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--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,758
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:22,517 --> 00:00:26,413
Narrator:
TODAY ON "HOW IT'S MADE"...
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00:00:26,413 --> 00:00:28,344
FENCING MASKS...
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...BOOKS...
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00:00:38,068 --> 00:00:40,517
...OCEAN DRONE TRANSFORMERS...
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00:00:43,965 --> 00:00:45,862
...AND 3-D PUZZLES.
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00:00:53,103 --> 00:00:57,448
FENCING IS ONE OF THE
OLDEST FORMS OF ARMED COMBAT.
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00:00:57,448 --> 00:01:01,517
IN THE LATE 18th CENTURY,
FENCING EVOLVED INTO A SPORT.
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00:01:01,517 --> 00:01:03,620
AS FENCING GAINED POPULARITY,
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00:01:03,620 --> 00:01:05,965
A STEEL MESH MASK WAS INVENTED
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00:01:05,965 --> 00:01:09,034
TO PROTECT THE EYES AND FACE
FROM INJURY.
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00:01:13,379 --> 00:01:17,655
BEFORE FENCERS SAY "EN GARDE,"
THEY DON A FACE GUARD.
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00:01:17,655 --> 00:01:21,689
TODAY, FENCING IS RECOGNIZED
AS AN OLYMPIC SPORT,
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00:01:21,689 --> 00:01:25,724
SO SPECIAL MESH MASKS ARE
REQUIRED TO COMPETE.
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00:01:25,724 --> 00:01:28,172
REGULATION FENCING MASKS
ARE MADE
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00:01:28,172 --> 00:01:31,758
FROM RECTANGULAR PIECES
OF TIGHT STEEL MESH.
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00:01:31,758 --> 00:01:34,344
A MACHINIST USES
A GUILLOTINE BLADE
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00:01:34,344 --> 00:01:38,620
TO CUT THE CORNERS OF
THE MESH PIECE ON AN ANGLE.
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00:01:38,620 --> 00:01:41,413
THEN HE TRANSFERS
THE MESH TO A PRESS
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00:01:41,413 --> 00:01:44,206
WITH A LARGE MOLD THAT'S
SHAPED LIKE A FACE.
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00:01:44,206 --> 00:01:47,482
THE HYDRAULICALLY POWERED
MOLD PRESS BEARS DOWN
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00:01:47,482 --> 00:01:50,965
ON THE STEEL MESH AND FORCES
IT INTO A ROUNDED SHAPE.
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00:01:52,379 --> 00:01:55,827
USING A SPECIAL TOOL,
THE MACHINIST BENDS STEEL WIRE
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00:01:55,827 --> 00:01:57,068
TO A FORM.
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00:01:59,344 --> 00:02:03,241
HE BRINGS THE ENDS OF THE WIRE
TOGETHER TO CLOSE THE LOOP.
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00:02:04,344 --> 00:02:06,862
AN AUTOMATED WELDER
FUSES THE ENDS.
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00:02:09,379 --> 00:02:12,655
THE MACHINIST TRANSFERS THE HOOP
TO THE NEXT FIXTURE
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00:02:12,655 --> 00:02:16,206
AND PLACES THE ROUNDED
STEEL MESH ON TOP OF THE HOOP.
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00:02:17,517 --> 00:02:21,413
A FRAME DESCENDS,
AFFIXING THE MESH TO THE HOOP.
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00:02:21,413 --> 00:02:24,379
THEN MULTIPLE WELDING GUNS
SPOT-WELD THE MESH
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00:02:24,379 --> 00:02:26,413
TO THE HOOP.
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00:02:26,413 --> 00:02:30,827
A LARGE WELDING GUN CLOSES
THE GAPS BETWEEN THE SPOT-WELDS.
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00:02:30,827 --> 00:02:32,068
ONCE FUSED,
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00:02:32,068 --> 00:02:34,586
THE HOOP WILL PREVENT THE MESH
FROM FRAYING
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00:02:34,586 --> 00:02:36,862
AND ADD STRUCTURAL RIGIDITY.
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00:02:40,379 --> 00:02:41,827
USING A NIBBLER TOOL,
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00:02:41,827 --> 00:02:43,448
THE MACHINIST TRIMS THE MESH,
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00:02:43,448 --> 00:02:45,793
REVEALING A CLEAN EDGE.
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00:02:45,793 --> 00:02:48,758
NEXT, THE TECHNICIAN WORKS
ON THE MASK'S SIDE PIECE
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00:02:48,758 --> 00:02:51,448
BY BENDING STEEL WIRE
INTO A RECTANGLE.
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00:02:53,344 --> 00:02:56,517
HE PLACES THE RECTANGULAR
FRAME IN A FIXTURE
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00:02:56,517 --> 00:02:59,137
AND SETS A PIECE OF MESH
OVER THE FRAME.
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00:03:02,379 --> 00:03:05,551
HE SPOT-WELDS
THE MESH TO THE FRAME.
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00:03:05,551 --> 00:03:08,172
THIS STEP PROVIDES
A MORE CONSISTENT WELD
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00:03:08,172 --> 00:03:09,965
AROUND THE ENTIRE MASK.
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00:03:12,482 --> 00:03:16,827
COPPER WELDING WHEELS FUSE
AND SEAL THE MESH TO THE FRAME.
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00:03:20,000 --> 00:03:22,275
THEN THE MACHINIST USES
A GRINDING WHEEL
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00:03:22,275 --> 00:03:26,586
TO REMOVE ANY SHARP BITS
OR PROTRUSIONS.
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THIS IS THE RESULT.
