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--Captions by VITAC--
www.vitac.com
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00:00:05,000 --> 00:00:08,000
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator: THE DISTINCTIVE SOUND
OF THE ACCORDION
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APPEARS IN ALMOST EVERY KIND
OF MUSIC.
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THE PIANO-STYLE KEYBOARD
ON THE RIGHT-HAND SIDE
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00:00:58,965 --> 00:01:00,413
PRODUCES THE MELODY,
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WHILE THE BUTTONS ON THE LEFT
PRODUCE THE CHORD ACCOMPANIMENT.
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00:01:03,551 --> 00:01:06,724
IN BETWEEN ARE BELLOWS
THAT FORCE AIR THROUGH REEDS,
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00:01:06,724 --> 00:01:09,724
PRODUCING THAT UNMISTAKABLE
ACCORDION SOUND.
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00:01:16,482 --> 00:01:19,793
THE ACCORDION IS A BEAUTIFUL
AND COMPLEX INSTRUMENT.
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00:01:19,793 --> 00:01:22,862
IT CONTAINS UP TO 10 SETS
OF STEEL REEDS
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00:01:22,862 --> 00:01:24,827
WITH DIFFERENT PITCHES.
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00:01:24,827 --> 00:01:27,931
EACH REED SET
GOES INTO A WOODEN BLOCK.
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00:01:27,931 --> 00:01:31,551
UNDER EVERY SECTION IS
AN OPENING CALLED A TONE HOLE.
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00:01:31,551 --> 00:01:33,827
THE BELLOWS
DRIVES AIR THROUGH IT,
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VIBRATING THE REED ABOVE
TO PRODUCE A MUSICAL NOTE.
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THESE LEATHER-AND-PLASTIC PADS
COVER THE SLOTS
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ON THE ACCORDION'S
ALUMINUM REED PLATES.
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EACH PLATE HOLDS TWO REEDS.
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BOTH REEDS PRODUCE
THE SAME NOTE --
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ONE WHEN YOU PUSH THE BELLOWS,
THE OTHER WHEN YOU PULL.
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00:01:52,379 --> 00:01:56,931
THEY NOW APPLY A SPECIAL WAX TO
SECURE THE REEDS TO THE BLOCK.
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IF THEY USED GLUE, THEY WOULDN'T
BE ABLE TO REMOVE THE PLATE
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SHOULD A REED EVER NEED REPAIR.
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00:02:02,137 --> 00:02:06,172
EACH REED PLAYED CORRESPONDS
TO A SPECIFIC NOTE OR CHORD.
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TO ASSEMBLE THE KEYBOARD,
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THEY BEGIN WITH A LEVER MADE OF
FIBERGLASS-REINFORCED PLASTIC.
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00:02:14,448 --> 00:02:17,689
IT HAS A WOODEN CORE TO GIVE
THE KEYS SUFFICIENT WEIGHT.
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00:02:19,034 --> 00:02:21,517
A LONG METAL LEVER
GOES INTO THE TOP.
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00:02:21,517 --> 00:02:23,482
WHEN THE MUSICIAN PRESSES A KEY,
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ITS MECHANISM UNBLOCKS
THE CORRESPONDING TONE HOLE,
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ALLOWING AIR TO FLOW INSIDE
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00:02:28,551 --> 00:02:31,344
AND VIBRATE ONE OF THE PLATE'S
TWO REEDS.
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00:02:35,000 --> 00:02:39,965
NEXT, THEY DRIVE IN THE STEEL
AXLE ON WHICH THE KEYS PIVOT.
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00:02:42,896 --> 00:02:46,137
THEN THEY APPLY SUCTION
TO A KEYBOARD-SIZE TRAY.
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IN IT, THEY LINE UP
THE PLASTIC KEY TOPS.
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00:02:48,965 --> 00:02:50,793
IN TOP-OF-THE-LINE MODELS,
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00:02:50,793 --> 00:02:53,655
THE WHITE KEY TOPS
ARE MADE OF CELLULOID.
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00:02:57,000 --> 00:02:59,482
WITH THE SUCTION
HOLDING THE KEYS DOWN,
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00:02:59,482 --> 00:03:01,724
IT'S JUST A MATTER
OF FLIPPING THE TRAY
41
00:03:01,724 --> 00:03:03,896
AND CLAMPING IT
ONTO THE KEYBOARD FRAME.
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00:03:03,896 --> 00:03:05,586
THE TOPS ADHERE TO THE LEVERS,
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WHICH HAVE SINCE RECEIVED
A COAT OF GLUE.
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AFTER ABOUT AN HOUR,
THE GLUE IS DRY.
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THEY CUT THE SUCTION, AND
THE KEYBOARD IS FINGER-READY.
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MEANWHILE, THE REED BLOCKS
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00:03:17,965 --> 00:03:20,482
ARE IN THE HANDS
OF A TUNING SPECIALIST,
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00:03:20,482 --> 00:03:22,241
WHO PUMPS AIR WITH A FOOT PEDAL
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00:03:22,241 --> 00:03:24,413
TO VIBRATE THE REEDS
ONE AT A TIME.
