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These are the user uploaded subtitles that are being translated: 1 00:00:02,000 --> 00:00:05,000 --Captions by VITAC-- www.vitac.com 2 00:00:05,000 --> 00:00:08,000 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 3 00:00:51,793 --> 00:00:54,310 Narrator: THE DISTINCTIVE SOUND OF THE ACCORDION 4 00:00:54,310 --> 00:00:56,413 APPEARS IN ALMOST EVERY KIND OF MUSIC. 5 00:00:56,413 --> 00:00:58,965 THE PIANO-STYLE KEYBOARD ON THE RIGHT-HAND SIDE 6 00:00:58,965 --> 00:01:00,413 PRODUCES THE MELODY, 7 00:01:00,413 --> 00:01:03,551 WHILE THE BUTTONS ON THE LEFT PRODUCE THE CHORD ACCOMPANIMENT. 8 00:01:03,551 --> 00:01:06,724 IN BETWEEN ARE BELLOWS THAT FORCE AIR THROUGH REEDS, 9 00:01:06,724 --> 00:01:09,724 PRODUCING THAT UNMISTAKABLE ACCORDION SOUND. 10 00:01:16,482 --> 00:01:19,793 THE ACCORDION IS A BEAUTIFUL AND COMPLEX INSTRUMENT. 11 00:01:19,793 --> 00:01:22,862 IT CONTAINS UP TO 10 SETS OF STEEL REEDS 12 00:01:22,862 --> 00:01:24,827 WITH DIFFERENT PITCHES. 13 00:01:24,827 --> 00:01:27,931 EACH REED SET GOES INTO A WOODEN BLOCK. 14 00:01:27,931 --> 00:01:31,551 UNDER EVERY SECTION IS AN OPENING CALLED A TONE HOLE. 15 00:01:31,551 --> 00:01:33,827 THE BELLOWS DRIVES AIR THROUGH IT, 16 00:01:33,827 --> 00:01:37,689 VIBRATING THE REED ABOVE TO PRODUCE A MUSICAL NOTE. 17 00:01:37,689 --> 00:01:40,689 THESE LEATHER-AND-PLASTIC PADS COVER THE SLOTS 18 00:01:40,689 --> 00:01:43,965 ON THE ACCORDION'S ALUMINUM REED PLATES. 19 00:01:43,965 --> 00:01:46,517 EACH PLATE HOLDS TWO REEDS. 20 00:01:46,517 --> 00:01:48,862 BOTH REEDS PRODUCE THE SAME NOTE -- 21 00:01:48,862 --> 00:01:52,379 ONE WHEN YOU PUSH THE BELLOWS, THE OTHER WHEN YOU PULL. 22 00:01:52,379 --> 00:01:56,931 THEY NOW APPLY A SPECIAL WAX TO SECURE THE REEDS TO THE BLOCK. 23 00:01:56,931 --> 00:01:59,931 IF THEY USED GLUE, THEY WOULDN'T BE ABLE TO REMOVE THE PLATE 24 00:01:59,931 --> 00:02:02,137 SHOULD A REED EVER NEED REPAIR. 25 00:02:02,137 --> 00:02:06,172 EACH REED PLAYED CORRESPONDS TO A SPECIFIC NOTE OR CHORD. 26 00:02:08,172 --> 00:02:10,068 TO ASSEMBLE THE KEYBOARD, 27 00:02:10,068 --> 00:02:14,448 THEY BEGIN WITH A LEVER MADE OF FIBERGLASS-REINFORCED PLASTIC. 28 00:02:14,448 --> 00:02:17,689 IT HAS A WOODEN CORE TO GIVE THE KEYS SUFFICIENT WEIGHT. 29 00:02:19,034 --> 00:02:21,517 A LONG METAL LEVER GOES INTO THE TOP. 30 00:02:21,517 --> 00:02:23,482 WHEN THE MUSICIAN PRESSES A KEY, 31 00:02:23,482 --> 00:02:26,724 ITS MECHANISM UNBLOCKS THE CORRESPONDING TONE HOLE, 32 00:02:26,724 --> 00:02:28,551 ALLOWING AIR TO FLOW INSIDE 33 00:02:28,551 --> 00:02:31,344 AND VIBRATE ONE OF THE PLATE'S TWO REEDS. 