All language subtitles for How.Its.Made.S13E06.Gears.and.Kitchen.Shears.1080p.AMZN.WEB-DL.DDP2.0.H.264-SLAG_track4_[eng]

Narrator: IF YOU'VE EVER
LOOKED INSIDE A WIND-UP WATCH

OR A CAR'S TRANSMISSION,
YOU'VE SEEN A SYSTEM OF GEARS.

A GEAR IS A WHEEL WITH TEETH

THAT MESHES WITH THE TEETH
OF ANOTHER GEAR

TO TRANSMIT POWER
ON A CONTINUOUS BASIS.

COMBINING GEARS
OF DIFFERENT DIAMETERS

AFFECTS ROTATION SPEED
AND FORCE.

THIS FACTORY MAKES GEARS

THAT GO INTO TRANSMISSIONS
FOR INDUSTRIAL MACHINES.

PRODUCTION BEGINS WITH A LARGE,
ROUND BAR OF HIGH-GRADE STEEL,

WHICH CONTAINS
A CERTAIN AMOUNT OF CARBON

TO MAKE IT EVEN STRONGER.

AN AUTOMATED BAND SAW

SLICES OFF A PIECE
THAT'S THE RIGHT THICKNESS

FOR THE SIZE OF GEAR
THEY'RE MAKING.

THIS PIECE IS CALLED
A GEAR BLANK.

THEY MOUNT THE BLANK
ON A COMPUTER-CONTROLLED BLADE.

AS IT SPINS,

A TURRET CARRYING A SERIES
OF CARBIDE TOOLS MOVES IN.

ONE TOOL AFTER ANOTHER TAKES
ITS TURN MACHINING THE BLANK

TO A SPECIFIC SHAPE.

A SHOWER OF COOLANT
PREVENTS OVERHEATING

WHEN THE JUMBO DRILL
HAS ITS TURN.

IT BORES A HOLE RIGHT THROUGH
THE MIDDLE OF THE BLANK.

THE LAST TOOL CARVES A GROOVE
ON THE FRONT OF THE BLANK.

THIS FINAL BIT OF METAL REMOVAL
LESSENS THE GEAR'S WEIGHT.

NOW THE BLANK GOES INTO
A COMPUTER-CONTROLLED MILL.

THE MILL DRILLS HOLES THROUGH
WHICH LUBRICATION WILL FLOW

WHEN THE GEAR IS OPERATING.

THESE HOLES ALSO LIGHTEN
THE GEAR'S WEIGHT.

WHEN THE BLANK
COMES OFF THE MILL,

THEY STAMP IT WITH THE COMPANY
NAME AND PART NUMBER.

NOW FOR THE GEAR'S TEETH.

A MACHINE CALLED A GEAR SHAPER
CARVES OUT THE INNER TEETH --

THE ONES
LINING THE CENTER HOLE --

WITH ITS
TITANIUM-COATED CUTTER.

THE MACHINE'S OTHER COMPONENTS

KEEP THE CUTTER'S MOVEMENT
CORRECTLY TIMED.

THE NUMBER OF TEETH AND TOOTH
SIZE VARY FROM GEAR TO GEAR,

SO FOR EACH MODEL, THE FACTORY
HAS TO FIT THE GEAR SHAPER

WITH A SPECIFIC CUTTER.

NOW FOR THE OUTSIDE GEAR TEETH.

THE COMPUTER-CONTROLLED MACHINE
THAT CUTS THEM

IS CALLED A GEAR HOBBER.

THE GEAR TURNS AGAINST IT
AS IT CUTS.

IF THE HOBBER WOULD CUT THE FULL
DEPTH OF THE TEETH IN ONE SHOT,

THE CUTTER WOULD CHIP,

SO THE GEAR KEEPS TURNING
AROUND AND AROUND AGAIN

AS THE HOBBER CUTS
A BIT MORE WITH EACH PASS,

UNTIL THE TEETH
ARE THE RIGHT DEPTH.