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HE COMPARES EACH NOTE
TO A REFERENCE TONE
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FROM A TUNING APPARATUS
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AND FILES THE REEDS GRADUALLY
UNTIL THEIR PITCHES MATCH.
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NOW FOR THE BUTTON KEYBOARD.
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00:03:34,379 --> 00:03:36,068
STARTING WITH THE VALVES,
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00:03:36,068 --> 00:03:39,724
THEY INSTALL A WOODEN PALLET
OVER EACH TONE HOLE.
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00:03:39,724 --> 00:03:42,137
TO THAT,
THEY GLUE A STEEL LEVER.
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00:03:43,896 --> 00:03:47,517
THEN TO THAT,
THEY CONNECT A BRASS RAKE.
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00:03:50,000 --> 00:03:52,862
WHEN THE RAKE MOVES,
IT PULLS THE LEVER,
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00:03:52,862 --> 00:03:56,172
WHICH OPENS THE VALVE,
UNBLOCKING THE TONE HOLE.
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00:03:56,172 --> 00:03:59,379
AIR ENTERS AND VIBRATES
THE REED, PRODUCING THE NOTE.
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00:04:03,517 --> 00:04:06,275
EACH KEYBOARD BUTTON
OPENS THREE VALVES.
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00:04:06,275 --> 00:04:10,000
THAT'S WHY PUSHING ONE BUTTON
PRODUCES A THREE-NOTE CHORD.
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00:04:11,413 --> 00:04:12,896
WITH THE COMPLEX CONNECTIONS
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BETWEEN BUTTONS AND REEDS
COMPLETE,
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00:04:14,965 --> 00:04:18,620
THE REED BLOCKS GO INTO
A CELLULOID-ON-PLYWOOD HOUSING.
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00:04:18,620 --> 00:04:22,206
IT'LL ATTACH TO THE BELLOWS
MADE OF STRONG PLEATED CARDBOARD
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00:04:22,206 --> 00:04:25,586
REINFORCED WITH LEATHER
AND METAL CORNER PROTECTORS.
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00:04:29,206 --> 00:04:31,862
BUT BEFORE PERMANENTLY ATTACHING
THE BELLOWS,
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ALL THE REEDS HAVE TO UNDERGO
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A FINAL AND VERY EXTENSIVE
TUNING ADJUSTMENT.
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00:04:42,827 --> 00:04:45,586
AN ACCORDION CAN HAVE
UP TO 600 REEDS,
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SO THIS METICULOUS REED-BY-REED
TUNING CAN TAKE UP TO 16 HOURS.
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THEY NOW PIN
THE BELLOWS' WOOD FRAME ENDS
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00:05:00,758 --> 00:05:03,172
TO THE TREBLE AND BASS HOUSINGS.
75
00:05:03,172 --> 00:05:07,206
THEN THEY CAP EACH HOUSING
WITH A CLOTH-COVERED GRILLE
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00:05:07,206 --> 00:05:08,620
TO KEEP OUT DUST.
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00:05:08,620 --> 00:05:12,862
AFTER POLISHING THE ACCORDION
TO A HIGH-GLOSS FINISH,
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00:05:12,862 --> 00:05:16,000
IT'S TIME FOR A MUSICAL
ROAD TEST IN WHITE GLOVES.
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THERE'S NO SENSE
IN LEAVING FINGERPRINTS
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00:05:18,620 --> 00:05:21,275
ON THAT EXQUISITELY POLISHED
SURFACE.
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00:05:21,275 --> 00:05:23,724
WITH THE TEST CHECKLIST
COMPLETE,
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00:05:23,724 --> 00:05:25,689
THE INSPECTOR SIGNS OFF ON IT.
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00:05:25,689 --> 00:05:29,655
YOU CAN'T SAY THIS JOB'S
ALL WORK AND NO PLAY.
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Narrator: THE PINEAPPLE
IS NATIVE TO SOUTH AMERICA,
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BUT COLONIZATION SPREAD IT
TO OTHER TROPICAL AREAS.
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THE LATIN NAME FOR PINEAPPLE
IS "ANANAS,"
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00:06:00,413 --> 00:06:03,241
WHICH COMES FROM NANA, WHAT
THE NATIVES CALLED THE PLANT.
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THE ENGLISH WORD "PINEAPPLE"
CAME FROM THE EUROPEAN EXPLORERS
89
00:06:06,482 --> 00:06:09,172
WHO THOUGHT THAT THIS STRANGE
BUT DELICIOUS FRUIT
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00:06:09,172 --> 00:06:10,931
LOOKED LIKE A GIANT PINECONE.
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00:06:14,275 --> 00:06:16,448
PINEAPPLES NEED TEMPERATURES
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BETWEEN 73 AND 86 DEGREES
FAHRENHEIT AND FULL SUN.
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00:06:20,310 --> 00:06:22,896
IT TAKES SEVEN MONTHS
FOR THE PINEAPPLE PLANT
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00:06:22,896 --> 00:06:25,758
TO PRODUCE A BUNCH OF LITTLE
REDDISH-PURPLE FLOWERS.
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00:06:25,758 --> 00:06:28,068
AT THIS FIRST BLOOM,
AS IT'S CALLED,
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FARMERS SPRAY THE PLANT
WITH ETHYLENE,
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00:06:30,551 --> 00:06:33,448
A NATURAL GAS THAT STIMULATES
FULL FLOWERING.