34 00:02:35,000 --> 00:02:39,965 NEXT, THEY DRIVE IN THE STEEL AXLE ON WHICH THE KEYS PIVOT. 35 00:02:42,896 --> 00:02:46,137 THEN THEY APPLY SUCTION TO A KEYBOARD-SIZE TRAY. 36 00:02:46,137 --> 00:02:48,965 IN IT, THEY LINE UP THE PLASTIC KEY TOPS. 37 00:02:48,965 --> 00:02:50,793 IN TOP-OF-THE-LINE MODELS, 38 00:02:50,793 --> 00:02:53,655 THE WHITE KEY TOPS ARE MADE OF CELLULOID. 39 00:02:57,000 --> 00:02:59,482 WITH THE SUCTION HOLDING THE KEYS DOWN, 40 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. 42 00:03:03,896 --> 00:03:05,586 THE TOPS ADHERE TO THE LEVERS, 43 00:03:05,586 --> 00:03:07,965 WHICH HAVE SINCE RECEIVED A COAT OF GLUE. 44 00:03:07,965 --> 00:03:11,241 AFTER ABOUT AN HOUR, THE GLUE IS DRY. 45 00:03:11,241 --> 00:03:16,344 THEY CUT THE SUCTION, AND THE KEYBOARD IS FINGER-READY. 46 00:03:16,344 --> 00:03:17,965 MEANWHILE, THE REED BLOCKS 47 00:03:17,965 --> 00:03:20,482 ARE IN THE HANDS OF A TUNING SPECIALIST, 48 00:03:20,482 --> 00:03:22,241 WHO PUMPS AIR WITH A FOOT PEDAL 49 00:03:22,241 --> 00:03:24,413 TO VIBRATE THE REEDS ONE AT A TIME. 50 00:03:24,413 --> 00:03:26,862 HE COMPARES EACH NOTE TO A REFERENCE TONE 51 00:03:26,862 --> 00:03:28,310 FROM A TUNING APPARATUS 52 00:03:28,310 --> 00:03:31,448 AND FILES THE REEDS GRADUALLY UNTIL THEIR PITCHES MATCH. 53 00:03:32,586 --> 00:03:34,379 NOW FOR THE BUTTON KEYBOARD. 54 00:03:34,379 --> 00:03:36,068 STARTING WITH THE VALVES, 55 00:03:36,068 --> 00:03:39,724 THEY INSTALL A WOODEN PALLET OVER EACH TONE HOLE. 56 00:03:39,724 --> 00:03:42,137 TO THAT, THEY GLUE A STEEL LEVER. 57 00:03:43,896 --> 00:03:47,517 THEN TO THAT, THEY CONNECT A BRASS RAKE. 58 00:03:50,000 --> 00:03:52,862 WHEN THE RAKE MOVES, IT PULLS THE LEVER, 59 00:03:52,862 --> 00:03:56,172 WHICH OPENS THE VALVE, UNBLOCKING THE TONE HOLE. 60 00:03:56,172 --> 00:03:59,379 AIR ENTERS AND VIBRATES THE REED, PRODUCING THE NOTE. 61 00:04:03,517 --> 00:04:06,275 EACH KEYBOARD BUTTON OPENS THREE VALVES. 62 00:04:06,275 --> 00:04:10,000 THAT'S WHY PUSHING ONE BUTTON PRODUCES A THREE-NOTE CHORD. 63 00:04:11,413 --> 00:04:12,896 WITH THE COMPLEX CONNECTIONS 64 00:04:12,896 --> 00:04:14,965 BETWEEN BUTTONS AND REEDS COMPLETE, 65 00:04:14,965 --> 00:04:18,620 THE REED BLOCKS GO INTO A CELLULOID-ON-PLYWOOD HOUSING. 66 00:04:18,620 --> 00:04:22,206 IT'LL ATTACH TO THE BELLOWS MADE OF STRONG PLEATED CARDBOARD 67 00:04:22,206 --> 00:04:25,586 REINFORCED WITH LEATHER AND METAL CORNER PROTECTORS. 68 00:04:29,206 --> 00:04:31,862 BUT BEFORE PERMANENTLY ATTACHING THE BELLOWS, 69 00:04:31,862 --> 00:04:33,758 ALL THE REEDS HAVE TO UNDERGO 70 00:04:33,758 --> 00:04:36,758 A FINAL AND VERY EXTENSIVE TUNING ADJUSTMENT. 