ready
For some serious competition

In the pool hall.

Narrator: ice sculptures
Can make quite an impression

At a party or social engagement.

Before they melt, their beauty
Can be seen and admired.

Mass production of
Ice sculptures is now possible

With new machines and tools.

And the market for
Ice sculptures is expanding.

It's a curtain of ice,

And it's in demand
For big events.

They string beads of ice on
Plastic-coated aircraft cable.

As it melts,
It creates a waterfall effect.

It's guaranteed
To make an impression.

But just how do they get
This ice to be crystal clear?

They start by tucking
A plastic liner into a big tank.

They pipe filtered water
Into it.

Then a worker places
A measuring bar with a dipstick

Across the tank.

The dipstick
Is set at 10 inches.

That's how thick
The block of ice needs to be.

He clamps electric submersible
Pumps on each end of the tank

And positions them underwater
At a 45-degree angle.

These pumps are key.

They keep the water moving,

Forcing bubbles and impurities
To the top

While clear water below freezes.

He shuts the lid
To allow the water to freeze.

24 hours into it,
He'll remove one of the pumps.

Three days later,

He probes the ice under
The watery surface with a pick.

It needs to be level,

So he checks the entire ice
Surface with a measuring bar.

Next, he siphons off the
Excess water with a wet vacuum.

He'll take off
A couple of buckets full.

Then he attaches a lifting bar

To brackets
On each end of the tank

And lifts the 300-pound
Ice block with a chain hoist.

Now he peels away
The plastic liner and inspects.

The ice has to be
Absolutely perfect --

No clouds, cracks,
Or impurities.

Because water expands
When it freezes,

The block is a bit too thick,

So they slice off the excess ice
With an electric band saw,

Trimming it back
To the desired 10-inch mark.

The steel blade
Cuts cleanly and evenly.

He slides the extra pieces
Of ice into a heated pit,

Where they'll melt and be
Recycled back into the system.

Before the ice is carved,
They put the design on paper.

The artist
Is sketching a liquor luge --

Two vodka bottles made of ice,
Through which drinks will flow.

Now its time to cut the ice.

The block turns
On a special lathe.

Then they propel
An electric router

Across the spinning block.

The sharp edges of the router
Cut into the ice.

A guide wheel above the router

Follows a plastic outline
Of a bottle

So it cuts precisely
To the design.

All this is done in the freezer.

The temperature in here is
Just over 17 degrees fahrenheit.

Now the vodka bottle
Is starting to take shape.

It takes about four minutes
For this machine to carve it.

This task couldn't be performed
As quickly or precisely by hand.

After the carving, the worker
Brushes off the ice shavings.

Then its time for the blowtorch.

It melts the frost
So the ice looks like glass,

Through which you can clearly
See the label and plastic tubing

That have been frozen inside.

Now we have
The finished vodka luge,

Which will be used
To serve drinks at parties.

The barman pours the drinks
Through a funnel at the top,

And the drink chills all the way
Down to the martini glass.

If a fish fountain
Is more your style,

This is how it's done,
The old-fashioned way.

The sculptor,
Armed with a chainsaw,

Shapes the ice
Following a cardboard template.

She smoothes the ice

With an electrically powered
Disk grinder,

Then cuts in detail

By using a die grinder
With a triangular bit.

She dusts off the snow...

And then polishes the ice
With a blast from the blowtorch.

Now, that's a work of art.

Narrator: in today's world,
Suits are common,

Allowing both men and women
To dress the part

For any situation --

Everyday work
Or a special occasion.

While men and women may wear
Different parts of a suit,

The basics of the suit have been
Unaltered for over a century --

A jacket and trousers or skirt.

It's a look
That's never out of style.

Every suit begins
With a design on paper.

The style is precisely sketched.

It's a creative process
But also highly technical.

He plans the entire outfit,
Right down to the last stitch.

No detail
Is left to chance here.

They feed the design data

To this computerized
Cutting machine.

The blade slices through fabric
Placed under paper.

And because it's computerized,
It's very precise,

Producing pieces that will
Fit together like a puzzle.

This is how they used
To cut the fabric -- by hand.

It was more time-consuming,

And the margin for error
Was much greater.

Now it's time
To reinforce the fabric.

She places fusing tape made of
Fabric onto a sleeve piece

And then sends it
To a heat chamber with rollers

That will bond the tape to the
Material, giving it strength.

Next, it's over
To the sewing machine.

A worker lines up
Two sleeve layers,

And it's hands-free from here.

A rail powered by compressed air
Descends

And guides the fabric
Under the needle.

A computer controls the sewing.

This frees up the operator

To continuously feed
The machine.

This is an
Automatic pocket welt machine.

She places the front of a jacket
Under a clamp

And puts the welt fabric
In the clamp

And a pocket flap at the side.

The clamp automatically
Slides the fabrics to needles

That sew the welt and flap
Onto the jacket.

Then two tiny knives emerge
And cut the pocket open.

The result -- a precisely made
Pocket completely by automation.

The only human involvement
Is to feed the machine

And then collect
The finished product.

Now over at another station,

An operator irons fusible tape
Onto the open seams.

This stabilizes them
And gives them a crisp finish.

A worker places
The front of the jacket

On a headless mannequin
Called a buck.

A hot metal press moves in,

And the pressing
Reshapes the jacket

To the contours of the buck.

Now she puts a sleeveless jacket
On another buck

And tucks a shoulder pad
Underneath.

She presses a pedal
To activate the machine,

And the hot presses lower,

Melting the glue
On the shoulder pad,

Which fuses it to the jacket.

Now to steam the fabric.

Another jacket
Is on another mannequin.

And a worker
Clamps down the sleeves.

A big steam bag
Made of porous vinyl swings in,

Wafting steam
Onto the front of the jacket.

At the same time,

Hoses pipe steam into
The porous mannequin cavity,

So this jacket gets
A steam press from both sides.

This machine is a collar master.

She folds the collar
Into the correct position

And lowers a big fabric-covered
Metal press onto the collar

To iron down the fold.

It's time
For the auto-jig machine.

It's making an extension piece
To the second button

For a pant waistband.

This is the piece
That goes over the second button

On the waistband of dress pants.

It sews and cuts two layers
Of fabric that are held in a jig

And then feeds the excess fabric
To a vacuum tube for disposal.

Now it's time to define a crease
In a pair of trousers.

An operator slides
A pair of pants, inside out,

Onto a double rail.

Then using a device
Similar to a caulking gun,

She pipes a silicone-based
Liquid along the crease line.

The liquid
Is a perma-crease mixture,

Which will give the crease
Some staying power.

There's also a nib
On the end of this gun

Which sharpens the crease.

All that stitching and steaming

Seems to have gone
Without a hitch.

But the designer
Still needs to inspect the work

To see if it measures up
To his original concept.

If adjustments have to be made,

He marks the spots.

That's because how it fits

Can be just as important
As how it looks.

--captions by vitac--
Www.Vitac.Com

Captions paid for by
Discovery communications, inc.

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