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00:06:33,448 --> 00:06:35,793
AS THAT HAPPENS,
THE STEM OF THE FLOWER BUNCH
99
00:06:35,793 --> 00:06:38,793
GRADUALLY THICKENS
AND BECOMES BULBOUS.
100
00:06:38,793 --> 00:06:40,965
THIS IS THE PINEAPPLE.
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00:06:40,965 --> 00:06:45,862
FIVE MONTHS AFTER FIRST BLOOM,
A YEAR SINCE THE LAST HARVEST,
102
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A FRESH CROP OF PINEAPPLES
IS RIPE FOR THE PICKING.
103
00:06:49,551 --> 00:06:52,172
BUT NOT BEFORE THE FARM
HAS TESTED SAMPLES
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00:06:52,172 --> 00:06:55,068
TO MAKE SURE THE SWEETNESS LEVEL
IS JUST RIGHT.
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00:06:57,172 --> 00:07:00,827
THIS IS PRICKLY BUSINESS, SO
THE WORKERS HAVE TO WEAR GLOVES,
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00:07:00,827 --> 00:07:06,724
LONG SLEEVES, SAFETY GLASSES,
AND RUBBER BOOTS.
107
00:07:06,724 --> 00:07:08,137
THE PINEAPPLES TRAVEL
108
00:07:08,137 --> 00:07:10,586
FROM THE FIELD TO THE FACTORY
UPSIDE DOWN.
109
00:07:10,586 --> 00:07:13,448
THAT WAY THE CROWN OF LEAVES
BEARS THE WEIGHT OF THE FRUIT
110
00:07:13,448 --> 00:07:15,586
DURING THE BUMPY RIDE.
111
00:07:18,758 --> 00:07:20,482
UPON ARRIVAL AT THE FACTORY,
112
00:07:20,482 --> 00:07:23,241
THE PINEAPPLES GO THROUGH
A 10-STEP CLEANING
113
00:07:23,241 --> 00:07:24,586
IN CHLORINATED WATER.
114
00:07:24,586 --> 00:07:27,379
THIS WASHES AWAY INSECTS
AND FROG EGGS.
115
00:07:27,379 --> 00:07:30,931
FROGS LIKE TO LAY THEIR EGGS
IN PINEAPPLE CROWNS.
116
00:07:30,931 --> 00:07:35,275
A FINAL RINSE WITH CLEAN WATER
REMOVES ANY CHLORINE RESIDUE.
117
00:07:35,275 --> 00:07:37,827
NOW WORKERS CLASSIFY
THE PINEAPPLES
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00:07:37,827 --> 00:07:39,862
AND CUT OFF MISSHAPEN CROWNS.
119
00:07:39,862 --> 00:07:42,413
A FIRST-CLASS PINEAPPLE
HAS A STRAIGHT CROWN
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00:07:42,413 --> 00:07:44,620
AND NO MORE
THAN THREE DAMAGED EYES,
121
00:07:44,620 --> 00:07:46,827
THOSE DIAMOND SHAPES
ON THE PEEL.
122
00:07:46,827 --> 00:07:49,758
IF A PINEAPPLE PASSES
THE FIRST-CLASS TEST,
123
00:07:49,758 --> 00:07:51,206
IT'S FIT FOR EXPORT.
124
00:07:51,206 --> 00:07:54,137
SECOND-CLASS SELLS
ON THE DOMESTIC MARKET.
125
00:07:54,137 --> 00:07:57,310
THIRD BECOMES DRIED FRUIT,
AND FOURTH, JUICE.
126
00:07:57,310 --> 00:08:00,586
AT THE DRYING PLANT
FOR THIRD-CLASS PINEAPPLES,
127
00:08:00,586 --> 00:08:02,758
WORKERS FIRST
CHOP OFF THE CROWN,
128
00:08:02,758 --> 00:08:05,448
AND THEN ABOUT TWO INCHES
FROM THE BOTTOM END.
129
00:08:05,448 --> 00:08:06,896
WITH A CORING MACHINE,
130
00:08:06,896 --> 00:08:10,000
THEY REMOVE THE PINEAPPLE'S
HARD CENTER CALLED THE HEART.
131
00:08:16,586 --> 00:08:19,241
KNIFE-WIELDING EMPLOYEES
WORK THEIR MAGIC,
132
00:08:19,241 --> 00:08:22,275
EACH PEELING FIVE TO SEVEN
PINEAPPLES PER MINUTE.
133
00:08:22,275 --> 00:08:24,896
THE COARSE SKIN
DULLS THE BLADES QUICKLY,
134
00:08:24,896 --> 00:08:27,655
SO THEY HAVE TO KEEP SHARPENING
THEIR KNIVES
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00:08:27,655 --> 00:08:29,034
ABOUT EVERY HALF-HOUR.
136
00:08:38,344 --> 00:08:42,103
THE PEELED PINEAPPLES THEN
MOVE ON TO A SLICING MACHINE,
137
00:08:42,103 --> 00:08:45,482
WHICH PRODUCES SLICES A LITTLE
MORE THAN A HALF-INCH THICK.