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00:03:31,103 --> 00:03:33,137
A BENDING DEVICE ROUNDS THE PART
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SO THAT IT WILL FIT TO
THE SIDES AND TOP OF THE HEAD.
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HE WELDS THE ROUNDED PART TO
THE BACK OF THE FENCING MASK.
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A LARGE WELDING GUN
SPOT-WELDS THE ASSEMBLY TOGETHER
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00:03:46,724 --> 00:03:49,034
IN PREPARATION FOR A FINAL WELD.
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00:03:55,344 --> 00:03:58,965
ONCE COMPLETE, THE MACHINIST
MAKES A FULL SEAM WELD,
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00:03:58,965 --> 00:04:00,655
CLOSING ALL GAPS.
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00:04:00,655 --> 00:04:03,655
THIS WILL PREVENT A SWORD
FROM PIERCING THROUGH THE MASK,
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00:04:03,655 --> 00:04:07,275
POTENTIALLY WOUNDING THE WEARER.
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00:04:07,275 --> 00:04:10,310
NEXT, THE TECHNICIAN
POUNDS OUT ANY REMAINING DENTS
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00:04:10,310 --> 00:04:12,413
WITH A HAMMER,
RESTORING THE MASK
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00:04:12,413 --> 00:04:14,241
TO THE DESIRED CONTOURS.
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00:04:17,206 --> 00:04:20,275
HE PLACES THE FENCING MASK
ON A ROUNDED POST
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00:04:20,275 --> 00:04:23,103
AND USES A PLASTIC MALLET
TO HAMMER THE MASK
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00:04:23,103 --> 00:04:24,689
AGAINST THE POST.
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00:04:24,689 --> 00:04:28,896
THIS STEP WILL IMPROVE
THE OVERALL SHAPE OF THE MASK.
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00:04:28,896 --> 00:04:32,655
THEY BIG IS MADE OUT OF
HIGH MOLECULAR POLYETHYLENE,
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00:04:32,655 --> 00:04:35,965
WHICH IS STRONG
AND EXTREMELY LIGHT WEIGHT.
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00:04:35,965 --> 00:04:38,000
THE BIB INCLUDES
A THICK RUBBER BAND
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00:04:38,000 --> 00:04:39,931
THAT ATTACHES TO THE MESH MASK.
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00:04:41,310 --> 00:04:43,620
ONCE THE MESH
IS COATED WITH PLASTIC,
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00:04:43,620 --> 00:04:45,758
ANOTHER TECHNICIAN INSTALLS
RUBBER TRIM
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00:04:45,758 --> 00:04:48,310
ALONG THE PERIMETER
OF THE MASK.
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00:04:48,310 --> 00:04:50,034
THE PLASTIC COATING
ON THE MESH
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00:04:50,034 --> 00:04:53,448
INSULATES THE MASK, PREVENTING
ELECTRICAL INTERFERENCE
76
00:04:53,448 --> 00:04:55,482
FROM THE SCORING
SYSTEM'S WIRING.
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00:04:57,172 --> 00:05:00,379
THE TECHNICIAN PIPES EPOXY GLUE
AROUND THE MASK
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00:05:00,379 --> 00:05:02,931
JUST ABOVE THE RUBBER TRIM.
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00:05:02,931 --> 00:05:05,862
HE PULLS THE BIB'S
RUBBER BAND OVER THE MASK
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00:05:05,862 --> 00:05:08,034
AND DOWN TO THE BEAD OF GLUE
AT THE BOTTOM.
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00:05:12,137 --> 00:05:14,034
HE TUCKS THE PIECES OF MATERIAL
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00:05:14,034 --> 00:05:16,689
UNDER THE BAND
FOR A NEATER LOOK.
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00:05:16,689 --> 00:05:18,517
AS THE GLUE CURES,
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00:05:18,517 --> 00:05:21,620
THE BIB'S RUBBER BAND
ADHERES TO THE FENCING MASK.
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00:05:24,206 --> 00:05:26,206
ANOTHER MACHINIST
DRILLS RIVET HOLES
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00:05:26,206 --> 00:05:29,827
THROUGH THE BIB AND MESH
ALONG THE SIDES OF THE MASK.
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00:05:37,241 --> 00:05:39,758
THEN HE INSERTS
AND FLATTENS THE RIVETS
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00:05:39,758 --> 00:05:42,103
TO PULL THE BIB FLUSH
TO THE MESH.
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00:05:44,241 --> 00:05:45,482
EACH FENCING DISCIPLINE
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00:05:45,482 --> 00:05:48,827
REQUIRES ITS OWN
UNIQUELY DESIGNED MASK.
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00:05:48,827 --> 00:05:52,586
REGARDLESS OF THE DESIGN,
EACH MASK WILL ALLOW THE ATHLETE
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00:05:52,586 --> 00:05:55,206
TO SAFELY ENJOY THE SPORT.
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00:06:05,000 --> 00:06:07,482
Narrator: BOOK-MAKING
HAS EVOLVED OVER TIME,
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00:06:07,482 --> 00:06:08,724
FROM SCROLLS
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00:06:08,724 --> 00:06:11,310
TO WRITING ON SHEETS OF PAPER
BOUND TOGETHER,
96
00:06:11,310 --> 00:06:13,379
TO THE INVENTION
OF THE PRINTING PRESS.
97
00:06:13,379 --> 00:06:17,344
PEOPLE CONTINUE TO DEVELOP
NEW WAYS OF RECORDING HISTORY.