THEN THE GEAR UNDERGOES
A COMPUTERIZED INSPECTION.

A PROBE SCANS THE ENTIRE
SURFACE, INCLUDING EVERY TOOTH.

IT SENDS DATA TO A COMPUTER

WHICH THEN ANALYZES
THE DIMENSIONS

AND ENSURES THEY MEET
THE ENGINEERING SPECIFICATIONS.

GEARS THAT PASS
THIS QUALITY-CONTROL INSPECTION

GO INTO A FURNACE
FOR HEAT TREATMENT.

THIS STRENGTHENS THE STEEL.

WHEN THE FURNACE
REACHES A CERTAIN TEMPERATURE,

THEY INJECT CARBON INSIDE.

THE GEARS ABSORB IT, AND THE
STEEL STRENGTHENS EVEN FURTHER.

A SOAKING IN OIL AFTERWARD
HARDENS THE METAL.

HEAT TREATMENT, HOWEVER,
DISTORTS STEEL SOMEWHAT,

SO EACH GEAR NOW GOES TO
A COMPUTER-CONTROLLED GRINDER.

IT RESTORES THEM
TO VERY PRECISE SPECIFICATIONS

FOR BEARINGS TO FIT PROPERLY.

THIS FACTORY MANUFACTURES GEARS
IN VARIOUS SIZES,

AND NOT ONLY IN STEEL.

IT ALSO MAKES GEARS IN MATERIAL
SUCH AS NYLON, ALUMINUM,

BRASS, AND STAINLESS STEEL.

SOME GEARS HAVE STRAIGHT TEETH,
OTHERS ANGLED TEETH,

WHICH MAKES LESS NOISE
WHEN TURNING.

GEARS ARE AN ESSENTIAL COMPONENT

IN EVERYTHING FROM WATCHES
TO HEAVY MINING EQUIPMENT,

KEEPING MACHINERY
GOING AT EVERY TURN.

Narrator:
WHEN IT COMES TO WRISTWATCHES,

THERE'S NOTHING QUITE LIKE
A BAND MADE OF GENUINE LEATHER.

IT HAS A CLASSIC LOOK
THAT'S VERSATILE,

WORKING WITH BOTH CASUAL
AND FORMAL ATTIRE.

AND A LEATHER WATCHBAND
IS ALWAYS COMFORTABLE

AGAINST THE SKIN

BECAUSE, UNLIKE SYNTHETICS,
LEATHER BREATHES.

THESE PREMIUM WATCHBANDS
ARE MADE OF ALLIGATOR,

A LEATHER WITH AN UNMISTAKABLE
TEXTURE AND SHINE.

THE TANNERY DYES THE
CROC LEATHERS IN CLASSIC SHADES,

AS WELL AS IN THE LATEST
HIGH-FASHION COLORS AND STYLES.

NEARLY ALL THE PRODUCTION STEPS
ARE MANUAL,

BEGINNING WITH
CUTTING LEATHER PIECES

FOR THE BAND'S TWO STRAPS.

EVERY WATCHBAND MODEL
REQUIRES A STEEL CUTTER

FOR EACH STRAP IN EVERY SIZE.

NOW THEY COAT THE BACK SIDE
OF EACH PIECE WITH GLUE.

LATER, WHEN IT'S ALMOST DRY,

THEY CENTER A WATCHBAND CORE
ONTO IT.

THIS FLEXIBLE FORM
IS MADE OF SYNTHETIC MATERIAL

REINFORCED WITH FIBERGLASS.

USING A MACHINE
WITH A FINE BLADE,

THEY MAKE SMALL CUTS AT THE ENDS

TO LET THE LEATHER FOLD SMOOTHLY
OVER THE FORM.

ONE SIDE OF EACH STRAP
ATTACHES TO THE WATCH FACE

WITH A SPRING-LOADED BAR.

THEY MARK EXACTLY
WHERE THE BAR GOES,

THEN PUNCH A TINY HOLE
FOR ITS TINY BASE.