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00:08:45,482 --> 00:08:48,344
THE AVERAGE PINEAPPLE YIELDS
ABOUT SEVEN SLICES.
139
00:09:01,241 --> 00:09:06,724
WORKERS PLACE THE SLICES
ON LARGE TRAYS...
140
00:09:06,724 --> 00:09:12,689
LOAD THE TRAYS ON LARGE RACKS...
141
00:09:12,689 --> 00:09:16,034
THEN ROLL THE RACKS
INTO A GAS OVEN.
142
00:09:17,448 --> 00:09:19,724
THE SLICES BAKE FOR 24 HOURS
143
00:09:19,724 --> 00:09:24,310
BETWEEN 147 AND 151 DEGREES
FAHRENHEIT.
144
00:09:24,310 --> 00:09:27,068
THIS DRIES THEM
ALMOST COMPLETELY.
145
00:09:27,068 --> 00:09:30,620
WHEN THEY COME OUT OF THE OVEN,
THEIR MOISTURE LEVEL IS 6%,
146
00:09:30,620 --> 00:09:33,793
JUST ENOUGH TO ENSURE
THE SLICES ARE CHEWY.
147
00:09:39,758 --> 00:09:42,206
FROM THE OVEN TO PACKAGING.
148
00:09:42,206 --> 00:09:45,103
THESE PRESERVATIVE-FREE
DRIED PINEAPPLE SLICES
149
00:09:45,103 --> 00:09:47,724
STAY FRESH IN THE PACKAGE
FOR 18 MONTHS.
150
00:10:02,758 --> 00:10:05,344
NOW BACK
TO THE PINEAPPLE FACTORY,
151
00:10:05,344 --> 00:10:09,448
WHERE THE FIRST-CLASS FRUITS
PASS UNDER A SHOWER OF HOT WAX.
152
00:10:09,448 --> 00:10:11,172
FANS COOL AND HARDEN THE WAX
153
00:10:11,172 --> 00:10:13,862
INTO A COATING
THAT CREATES AN AIR BARRIER.
154
00:10:13,862 --> 00:10:15,827
THIS SLOWS THE RIPENING PROCESS,
155
00:10:15,827 --> 00:10:18,310
ENSURING THE PINEAPPLES
DON'T OVERRIPEN
156
00:10:18,310 --> 00:10:21,517
BY THE TIME THEY ARRIVE
AT THEIR EXPORT DESTINATION.
157
00:10:21,517 --> 00:10:24,586
LAST STOP IS THE PACKAGING
AND LABELING DEPARTMENT.
158
00:10:24,586 --> 00:10:27,655
WORKERS BOX PINEAPPLES WITH
AND WITHOUT CROWNS SEPARATELY.
159
00:10:27,655 --> 00:10:30,241
THOSE WITH CROWNS
ARE FOR EXPORT.
160
00:10:30,241 --> 00:10:33,413
THE CROWNLESS ONES
GO TO A CANNING FACTORY
161
00:10:33,413 --> 00:10:35,724
TO BE SLICED, DICED, OR CRUSHED.
162
00:10:35,724 --> 00:10:38,103
FROM THE FIELD TO YOUR TABLE,
163
00:10:38,103 --> 00:10:41,758
PINEAPPLES ARE THE FRUIT
OF MANY PEOPLE'S LABORS.
164
00:10:53,172 --> 00:10:54,896
Narrator:
ARTIFICIAL BODY PARTS
165
00:10:54,896 --> 00:10:56,965
USED TO BE THE STUFF
OF SCIENCE FICTION.
166
00:10:56,965 --> 00:10:59,448
NOWADAYS ARTIFICIAL JOINTS,
AT LEAST, ARE ROUTINE.
167
00:10:59,448 --> 00:11:02,724
AN ARTIFICIAL JOINT IS A
PROSTHESIS THAT SURGEONS INSERT
168
00:11:02,724 --> 00:11:05,655
TO REPLACE DISEASED OR WORN-OUT
BONE AND CARTILAGE.
169
00:11:05,655 --> 00:11:08,137
IN NEARLY ALL CASES,
AN ARTIFICIAL JOINT
170
00:11:08,137 --> 00:11:11,310
RELIEVES PAIN AND IMPROVES
THE RANGE OF MOTION.
171
00:11:14,793 --> 00:11:18,896
FROM YOUR KNEES AND HIPS TO YOUR
WRISTS, ELBOW, AND SHOULDERS,
172
00:11:18,896 --> 00:11:21,793
IF YOUR JOINTS GO,
YOU CAN REPLACE THEM.
173
00:11:21,793 --> 00:11:25,344
AN ARTIFICIAL JOINT HAS BOTH
METAL AND PLASTIC COMPONENTS.
174
00:11:25,344 --> 00:11:29,551
THE METAL ACTS AS BONE,
THE PLASTIC IS CARTILAGE.
175
00:11:29,551 --> 00:11:32,689
THIS FACTORY MAKES
THE METAL PARTS THREE WAYS.
176
00:11:32,689 --> 00:11:36,137
IT EITHER CASTS THEM,
FORGES THEM, OR MACHINES THEM.
177
00:11:36,137 --> 00:11:38,448
CASTING IS THE MOST COMPLEX
METHOD.