98
00:06:17,344 --> 00:06:19,758
TODAY,
THANKS TO DIGITAL TECHNOLOGY,
99
00:06:19,758 --> 00:06:22,517
THE POSSIBILITIES
OF RECORDING THE SPOKEN WORD
100
00:06:22,517 --> 00:06:24,413
ARE ENDLESS.
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00:06:25,931 --> 00:06:27,758
A FINE BOOK-MAKING SPECIALIST
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00:06:27,758 --> 00:06:31,172
MAKES JUST A FEW
LIMITED EDITION BOOKS PER YEAR,
103
00:06:31,172 --> 00:06:34,000
USING TRADITIONAL PRINTING
AND BINDING TECHNIQUES.
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00:06:37,000 --> 00:06:41,689
PRODUCTION BEGINS WITH A CASE
OF TINY BRASS MOLDS.
105
00:06:41,689 --> 00:06:43,551
ONE MOLD,
CALLED A MATRIX,
106
00:06:43,551 --> 00:06:47,275
CONTAINS LETTERS, NUMBERS,
AND PUNCTUATION MARKS.
107
00:06:49,517 --> 00:06:53,620
A TYPECASTING SPECIALIST INSERTS
THE MATRIX CASE INTO A MACHINE
108
00:06:53,620 --> 00:06:56,172
CALLED A MONOTYPE
COMPOSITION CASTER.
109
00:06:58,034 --> 00:07:02,206
AND MELTS LEAD ALLOY INGOTS IN
THE MACHINE'S GAS HEATED POT.
110
00:07:04,931 --> 00:07:07,620
GUIDED BY A COMPUTER,
THE MACHINE CASTS
111
00:07:07,620 --> 00:07:12,793
ONE CHARACTER AT A TIME
FOR EVERY WORD OF THE BOOK.
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00:07:12,793 --> 00:07:17,517
THE COMPUTER PROGRAM ASSIGNS
A LOCATION CODE TO EVERY MATRIX.
113
00:07:17,517 --> 00:07:20,344
TO CAST A CHARACTER,
THE PROGRAM COMMUNICATES
114
00:07:20,344 --> 00:07:23,241
A SPECIFIC CODE
THROUGH PLASTIC TUBES,
115
00:07:23,241 --> 00:07:26,241
WHILE PUFFS OF AIR
ALIGN THAT CHARACTER'S MATRIX
116
00:07:26,241 --> 00:07:28,000
WITH THE INJECTION NOZZLE.
117
00:07:28,000 --> 00:07:31,310
THE NOZZLE DISPENSES MOLTEN LEAD
INTO THE MATRIX
118
00:07:31,310 --> 00:07:33,689
WHILE THE MACHINE EJECTS
THE CAST CHARACTER
119
00:07:33,689 --> 00:07:36,551
ONTO A TRAY
CALLED THE GALLEY.
120
00:07:36,551 --> 00:07:39,379
AS THE LINES OF TEXT EXIT
THE MACHINE,
121
00:07:39,379 --> 00:07:42,379
THE TYPECAST SPECIALIST INSERTS
A STRIP OF LEAD
122
00:07:42,379 --> 00:07:46,931
TO CREATE SPACING, CALLED
LEADING, BETWEEN EACH LINE.
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00:07:46,931 --> 00:07:49,827
HE TRANSFERS THE GALLEY
TO THE PRESS ROOM,
124
00:07:49,827 --> 00:07:53,137
WHERE A PROOFING PRESS
SPREADS INK ON THE TYPE.
125
00:07:53,137 --> 00:07:56,482
HE PLACES A SHEET OF
NEWSPRINT OVER THE GALLEY
126
00:07:56,482 --> 00:07:58,793
AND RELEASES
AN IMPRESSION ROLLER.
127
00:07:58,793 --> 00:08:01,310
THE ROLLER PRINTS THE CHARACTERS
ON TO THE PAPER,
128
00:08:01,310 --> 00:08:03,068
GENERATING A PROOF.
129
00:08:08,000 --> 00:08:09,689
MEANWHILE, A TYPESETTER
130
00:08:09,689 --> 00:08:12,620
ASSEMBLES THE LARGER
DISPLAY COPY MANUALLY
131
00:08:12,620 --> 00:08:14,517
BY PLACING INDIVIDUAL LETTERS
132
00:08:14,517 --> 00:08:16,551
INTO A COMPOSITION STICK.
133
00:08:16,551 --> 00:08:20,034
THIS METHOD WAS USED FOR ALL
COPY PRIOR TO THE INVENTION
134
00:08:20,034 --> 00:08:23,931
OF THE AUTOMATIC TYPECASTING
MACHINES IN THE 1890s.
135
00:08:25,965 --> 00:08:28,206
BOOKS PRINTED
IN LARGE SIZES OF TYPE
136
00:08:28,206 --> 00:08:31,379
MUST BE MADE ENTIRELY
BY MANUAL TYPESET.
137
00:08:34,068 --> 00:08:35,413
ONCE COMPLETE,
138
00:08:35,413 --> 00:08:38,517
MULTIPLE GALLEYS THAT MAKE UP
SEVERAL PAGES OF THE BOOK
139
00:08:38,517 --> 00:08:41,586
ARE PLACED IN A STEEL FRAME
CALLED A CHASE
140
00:08:41,586 --> 00:08:45,862
AND LOADED INTO
THE PRINTING PRESS.
141
00:08:45,862 --> 00:08:49,448
THIS CYLINDER PRESS FEEDS
ONE SHEET OF PAPER AT A TIME
142
00:08:49,448 --> 00:08:53,896
TO GRIPPERS THAT PULL THE PAPER
AROUND A CYLINDRICAL ROLLER.