71 00:04:42,827 --> 00:04:45,586 AN ACCORDION CAN HAVE UP TO 600 REEDS, 72 00:04:45,586 --> 00:04:50,758 SO THIS METICULOUS REED-BY-REED TUNING CAN TAKE UP TO 16 HOURS. 73 00:04:57,586 --> 00:05:00,758 THEY NOW PIN THE BELLOWS' WOOD FRAME ENDS 74 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 76 00:05:07,206 --> 00:05:08,620 TO KEEP OUT DUST. 77 00:05:08,620 --> 00:05:12,862 AFTER POLISHING THE ACCORDION TO A HIGH-GLOSS FINISH, 78 00:05:12,862 --> 00:05:16,000 IT'S TIME FOR A MUSICAL ROAD TEST IN WHITE GLOVES. 79 00:05:16,000 --> 00:05:18,620 THERE'S NO SENSE IN LEAVING FINGERPRINTS 80 00:05:18,620 --> 00:05:21,275 ON THAT EXQUISITELY POLISHED SURFACE. 81 00:05:21,275 --> 00:05:23,724 WITH THE TEST CHECKLIST COMPLETE, 82 00:05:23,724 --> 00:05:25,689 THE INSPECTOR SIGNS OFF ON IT. 83 00:05:25,689 --> 00:05:29,655 YOU CAN'T SAY THIS JOB'S ALL WORK AND NO PLAY. 84 00:05:53,379 --> 00:05:55,862 Narrator: THE PINEAPPLE IS NATIVE TO SOUTH AMERICA, 85 00:05:55,862 --> 00:05:58,344 BUT COLONIZATION SPREAD IT TO OTHER TROPICAL AREAS. 86 00:05:58,344 --> 00:06:00,413 THE LATIN NAME FOR PINEAPPLE IS "ANANAS," 87 00:06:00,413 --> 00:06:03,241 WHICH COMES FROM NANA, WHAT THE NATIVES CALLED THE PLANT. 88 00:06:03,241 --> 00:06:06,482 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 90 00:06:09,172 --> 00:06:10,931 LOOKED LIKE A GIANT PINECONE. 91 00:06:14,275 --> 00:06:16,448 PINEAPPLES NEED TEMPERATURES 92 00:06:16,448 --> 00:06:20,310 BETWEEN 73 AND 86 DEGREES FAHRENHEIT AND FULL SUN. 93 00:06:20,310 --> 00:06:22,896 IT TAKES SEVEN MONTHS FOR THE PINEAPPLE PLANT 94 00:06:22,896 --> 00:06:25,758 TO PRODUCE A BUNCH OF LITTLE REDDISH-PURPLE FLOWERS. 95 00:06:25,758 --> 00:06:28,068 AT THIS FIRST BLOOM, AS IT'S CALLED, 96 00:06:28,068 --> 00:06:30,551 FARMERS SPRAY THE PLANT WITH ETHYLENE, 97 00:06:30,551 --> 00:06:33,448 A NATURAL GAS THAT STIMULATES FULL FLOWERING. 98 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. 101 00:06:40,965 --> 00:06:45,862 FIVE MONTHS AFTER FIRST BLOOM, A YEAR SINCE THE LAST HARVEST, 102 00:06:45,862 --> 00:06:49,551 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 104 00:06:52,172 --> 00:06:55,068 TO MAKE SURE THE SWEETNESS LEVEL IS JUST RIGHT. 105 00:06:57,172 --> 00:07:00,827 THIS IS PRICKLY BUSINESS, SO THE WORKERS HAVE TO WEAR GLOVES, 106 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 118 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 120 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 135 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. 138 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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