178
00:11:38,448 --> 00:11:41,034
THE FIRST STEP IS
TO PRESSURE-INJECT MELTED WAX
179
00:11:41,034 --> 00:11:42,862
INTO AN ALUMINUM MOLD.
180
00:11:42,862 --> 00:11:47,103
THIS MAKES A PATTERN,
A WAX REPLICA OF THE METAL PART.
181
00:11:47,103 --> 00:11:51,275
NOW THEY BUILD THE MOLD
FOR CASTING THE PART IN METAL.
182
00:11:51,275 --> 00:11:54,689
WORKERS FUSE A GROUP OF PATTERNS
WITH HOT WAX
183
00:11:54,689 --> 00:11:57,172
TO A HOLDER ALSO MADE OF WAX.
184
00:11:57,172 --> 00:11:59,586
THE PATTERNS WILL SHAPE
THE CAVITY IN THE MOLDS.
185
00:12:04,344 --> 00:12:07,000
THEY SUBMERGE THE PATTERNS
IN A THICK LIQUID CERAMIC
186
00:12:07,000 --> 00:12:11,689
WHICH SOON HARDENS INTO
A FRAGILE SHELL AROUND THE WAX.
187
00:12:11,689 --> 00:12:13,482
THEN THEY SPRINKLE THE SHELL
188
00:12:13,482 --> 00:12:15,758
WITH A MIXTURE
OF TWO MINERALS --
189
00:12:15,758 --> 00:12:20,344
SILICA SAND AND ZIRCON -- TO
BUILD UP A STRENGTHENING CRUST.
190
00:12:20,344 --> 00:12:24,172
THE SHELLS NOW GO INTO A FURNACE
FOR ABOUT TWO HOURS.
191
00:12:24,172 --> 00:12:28,448
THE INTENSE HEAT HARDENS THEM
AND INCINERATES THE WAX INSIDE,
192
00:12:28,448 --> 00:12:30,896
LEAVING A CAVITY
IN THE PATTERN SHAPE.
193
00:12:30,896 --> 00:12:32,517
THE SHELLS ARE NOW MOLDS
194
00:12:32,517 --> 00:12:35,172
STRONG ENOUGH TO WITHSTAND
MOLTEN METAL.
195
00:12:35,172 --> 00:12:37,620
THAT METAL IS COBALT CHROME.
196
00:12:37,620 --> 00:12:41,931
IN THIS CRUCIBLE, THE CHROME
LIQUEFIES IN ABOUT 10 MINUTES.
197
00:12:43,379 --> 00:12:45,896
THEY REMOVE THE MOLDS
FROM THE FURNACE
198
00:12:45,896 --> 00:12:49,517
AND LOCK THEM TO THE TOP OF
ANOTHER ONE ABOVE THE CRUCIBLE.
199
00:12:51,034 --> 00:12:53,000
THEN THEY FLIP IT OVER.
200
00:12:53,000 --> 00:12:56,310
THE MOLTEN METAL FLOWS FROM
THE CRUCIBLE INTO THE MOLDS.
201
00:12:56,310 --> 00:12:58,448
IT SOLIDIFIES
WITHIN TWO MINUTES.
202
00:12:58,448 --> 00:13:01,551
THEN THEY TRANSFER THE HOT MOLDS
TO A COOLING BIN.
203
00:13:01,551 --> 00:13:04,241
COLD AIR FLOWS AROUND THEM
FOR ABOUT TWO HOURS
204
00:13:04,241 --> 00:13:06,896
UNTIL THEY'RE FINALLY COOL
ENOUGH TO HANDLE.
205
00:13:06,896 --> 00:13:09,896
THEN WORKERS MOUNT EACH TREE
ON AN AUTOMATED MACHINE
206
00:13:09,896 --> 00:13:11,620
THAT WORKS LIKE A JACKHAMMER.
207
00:13:11,620 --> 00:13:15,655
EACH MOLD DISINTEGRATES, FREEING
THE CAST-METAL PART INSIDE.
208
00:13:18,448 --> 00:13:21,758
THEY USE A SAW TO SEPARATE
THE PARTS FROM THE TREE,
209
00:13:21,758 --> 00:13:24,793
THEN A GRINDING BELT TO REMOVE
ANY UNNECESSARY METAL
210
00:13:24,793 --> 00:13:27,103
THAT HARDENED IN THE CHANNELS.
211
00:13:30,586 --> 00:13:33,827
NEXT, THEY LASER-ENGRAVE
A UNIQUE SERIAL NUMBER
212
00:13:33,827 --> 00:13:36,379
ON EACH PART
FOR TRACKING PURPOSES.
213
00:13:36,379 --> 00:13:39,448
EVERY PART UNDERGOES
A THOROUGH INSPECTION.
214
00:13:39,448 --> 00:13:41,862
THEY DUST THE PART
WITH FLUORESCENT POWDER,
215
00:13:41,862 --> 00:13:43,000
THEN RINSE IT OFF.
216
00:13:43,000 --> 00:13:45,724
POWDER RESIDUE SETTLES
IN ANY FLAW
217
00:13:45,724 --> 00:13:48,482
AND GLOWS
UNDER ULTRAVIOLET LIGHT.