143
00:08:53,896 --> 00:08:55,724
AS THE ROLLER ROTATES,
144
00:08:55,724 --> 00:08:58,206
THE PAPER DROPS
ONTO THE INKED TYPE,
145
00:08:58,206 --> 00:09:01,448
PRINTING THE CHARACTERS
INTO THE SHEET.
146
00:09:01,448 --> 00:09:05,689
ONE PRESS SHEET TYPICALLY
CONTAINS EIGHT PAGES PER SIDE.
147
00:09:05,689 --> 00:09:08,068
ANOTHER MACHINE
FOLDS THE SHEETS,
148
00:09:08,068 --> 00:09:10,689
THEN BOOKBINDERS
MANUALLY COLLATE GROUPS
149
00:09:10,689 --> 00:09:13,206
OF 16 CONSECUTIVE PAGES TO FORM
150
00:09:13,206 --> 00:09:16,137
SECTIONS OF THE BOOK
CALLED SIGNATURES.
151
00:09:17,620 --> 00:09:21,137
NEXT, A BOOKBINDER SEWS
THE SIGNATURES TOGETHER
152
00:09:21,137 --> 00:09:22,068
ONE AT A TIME
153
00:09:22,068 --> 00:09:26,206
UNTIL THE BOOK IS
FULLY ASSEMBLED.
154
00:09:26,206 --> 00:09:29,620
THIS METHOD OF BOOKBINDING,
CALLED SMYTH SEWN BINDING,
155
00:09:29,620 --> 00:09:33,862
AFTER ITS 19th CENTURY INVENTOR,
IS OF THE HIGHEST QUALITY
156
00:09:33,862 --> 00:09:37,275
BECAUSE PAGES CAN'T
FALL OUT OR BE REMOVED.
157
00:09:42,103 --> 00:09:43,310
LIKE THE BINDING,
158
00:09:43,310 --> 00:09:47,034
THE BOOK COVER IS
METICULOUSLY HANDCRAFTED.
159
00:09:47,034 --> 00:09:49,517
A BOOK BINDER HOT GLUES
A PIECE OF CLOTH
160
00:09:49,517 --> 00:09:52,000
TO THE BACK OF THE COVER.
161
00:09:52,000 --> 00:09:54,103
THE COVER IS MADE
OF FLEXIBLE PAPER
162
00:09:54,103 --> 00:09:58,758
AND THICK CARDBOARD.
163
00:09:58,758 --> 00:10:02,172
THEN SHE FLATTENS THE CLOTH
ON ALL SIDES.
164
00:10:04,965 --> 00:10:07,931
USING A RAZOR BLADE,
THE BOOK BINDER MAKES A SLIT
165
00:10:07,931 --> 00:10:09,137
FOR THE CLOTH,
166
00:10:09,137 --> 00:10:12,103
WHERE SHE'LL PLACE
A RECESSED LABEL LATER.
167
00:10:12,103 --> 00:10:14,620
THIS ENABLES THE CLOTH
TO SPREAD OUT
168
00:10:14,620 --> 00:10:17,655
AND FORM TO THE SPINE'S
ROUNDED SHAPE.
169
00:10:17,655 --> 00:10:19,655
THE CLOTH IS PRESSED
FIRMLY AGAINST
170
00:10:19,655 --> 00:10:23,379
THE STRUCTURAL COMPONENTS WITH
A PLASTIC TOOL CALLED A BONE.
171
00:10:24,862 --> 00:10:26,896
ANOTHER BOOK BINDER
ATTACHES THE COVER
172
00:10:26,896 --> 00:10:30,655
TO THE BOUND PAGES,
CALLED THE BOOK BLOCK.
173
00:10:30,655 --> 00:10:33,551
FIRST, SHE APPLIES GLUE
TO BOTH COMPONENTS.
174
00:10:36,034 --> 00:10:39,482
THEN SHE POSITIONS
THE BOOK BLOCK ON THE COVER...
175
00:10:41,793 --> 00:10:43,586
...AND PRESSES THEM TOGETHER.
176
00:10:47,448 --> 00:10:50,034
SHE PLACES THE BOOK
IN A NIPPING PRESS.
177
00:10:50,034 --> 00:10:52,448
THAT PUTS PRESSURE
AROUND THE SPINE,
178
00:10:52,448 --> 00:10:55,275
FUSING THE BOOK BLOCK AND COVER
TOGETHER.
179
00:10:55,275 --> 00:10:57,034
THEN THE FRONT AND BACK
OF THE COVER
180
00:10:57,034 --> 00:11:00,103
ARE GLUED TO THE FIRST AND LAST
PAGES OF THE BOOK.
181
00:11:01,931 --> 00:11:04,931
THE BOOK THEN SITS IN
ANOTHER PRESS OVERNIGHT,
182
00:11:04,931 --> 00:11:08,068
BRINGING THIS BOOK-MAKING STORY
TO A CLOSE.
183
00:11:19,482 --> 00:11:21,758
Narrator: THERE'S A NEW CLASS
OF AUTONOMOUS VEHICLES
184
00:11:21,758 --> 00:11:23,655
THAT CAN TRAVEL THE OCEAN.
185
00:11:23,655 --> 00:11:28,724
SOME DIVE AND SOME SAIL,
BUT VERY FEW CAN DO BOTH.
186
00:11:28,724 --> 00:11:31,689
AN OCEAN DRONE TRANSFORMER
SHIFTS FROM SAILBOAT
187
00:11:31,689 --> 00:11:34,862
TO SUBMARINE
BY REARRANGING ITS SHAPE
188
00:11:34,862 --> 00:11:37,103
AND ALTERING
ITS MODE OF OPERATION.