NEXT THEY APPLY
SUPERSTRENGTH GLUE

AND FOLD THE LEATHER OVER
TO ENCASE THE BAR.

THE GLUE DRIES INSTANTLY.

THEY NOW COAT THE REST
OF THE FORM WITH GLUE,

THEN LAY IT IN A MOLD

THAT PUSHES THE LEATHER
AGAINST THE EDGE TIGHTLY

SO THEY CAN NEATLY
FOLD OVER THE REMAINDER.

NOW THEY RUN THE OPEN END
THROUGH A MACHINE

THAT CUTS A BEVELED EDGE.

NEXT, THEY RUN A TINY SANDER
OVER THE LEATHER

ON THE BACK SIDE.

THIS ROUGHENS THE SURFACE,

WHICH WILL HELP
THE LEATHER BACKING ADHERE.

TO MAKE THE LOOPS
WHICH GO ON THE BUCKLE STRAP,

THEY BEVEL THE ENDS
OF SMALL LEATHER STRIPS.

THEY GLUE AND FOLD THEM
INTO A LOOP,

MAKING SURE THEY'RE LARGE ENOUGH
TO FIT AROUND BOTH STRAPS.

ONE LOOP SITS
DIRECTLY BELOW THE BUCKLE.

A GLUED-OVER FLAP OF LEATHER
LOCKS IT IN POSITION.

THEY PRESS IT FLAT WITH PLIERS
TO ENSURE A GOOD BOND.

THEY MACHINE-STITCH EACH STRAP

WITH STRONG,
POLYETHYLENE-BASED THREAD.

TO PREVENT UNRAVELING, THEY MELT
THEM RIGHT INTO THE LEATHER.

ON THE BUCKLE END, THEY PIERCE
TWO HOLES FOR STITCHES

THAT REINFORCE
THE LOCKED-IN FIRST LOOP.

THEN THEY PUNCH TWO HOLES
IN THE BACK OF THE SECOND LOOP

FOR STITCHING TO REINFORCE
ITS GLUED-TOGETHER ENDS.

THIS LOOP HAS TO BE MOVABLE,

SO THEY DON'T STITCH IT
TO THE BAND.

THEY HEAT THE EDGE
OF EACH STRAP.

THE IRON'S ROUNDED TIP MOLDS
AN ATTRACTIVE, ROUNDED EDGE.

USING A HEATED TOOL AGAIN,

THEY WIDEN THE CHANNEL THROUGH
WHICH THE BUCKLE WILL PASS.

NOW THEY INSERT THE BUCKLE END
INTO A STAMPING PRESS.

IT CUTS A SLOT
FOR THE BUCKLE'S TONGUE.

A HEAT PRESS BURNS THE COMPANY'S
NAME INTO THE LEATHER LINING.

THAT SAME STRAP
THEN GOES INTO A PRESS,

WHICH PUNCHES THE SIZING HOLES.

FROM HERE, BOTH STRAPS GO OFF
TO THE BUCKLE DEPARTMENT.

RANDOM SAMPLES ARE SUBJECTED

TO RIGOROUS
QUALITY-CONTROL TESTING.

THIS MACHINE PULLS
THE ENDS OF THE STRAP

IN OPPOSITE DIRECTIONS, WITH UP
TO NEARLY 50 POUNDS OF TENSION,

FAR MORE THAN ANYONE WOULD EVER
APPLY TO THE WATCHBAND

WHEN THEY PULL TO BUCKLE IT.

Narrator:
VITRELLE IS A SUPER-DURABLE
DINNERWARE MATERIAL

INVENTED IN THE UNITED STATES
IN THE EARLY 1970s.

IT'S MADE OF THREE LAYERS
OF GLASS, FUSED TOGETHER.

VITRELLE DISHES ARE THIN
AND LIGHTWEIGHT,

YET THEY'RE STRONGER
AND FAR MORE BREAK-RESISTANT

THAN ORDINARY DINNERWARE.