218
00:13:48,482 --> 00:13:51,275
AFTER INSPECTION,
THEY BUFF EVERY PART
219
00:13:51,275 --> 00:13:55,793
UNTIL THE METAL'S SO SHINY,
YOU CAN SEE A REFLECTION.
220
00:13:55,793 --> 00:13:59,172
ANOTHER METHOD FOR MAKING
METAL PARTS IS FORGING.
221
00:13:59,172 --> 00:14:01,034
THEY USE A TITANIUM ALLOY,
222
00:14:01,034 --> 00:14:03,827
WHICH IS MORE FLEXIBLE
THAN COBALT CHROME,
223
00:14:03,827 --> 00:14:07,241
MAKING IT BETTER SUITED
FOR HIP JOINTS, IN PARTICULAR.
224
00:14:07,241 --> 00:14:11,275
THEY CLEAN THE METAL, THEN HEAT
IT IN A 2,200-DEGREE FURNACE.
225
00:14:11,275 --> 00:14:14,862
THIS 660-TON PRESS
FORMS ONE PIECE AT A TIME
226
00:14:14,862 --> 00:14:16,931
INTO A PRELIMINARY SHAPE.
227
00:14:16,931 --> 00:14:20,241
THEN THEY MOVE IT
TO THE NEXT DIE AND STAMP TWICE
228
00:14:20,241 --> 00:14:22,931
TO REFINE
AND THEN FINALIZE THE SHAPE.
229
00:14:22,931 --> 00:14:26,068
THE LAST STAMPING
ON THE THIRD DIE
230
00:14:26,068 --> 00:14:30,275
TRIMS OFF EXCESS METAL
AND ADDS DETAIL.
231
00:14:33,034 --> 00:14:36,275
THE FORGED PART NOW GOES
INTO A SANDBLASTING CHAMBER
232
00:14:36,275 --> 00:14:39,482
WHICH CLEANS THE METAL AND GIVES
THE SURFACE A MATTE FINISH.
233
00:14:41,275 --> 00:14:46,241
HERE'S WHAT THE PART LOOKS LIKE
BEFORE SANDBLASTING AND AFTER.
234
00:14:46,241 --> 00:14:48,758
NOW A COMPUTER-GUIDED
MILLING MACHINE
235
00:14:48,758 --> 00:14:50,482
SMOOTHS AWAY THE ROUGH EDGE
236
00:14:50,482 --> 00:14:53,275
THAT TRIMMING THE EXCESS METAL
LEFT BEHIND.
237
00:14:53,275 --> 00:14:55,724
THIS REMOVES
ALL BUT THE LAST BIT,
238
00:14:55,724 --> 00:14:58,931
SO THEY GET RID OF THAT
WITH A SANDING BELT.
239
00:14:58,931 --> 00:15:02,344
BUT SANDING LEAVES
METAL RESIDUE BEHIND.
240
00:15:02,344 --> 00:15:04,172
SO THE PARTS NOW GO FOR A BATH
241
00:15:04,172 --> 00:15:06,413
IN A WATER-BASED
CITRIC SOLUTION.
242
00:15:06,413 --> 00:15:09,137
THE METAL SURFACE
HAS TO BE PERFECTLY CLEAN
243
00:15:09,137 --> 00:15:12,413
IN ORDER TO STAMP ON
THE SERIAL NUMBER IN INK.
244
00:15:12,413 --> 00:15:16,689
QUITE A DIFFERENCE
BEFORE CLEANING AND AFTER.
245
00:15:16,689 --> 00:15:20,068
EACH AND EVERY METAL PART,
WHETHER FORGED OR CAST,
246
00:15:20,068 --> 00:15:22,551
GOES TO THE QUALITY CONTROL
DEPARTMENT.
247
00:15:22,551 --> 00:15:24,482
THERE, USING DIGITAL CALIPERS,
248
00:15:24,482 --> 00:15:27,172
AN INSPECTOR CHECKS
ALL THE DIMENSIONS,
249
00:15:27,172 --> 00:15:31,103
THEN EXAMINES THE PART
UNDER A MAGNIFYING GLASS.
250
00:15:31,103 --> 00:15:33,034
SO FAR WE'VE SEEN TWO
OF THE WAYS
251
00:15:33,034 --> 00:15:35,724
THEY MAKE THE METAL PARTS
OF AN ARTIFICIAL JOINT --
252
00:15:35,724 --> 00:15:37,689
CASTING AND FORGING.
253
00:15:37,689 --> 00:15:40,551
THE THIRD METHOD
IS COMING RIGHT UP.
254
00:15:53,551 --> 00:15:55,862
Narrator: THE METAL PORTION
OF AN ARTIFICIAL JOINT
255
00:15:55,862 --> 00:15:57,000
PLAYS THE ROLE OF BONE,
256
00:15:57,000 --> 00:15:59,034
WHILE THE PLASTIC PORTION
MIMICS CARTILAGE.
257
00:15:59,034 --> 00:16:02,172
HOWEVER, THE PLASTIC ISN'T
YOUR RUN-OF-THE-MILL PLASTIC.