189
00:11:40,172 --> 00:11:44,793
THIS IS AN AUTONOMOUS
UNDERWATER AND SURFACE VEHICLE.
190
00:11:44,793 --> 00:11:47,344
IT'S AN INFORMATION-GATHERING
MACHINE
191
00:11:47,344 --> 00:11:51,724
CAPABLE OF PROPELLING ITSELF
OVER AND UNDER WAVES,
192
00:11:51,724 --> 00:11:54,413
USING NOTHING BUT WIND
AND SOLAR POWER.
193
00:11:55,689 --> 00:11:57,655
TO CREATE THE VEHICLE'S HULL,
194
00:11:57,655 --> 00:12:01,413
TECHNICIANS UNROLL SHEETS
OF FIBERGLASS OVER A MOLD,
195
00:12:01,413 --> 00:12:05,034
WHICH HAS BEEN MACHINED
FROM A BLOCK OF STYROFOAM.
196
00:12:05,034 --> 00:12:07,275
THEY FIBERGLASS FABRIC
IS CUT TO FIT
197
00:12:07,275 --> 00:12:09,206
THE INTERIOR OF THE HULL.
198
00:12:09,206 --> 00:12:11,827
THANKS TO ITS
EXTRAORDINARY DURABILITY,
199
00:12:11,827 --> 00:12:14,137
THE FIBERGLASS WILL ALLOW
THE WATERCRAFT
200
00:12:14,137 --> 00:12:16,724
TO SPEND MONTHS AT A TIME
AT SEA.
201
00:12:16,724 --> 00:12:17,827
AND IT WON'T INTERFERE
202
00:12:17,827 --> 00:12:20,000
WITH THE VESSEL'S
ELECTRONIC SIGNALS.
203
00:12:22,482 --> 00:12:25,758
TECHNICIANS CAREFULLY TAPE
THE MATERIAL TO THE MOLD.
204
00:12:27,448 --> 00:12:31,448
THIS YELLOW MATERIAL WILL ALLOW
LIQUID RESIN TO FLOW EASILY.
205
00:12:32,862 --> 00:12:36,172
THEN TECHNICIANS UNROLL
A STRIP OF GRAY RIBBON
206
00:12:36,172 --> 00:12:38,586
WHICH WILL HELP
DIRECT THE FLOW OF RESIN.
207
00:12:39,482 --> 00:12:42,344
NEXT, AN INCISION IS MADE
IN THE MIDDLE OF THE RIBBON
208
00:12:42,344 --> 00:12:43,551
FOR THE NOZZLE,
209
00:12:43,551 --> 00:12:45,896
WHICH WILL BE
THE ENTRY POINT FOR THE RESIN.
210
00:12:47,379 --> 00:12:50,172
A LAYER OF PLASTIC
IS TAPED ONTO THE HULL,
211
00:12:50,172 --> 00:12:54,068
WHICH WILL HELP TO VACUUM SEAL
THE ASSEMBLY TOGETHER.
212
00:12:54,068 --> 00:12:57,413
A SHUT-OFF VALVE IS ADDED
TO CONTROL THE FLOW OF RESIN.
213
00:13:01,655 --> 00:13:04,689
THE RESIN IS POURED
INTO A CONTAINER.
214
00:13:04,689 --> 00:13:07,413
AND AS THE RESIN INFUSES
THE FLOW MEDIA,
215
00:13:07,413 --> 00:13:10,103
IT DISPLACES THE VACUUM
UNTIL IT HAS COMPLETELY
216
00:13:10,103 --> 00:13:14,448
SATURATED
THE FIBERGLASS MATERIAL.
217
00:13:14,448 --> 00:13:17,793
THE RESIN IS CURED FOR 12 HOURS.
218
00:13:17,793 --> 00:13:19,896
THE MOLD SPLITS OPEN
AT THE BOTTOM
219
00:13:19,896 --> 00:13:24,000
SO TECHNICIANS CAN EASILY
RELEASE THE HULL ASSEMBLY.
220
00:13:24,000 --> 00:13:26,482
A TECHNICIAN PAINTS
THE VEHICLE'S KEEL,
221
00:13:26,482 --> 00:13:29,137
WHICH IS MADE OF
MARINE-GRADE ALUMINUM.
222
00:13:29,137 --> 00:13:32,689
THE TORPEDO-SHAPED KEEL BULB
IS MADE OF LEAD.
223
00:13:32,689 --> 00:13:35,793
ELECTRIC CABLES RUN THROUGH
A HOLE DRILLED LENGTH-WISE
224
00:13:35,793 --> 00:13:38,620
DOWN THE CENTER OF THE KEEL.
225
00:13:38,620 --> 00:13:41,172
THE INTERIOR STRUCTURE
OF THE VEHICLE STARTS
226
00:13:41,172 --> 00:13:44,758
AS A FLAT MATERIAL MADE FROM
A COMBINATION OF FIBERGLASS
227
00:13:44,758 --> 00:13:48,000
AND EPOXY WHICH THEY
FORM INTO LARGE SHEETS
228
00:13:48,000 --> 00:13:51,241
USING INTENSE HEAT AND PRESSURE.
229
00:13:51,241 --> 00:13:54,724
THEN WATER JET TECHNOLOGY
PRECISION CUTS THE SHEETS
230
00:13:54,724 --> 00:13:58,310
INTO THE REQUIRED SHAPES
AND SIZES.
231
00:13:58,310 --> 00:14:01,172
TECHNICIANS ASSEMBLE
THE SHAPES INTO A STRUCTURE
232
00:14:01,172 --> 00:14:02,655
THAT SUPPORTS THE HULL
233
00:14:02,655 --> 00:14:04,655
WHILE HOUSING
THE VEHICLE'S EQUIPMENT.
234
00:14:06,551 --> 00:14:09,620
IN-HOUSE TECHNICIANS BUILD
THE MULTIPLE CIRCUIT BOARDS
235
00:14:09,620 --> 00:14:13,655
THAT MAKE UP THE CENTRAL
PROCESSING UNIT, OR CPU.
236
00:14:13,655 --> 00:14:16,862
EACH BOARD CONTROLS A SEPARATE
ELEMENT OF THE VEHICLE,
237
00:14:16,862 --> 00:14:21,068
SUCH AS THE SENSORS, THE WING,
OR THE COMMUNICATIONS SYSTEM.
238
00:14:22,482 --> 00:14:26,103
ELECTRONICS AND WATER ARE NOT
A COMPATIBLE COMBINATION,
239
00:14:26,103 --> 00:14:29,931
SO THE MANUFACTURER DESIGNED
A WATER-TIGHT ACRYLIC TUBE
240
00:14:29,931 --> 00:14:34,517
TO HOLD ALL 10 OF THE CIRCUIT
BOARDS THAT MAKE UP THE CPU.
241
00:14:34,517 --> 00:14:37,103
SPECIALIZED CABLE CONNECTORS
ARE INSTALLED
242
00:14:37,103 --> 00:14:40,482
SO WATER DOESN'T LEAK
THROUGH THE COVER PLATE.
243
00:14:40,482 --> 00:14:42,517
ONCE THE ENCLOSURE IS SEALED,
244
00:14:42,517 --> 00:14:45,551
TECHNICIANS VACUUM OUT
FLAMMABLE OXYGEN
245
00:14:45,551 --> 00:14:50,413
AND PUMP IN NON-FLAMMABLE
GASES TO PROTECT THE CPU.
246
00:14:50,413 --> 00:14:52,724
A TECHNICIAN
PREPARES THE BATTERY,
247
00:14:52,724 --> 00:14:55,344
WHICH IS AN OFF-THE-SHELF
LITHIUM ION UNIT.
248
00:14:58,482 --> 00:15:02,344
A BATTERY HOUSING IS 3-D PRINTED
OUT OF A.B.S.
249
00:15:02,344 --> 00:15:04,620
AND INFUSED WITH EPOXY
TO ENSURE
250
00:15:04,620 --> 00:15:07,655
THAT IT'S COMPLETELY
WATER TIGHT.
251
00:15:07,655 --> 00:15:10,068
NEXT, A TECHNICIAN INSTALLS
THE BATTERY
252
00:15:10,068 --> 00:15:12,689
IN ITS DESIGNATED SPOT.
253
00:15:12,689 --> 00:15:15,103
SOLAR PANELS ON
THE VEHICLE'S SURFACE
254
00:15:15,103 --> 00:15:17,517
WILL RECHARGE THE BATTERIES.
255
00:15:17,517 --> 00:15:20,517
A HOSE WILL ALLOW
THE CPU TO TRANSFER WATER
256
00:15:20,517 --> 00:15:22,896
FROM ONE BALLAST TANK TO ANOTHER
257
00:15:22,896 --> 00:15:26,206
TO CONTROL THE BOAT'S
UP AND DOWN MOTION OR PITCH.
258
00:15:27,379 --> 00:15:29,793
THE VEHICLE'S TAILS
SERVE AS HOUSINGS
259
00:15:29,793 --> 00:15:32,965
FOR THE BACKUP
COMMUNICATIONS ANTENNA SYSTEM.
260
00:15:32,965 --> 00:15:36,724
IN STEALTH MODE, THE VEHICLE
CAN SIT BELOW THE WATER SURFACE
261
00:15:36,724 --> 00:15:40,000
WITH ONLY ITS TAILS
ABOVE THE WAVES.
262
00:15:40,000 --> 00:15:42,310
DESIGNED TO FOLD DOWN
AND TUCK INTO THE BODY
263
00:15:42,310 --> 00:15:45,413
OF THE VEHICLE,
THE RIGID WING MULTI-TASKS
264
00:15:45,413 --> 00:15:47,827
AS THE PRIMARY ANTENNA
AND THE SAIL,
265
00:15:47,827 --> 00:15:51,344
WHICH PROPELS THE VEHICLE
WHEN IT'S ABOVE WATER.
266
00:15:51,344 --> 00:15:53,724
DUE TO ITS USER-FRIENDLY
TECHNOLOGY,
267
00:15:53,724 --> 00:15:55,620
AN OPERATOR CAN PROGRAM
A MISSION
268
00:15:55,620 --> 00:15:58,000
AT ANY TIME
FROM ANY LOCATION
269
00:15:58,000 --> 00:16:00,551
VIA SATELLITE OR WI-FI.
270
00:16:10,551 --> 00:16:12,793
Narrator: THE FIRST JIGSAW
PUZZLE WAS INVENTED
271
00:16:12,793 --> 00:16:15,103
IN EUROPE IN 1760.
272
00:16:15,103 --> 00:16:16,931
NEARLY TWO CENTURIES LATER,
273
00:16:16,931 --> 00:16:20,379
A CANADIAN INVENTOR RESHAPED
THE POPULAR PASTIME.