258
00:16:02,172 --> 00:16:03,965
IT'S MEDICAL-GRADE POLYETHYLENE,
259
00:16:03,965 --> 00:16:06,413
MEANING IT'S FORMULATED
TO BE LIGHTWEIGHT,
260
00:16:06,413 --> 00:16:07,896
BUT ALSO EXTREMELY DURABLE
261
00:16:07,896 --> 00:16:11,724
SO THAT IT WITHSTANDS YEARS OF
WEAR AND TEAR WITHIN THE BODY.
262
00:16:14,275 --> 00:16:15,689
THE TYPE OF METAL THEY USE
263
00:16:15,689 --> 00:16:18,206
TO MAKE THE BONE PORTION
OF AN ARTIFICIAL JOINT
264
00:16:18,206 --> 00:16:20,689
DEPENDS ON HOW FLEXIBLE
THAT JOINT HAS TO BE.
265
00:16:20,689 --> 00:16:22,965
A KNEE JOINT
REQUIRES LESS ELASTICITY,
266
00:16:22,965 --> 00:16:25,206
SO THEY MOLD IT
OUT OF COBALT CHROME.
267
00:16:25,206 --> 00:16:29,137
A HIP JOINT, ON THE OTHER HAND,
NEEDS TO BE MORE BENDABLE.
268
00:16:29,137 --> 00:16:31,344
SO FOR THAT, THEY USE TITANIUM.
269
00:16:31,344 --> 00:16:34,068
THEY EITHER FORGE THE SHAPE
IN A PRESS
270
00:16:34,068 --> 00:16:37,689
OR MOUNT THE TITANIUM BLOCK
ON A COMPUTER-GUIDED MILL.
271
00:16:37,689 --> 00:16:39,793
UNDER A STEADY SHOWER
OF LUBRICANT,
272
00:16:39,793 --> 00:16:42,068
THE MILL'S 20-ODD
MACHINING TOOLS
273
00:16:42,068 --> 00:16:45,034
CARVE THE BLOCK FROM ALL ANGLES.
274
00:16:45,034 --> 00:16:47,448
AFTER A PRIMARY ROUGH MACHINING,
275
00:16:47,448 --> 00:16:51,000
THE MILL'S PRECISION TOOLS
FINALIZE THE SHAPE.
276
00:16:51,000 --> 00:16:52,551
FROM START TO FINISH,
277
00:16:52,551 --> 00:16:55,793
MACHINING JUST ONE PART
TAKES ABOUT HALF AN HOUR.
278
00:16:55,793 --> 00:16:58,068
NOW A ROBOT TAKES OVER.
279
00:16:58,068 --> 00:17:01,448
IT RUNS THE PART AGAINST
A SERIES OF SANDING BELTS,
280
00:17:01,448 --> 00:17:03,862
THEIR GRITS PROGRESSING
FROM ROUGH TO FINE.
281
00:17:03,862 --> 00:17:07,551
THIS REMOVES MARKS THE MACHINING
TOOLS LEFT ON THE METAL
282
00:17:07,551 --> 00:17:10,482
AND POLISHES THE SURFACE
TO A MIRROR FINISH.
283
00:17:14,689 --> 00:17:17,000
THE ROBOT CAN'T REACH THE EDGES,
284
00:17:17,000 --> 00:17:22,275
SO A WORKER SANDS THEM MANUALLY
AND VERIFIES THE DIMENSIONS.
285
00:17:27,137 --> 00:17:30,551
THEN THE PARTS GO
FOR A THOROUGH CLEANING.
286
00:17:37,931 --> 00:17:41,275
THE FACTORY PUTS RANDOM SAMPLES
THROUGH WEAR TESTING.
287
00:17:41,275 --> 00:17:43,793
THE MACHINES SIMULATE
JOINT MOVEMENT,
288
00:17:43,793 --> 00:17:45,724
COMPLETE WITH FAKE JOINT FLUID.
289
00:17:45,724 --> 00:17:49,068
THE FACTORY SPRAYS SOME PARTS
WITH TITANIUM POWDER
290
00:17:49,068 --> 00:17:51,724
TO HELP BONE TISSUE
TO CLING TO THEM.
291
00:17:51,724 --> 00:17:54,137
THIS MACHINE,
CALLED AN OPTICAL COMPARATOR,
292
00:17:54,137 --> 00:17:56,655
PROJECTS AN IMAGE
OF THE PART'S COATED OUTLINE
293
00:17:56,655 --> 00:17:58,689
AGAINST A TECHNICALLY PERFECT
TEMPLATE.
294
00:17:58,689 --> 00:18:02,241
THE TECHNICIAN MAKES SURE
THE PART AND THE TEMPLATE MATCH.
295
00:18:04,310 --> 00:18:07,034
TO BECOME AN ARTIFICIAL JOINT,
296
00:18:07,034 --> 00:18:09,965
THE METAL BONE NOW NEEDS
ITS PLASTIC CARTILAGE.
297
00:18:09,965 --> 00:18:12,275
THAT REQUIRES
POLYETHYLENE POWDER.
298
00:18:12,275 --> 00:18:15,034
A TECHNICIAN WEIGHS OUT
A SPECIFIC AMOUNT,
299
00:18:15,034 --> 00:18:17,551
PUTS IT IN THE OUTER SLEEVE
OF A MOLD,
300
00:18:17,551 --> 00:18:20,000
THEN INSERTS
THE MOLD'S INNER PIECE.