274
00:16:20,379 --> 00:16:24,379
HIS PUZZLE PIECES, MADE OF THICK
FOAM RATHER THAN CARDBOARD,
275
00:16:24,379 --> 00:16:27,000
COULD STAND UPRIGHT,
TURNING THE PUZZLE
276
00:16:27,000 --> 00:16:28,931
INTO A THREE-DIMENSION MODEL.
277
00:16:30,482 --> 00:16:34,827
CONSTRUCTING A 3-D PUZZLE
YIELDS IMPRESSIVE RESULTS.
278
00:16:34,827 --> 00:16:39,206
TO DO SO, TWO 800-PIECE
PUZZLE SETS ARE USED TO CREATE
279
00:16:39,206 --> 00:16:43,862
THIS SPECTACULAR
CASTLE REPLICA.
280
00:16:43,862 --> 00:16:46,344
AN INDUSTRIAL DESIGNER CREATES
THE PUZZLE'S
281
00:16:46,344 --> 00:16:48,379
THREE-DIMENSIONAL STRUCTURE.
282
00:16:48,379 --> 00:16:52,034
AN ILLUSTRATOR USES TECHNIQUES,
SUCH AS VISUAL TEXTURES
283
00:16:52,034 --> 00:16:55,172
AND SHADING, TO TRANSFORM
FLAT GRAPHICS
284
00:16:55,172 --> 00:16:58,034
INTO A THREE-DIMENSIONAL
RENDERING.
285
00:16:58,034 --> 00:17:02,000
THE INDUSTRIAL DESIGNER PREPARES
THE PRINTING AND CUTTING LAYOUT,
286
00:17:02,000 --> 00:17:05,137
FITTING UP TO THREE
PUZZLES PER SHEET.
287
00:17:05,137 --> 00:17:08,517
THE PUZZLE PIECES ARE MADE
FROM RIGID FOAM.
288
00:17:08,517 --> 00:17:10,482
THE FOAM
IS SPECIFICALLY ENGINEERED
289
00:17:10,482 --> 00:17:13,758
TO BE CHEMICALLY COMPATIBLE
WITH THE PAPER GRAPHICS
290
00:17:13,758 --> 00:17:17,241
AND PROPRIETARY ADHESIVE.
291
00:17:17,241 --> 00:17:19,896
A TECHNICIAN FEEDS ONE
SHEET AT A TIME
292
00:17:19,896 --> 00:17:22,965
INTO A CUSTOM DESIGNED
LAMINATION MACHINE.
293
00:17:22,965 --> 00:17:24,931
THE FIRST STATION
SPREADS HOT GLUE
294
00:17:24,931 --> 00:17:27,034
OVER THE TOP OF THE FOAM SHEET.
295
00:17:28,517 --> 00:17:31,551
AN AUTOMATED ARM WITH
VACUUM SUCTION CUPS
296
00:17:31,551 --> 00:17:33,862
LIFTS A SINGLE SHEET
OF PRINTED PAPER
297
00:17:33,862 --> 00:17:37,862
AND PLACES IT ON
THE GLUE-COATED FOAM SHEET.
298
00:17:37,862 --> 00:17:40,482
AS SOON AS THE PAPER
ADHERES TO THE FOAM,
299
00:17:40,482 --> 00:17:43,206
THE SHE IS RELEASED
FROM THE SUCTION CUPS.
300
00:17:46,517 --> 00:17:48,655
THEN THE FOAM MOVES
UNDER A ROLLER
301
00:17:48,655 --> 00:17:50,517
THAT PRESSES DOWN THE PAPER.
302
00:17:52,620 --> 00:17:55,793
AS THE LAMINATED FOAM
EXITS THE MACHINE,
303
00:17:55,793 --> 00:17:59,310
A TECHNICIAN ROLLS A TUBE
OVER THE FOAM, PRESSING OUT
304
00:17:59,310 --> 00:18:00,931
ANY REMAINING AIR BUBBLES
305
00:18:00,931 --> 00:18:03,379
TO ENSURE THE PAPER
ADHERES FULLY.
306
00:18:05,793 --> 00:18:08,758
IN THE DEVELOPMENT PHASE,
THE INDUSTRIAL DESIGNER
307
00:18:08,758 --> 00:18:10,206
ASSEMBLED A BLUEPRINT
308
00:18:10,206 --> 00:18:12,517
FOR HOW THE PUZZLE PIECES
WOULD BE SHAPED
309
00:18:12,517 --> 00:18:14,620
AND LAID OUT.
310
00:18:14,620 --> 00:18:16,793
THAT DESIGN
WENT TO A TOOLMAKER
311
00:18:16,793 --> 00:18:19,172
WHO PRODUCED A CORRESPONDING
CUTTING DIE
312
00:18:19,172 --> 00:18:20,862
OUT OF STEEL KNIVES.
313
00:18:23,793 --> 00:18:26,689
THE DIE IS MOUNTED
INSIDE THE CUTTING MACHINE.
314
00:18:28,551 --> 00:18:31,931
A TECHNICIAN FEEDS THE MACHINE
ONE LAMINATED FOAM SHEET
315
00:18:31,931 --> 00:18:34,413
AT A TIME,
PAPER SIDE DOWN.
316
00:18:36,448 --> 00:18:38,724
GRIPPERS GRAB
THE EDGE OF THE PAPER,
317
00:18:38,724 --> 00:18:41,172
PULLING THE SHEET
INTO THE MACHINE.
318
00:18:41,172 --> 00:18:43,517
THE CUTTING DIE SLICES
THE PUZZLE PIECES
319
00:18:43,517 --> 00:18:44,551
INTO THE FOAM.
320
00:18:46,241 --> 00:18:49,379
EVEN THOUGH THE CUTTING PRESSURE
COMPRESSES THE FOAM,
321
00:18:49,379 --> 00:18:53,275
IT IMMEDIATELY BOUNCES BACK,
KEEPING THE SHEET INTACT.
322
00:18:55,172 --> 00:18:57,310
THANKS TO A HIGH-QUALITY
RUBBER SHEET
323
00:18:57,310 --> 00:18:59,655
INSERTED BETWEEN THE BLADES,
324
00:18:59,655 --> 00:19:03,000
THE PIECES DON'T GET STUCK
IN THE DIE.
325
00:19:03,000 --> 00:19:05,655
THE STIFF RUBBER
PROVIDES COUNTER-PRESSURE
326
00:19:05,655 --> 00:19:10,551
TO HELP REMOVE
THE FOAM SHEET.
327
00:19:10,551 --> 00:19:13,827
IF THE SHEET HAS TWO OR THREE
PUZZLES PRINTED ON IT,
328
00:19:13,827 --> 00:19:16,724
THE CUTTING DIE
SEPARATES THEM.
329
00:19:16,724 --> 00:19:19,241
THEN A TECHNICIAN PLACES
THE PUZZLE
330
00:19:19,241 --> 00:19:21,448
ON A SEMI-AUTOMATIC
CONVEYOR BELT
331
00:19:21,448 --> 00:19:24,586
THAT MOVES IT
TO THE DISMANTLING MACHINE.
332
00:19:24,586 --> 00:19:27,310
THE MACHINE INFUSES
THE DIE-CUT PUZZLE SHEET
333
00:19:27,310 --> 00:19:28,793
WITH STEAM.
334
00:19:28,793 --> 00:19:31,241
THE STEAM PREVENTS
STATIC ELECTRICITY,
335
00:19:31,241 --> 00:19:34,068
WHICH CAUSES PIECES
TO CLING TOGETHER
336
00:19:34,068 --> 00:19:37,103
OR TO THE INSIDE OF THE MACHINE.
337
00:19:37,103 --> 00:19:39,344
THE MACHINE
SEPARATES THE PIECES.
338
00:19:39,344 --> 00:19:44,137
AND DISPENSES THEM
INTO A PUZZLE BOX.
339
00:19:44,137 --> 00:19:46,965
A TECHNICIAN ADDS THE STANDARD
INSTRUCTIONS SHEET,
340
00:19:46,965 --> 00:19:51,793
AND SEALS THE BOX.
341
00:19:51,793 --> 00:19:53,827
THE INSTRUCTIONS ARE
IN BLACK AND WHITE,
342
00:19:53,827 --> 00:19:56,137
BUT CAN BE VIEWED
IN COLOR ONLINE.
343
00:19:57,379 --> 00:20:00,965
THE FIRST STEP IS TO SORT
THE PIECES BY COLOR AND DESIGN
344
00:20:00,965 --> 00:20:04,103
AND SET ASIDE THE ONES
MARKED WITH A RED DOT
345
00:20:04,103 --> 00:20:06,689
WHICH IS PART OF
THE MANUFACTURING PROCESS,
346
00:20:06,689 --> 00:20:09,448
NOT THE PUZZLE ITSELF.
347
00:20:09,448 --> 00:20:13,827
THE NEXT STEP IS TO ASSEMBLE
THE PUZZLE, SECTION BY SECTION.
348
00:20:13,827 --> 00:20:15,655
ALL THE SECTIONS ARE FLAT,
349
00:20:15,655 --> 00:20:19,034
SO THE FINAL STEP IS TO
ATTACH THE FLAT SECTIONS
350
00:20:19,034 --> 00:20:22,793
TO MAKE THE PUZZLE
THREE-DIMENSIONAL.
351
00:20:22,793 --> 00:20:24,482
FOR AN ADDITIONAL CHALLENGE,
352
00:20:24,482 --> 00:20:27,310
YOU CAN FORGO
THE STEP-BY-STEP INSTRUCTIONS
353
00:20:27,310 --> 00:20:30,103
AND REFER ONLY TO
THE PHOTOS ON THE BOX.
354
00:20:31,517 --> 00:20:33,862
IF YOU HAPPEN TO
LOSE A PUZZLE PIECE,
355
00:20:33,862 --> 00:20:35,965
YOU CAN GO TO
THE COMPANY'S WEBSITE
356
00:20:35,965 --> 00:20:38,551
TO TRACE THE NUMBER
OF YOUR MISSING PIECE,
357
00:20:38,551 --> 00:20:41,206
THEN ORDER A NEW PIECE ONLINE.
358
00:20:41,206 --> 00:20:42,758
THE COMPANY WILL MAIL IT TO YOU
359
00:20:42,758 --> 00:20:44,758
SO THAT YOU CAN
COMPLETE YOUR PUZZLE.
360
00:20:46,344 --> 00:20:48,586
UNLIKE A TRADITIONAL
FLAT PUZZLE,
361
00:20:48,586 --> 00:20:54,517
YOU CAN MOVE YOUR 3-D PUZZLE
WITHOUT IT FALLING APART.
362
00:20:54,517 --> 00:20:56,448
IT TAKES FOUR TO SIX MONTHS
363
00:20:56,448 --> 00:21:00,758
TO DEVELOP AND DESIGN
THIS INCREDIBLE 3-D PUZZLE.
364
00:21:00,758 --> 00:21:02,896
NOW IT'S TIME TO SPEND
EVEN LONGER
365
00:21:02,896 --> 00:21:05,206
PIECING THIS PUZZLE TOGETHER.
29146
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