301
00:18:20,000 --> 00:18:22,793
THE TECHNICIAN LOADS THE MOLD
INTO A PRESS
302
00:18:22,793 --> 00:18:26,344
THAT APPLIES BOTH PRESSURE
AND HEAT --
303
00:18:26,344 --> 00:18:28,793
374 DEGREES FAHRENHEIT.
304
00:18:31,448 --> 00:18:35,379
THE POWDER GETS SQUEEZED
BETWEEN THE MOLD'S TWO PARTS
305
00:18:35,379 --> 00:18:37,551
AND TURNS INTO SOLID PLASTIC.
306
00:18:42,586 --> 00:18:46,275
USING VARIOUS INSTRUMENTS,
THEY MEASURE THE MOLDED PART
307
00:18:46,275 --> 00:18:49,068
TO ENSURE ALL ITS DIMENSIONS
ARE EXACT.
308
00:18:51,862 --> 00:18:54,896
NOW A COMPUTER-GUIDED MACHINING
TOOL CARVES THE GROOVES
309
00:18:54,896 --> 00:18:57,068
INTO WHICH THE METAL PART
WILL SLIDE.
310
00:18:57,068 --> 00:19:00,862
THESE DETAILS ARE FAR TOO
INTRICATE FOR A MOLD TO SHAPE.
311
00:19:10,000 --> 00:19:14,344
THEN SOME FINAL MEASUREMENTS
TO MAKE SURE THE FINISHED PART
312
00:19:14,344 --> 00:19:16,448
ADHERES TO THE ENGINEERING
SPECIFICATIONS.
313
00:19:20,965 --> 00:19:23,344
RANDOM SAMPLES UNDERGO
FATIGUE TESTING
314
00:19:23,344 --> 00:19:26,931
EQUIVALENT TO 10 YEARS OF WEAR.
315
00:19:28,586 --> 00:19:32,689
SOME PLASTIC PARTS ARE JUST TOO
COMPLEX TO BE MOLDED OUTRIGHT,
316
00:19:32,689 --> 00:19:35,862
SO, INSTEAD, THE FACTORY MOLDS
A BLOCK OF PLASTIC,
317
00:19:35,862 --> 00:19:37,137
THEN MACHINES IT.
318
00:19:37,137 --> 00:19:38,931
THE BLOCK SPINS ON A LATHE
319
00:19:38,931 --> 00:19:41,551
AS VARIOUS COMPUTER-GUIDED TOOLS
SHAPE IT.
320
00:19:44,068 --> 00:19:47,896
SAMPLES OF THESE
ALSO UNDERGO WEAR TESTING.
321
00:19:47,896 --> 00:19:50,103
AFTER A SPECIFIC NUMBER
OF MOVEMENTS
322
00:19:50,103 --> 00:19:51,758
OVER A SPECIFIC TIME PERIOD,
323
00:19:51,758 --> 00:19:54,689
TECHNICIANS REMOVE THE PARTS
AND WEIGH THEM.
324
00:19:54,689 --> 00:19:56,827
BY COMPARING
TO THE STARTING WEIGHT,
325
00:19:56,827 --> 00:19:59,551
THEY CAN CALCULATE HOW MUCH
PLASTIC HAS WORN OFF.
326
00:19:59,551 --> 00:20:03,413
THE PACKAGING ROOM
IS WHAT THEY CALL A CLEAN ROOM,
327
00:20:03,413 --> 00:20:06,068
MEANING THE AIR RUNS
THROUGH A FILTER SYSTEM
328
00:20:06,068 --> 00:20:07,827
TO KEEP OUT DUST AND DIRT.
329
00:20:07,827 --> 00:20:10,931
WORKERS PACK THE ARTIFICIAL
JOINTS AGAINST FOAM
330
00:20:10,931 --> 00:20:12,862
TO PROTECT THE METAL SURFACE,
331
00:20:12,862 --> 00:20:16,620
BECAUSE EVEN THE TINIEST SCRATCH
CAN CAUSE PREMATURE WEAR.
332
00:20:18,000 --> 00:20:20,310
AFTER HEAT-SEALING THE PACKAGES,
333
00:20:20,310 --> 00:20:23,517
THE FACTORY SHIPS THEM OFF
TO A STERILIZATION PLANT.
334
00:20:23,517 --> 00:20:25,793
THERE, POWERFUL GAMMA RAYS
PENETRATE
335
00:20:25,793 --> 00:20:27,413
RIGHT THROUGH THE PACKAGING
336
00:20:27,413 --> 00:20:30,620
AND KILL OFF ANY BACTERIA
THAT MIGHT BE LURKING INSIDE.
337
00:20:33,896 --> 00:20:38,137
MAKE NO BONES ABOUT IT,
THESE JOINTS MAY BE ARTIFICIAL,
338
00:20:38,137 --> 00:20:42,241
BUT THE MOVEMENT THEY RESTORE
IS AS REAL AS IT GETS.
339
00:20:53,034 --> 00:20:55,482
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
340
00:20:55,482 --> 00:20:58,275
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
341
00:20:58,275 --> 00:21:00,206
DROP US A LINE AT...
28093
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