IN A PERFECT UNION
OF FORM, FUNCTION, AND FOOD,

THIS COMPANY SERVES UP
VITRELLE DINNERWARE

IN SEVERAL STRIKING DESIGNS.

THE DISHES ARE MADE
OF 65% RECYCLED GLASS

FROM EARLIER PRODUCTION RUNS.

TO MAKE THE OTHER 35%
THAT'S NEW GLASS,

THE FACTORY COMBINES
SEVERAL RAW MATERIALS --

SAND...

SALT...

LIMESTONE...

FELDSPAR...

AND TWO MORE TYPES OF SALT.

THE EXACT PROPORTIONS
ARE A CLOSELY GUARDED SECRET.

THE INGREDIENTS
GO INTO A FURNACE,

WHERE A FIERY
2,500 DEGREES FAHRENHEIT

MELTS THEM INTO LIQUID GLASS.

IT EXITS THE FURNACE.

AN EXTRUDER SHAPES IT
INTO A THREE-PLY SHEET

THAT LANDS IN A MOLD --
IN THIS CASE, A PLATE MOLD.

A TRIMMER CUTS OFF THE EXCESS,

WHILE COMPRESSED AIR
BLOWS DOWN FROM ABOVE

TO COOL AND SOLIDIFY THE GLASS.

A VACUUM ARM
THEN EXTRACTS EACH DISH,

AND THE LEFTOVERS ARE RECYCLED.

THE DISHES NOW UNDERGO
WHAT'S CALLED FIRE POLISHING.

EACH ONE PASSES THROUGH
A GAS-OXYGEN FLAME,

WHICH SEALS
THE THREE LAYERS OF GLASS.

IT ALSO MELTS THE OUTER RIM,

SMOOTHING AND ROUNDING OUT
THE ROUGH EDGE

CREATED BY THE TRIMMING.

OVAL DISHES GO ON
A DIFFERENT FIRE POLISHER,

DESIGNED FOR AN OVAL RIM
RATHER THAN A ROUND ONE.

NOW THE CONVEYOR SYSTEM FLIPS
EACH DISH OVER FOR BACKSTAMPING.

THE BOTTOM
OF EVERY VITRELLE DISH

HAS THE TRADE NAME
AND OTHER INFORMATION.

A SILK-SCREEN MACHINE
APPLIES THE LETTERING.

THEN A GAS-AIR FLAME
BAKES THE INK INTO THE GLASS.

ONCE THAT'S DONE,

THE CONVEYOR SYSTEM FLIPS
THE DISHES RIGHT SIDE UP AGAIN.

TO DECORATE THE DISHES,

A MACHINE SILK-SCREENS
THE DESIGN ONTO MEMBRANES.

ROBOTIC ARMS POSITION A MEMBRANE
ABOVE EACH DISH.

THEN A PRESS HEAD PUSHES THE
MEMBRANE DOWN ONTO THE SURFACE,

TRANSFERRING THE PAINT.

ROBOTIC ARMS
THEN MOVE THE DISHES

BACK ONTO A CONVEYOR BELT.

CERTAIN DISHES HAVE A DESIGN
ON THE OUTSIDE.

AN AUTOMATED SILK-SCREEN MACHINE

APPLIES THE PAINT
DIRECTLY TO THE SURFACE.

THE DECORATED DISHES
NOW TRAVEL THROUGH A TUNNEL OVEN

FOR 5 1/2 MINUTES.

THE NEARLY
1,500-DEGREE FAHRENHEIT HEAT

CURES THE ENAMEL PAINT.

AT THE END OF THE RIDE,

A TEMPERING PROCESS
THAT MAKES THE GLASS STRONGER.

THEN, NOZZLES SPRAY THE DISHES
IN A SOY-BASED SILICONE.

THIS WASH-OFF COATING PREVENTS
SCRATCHES DURING PACKAGING.

THE FACTORY SUBJECTS A SAMPLE
FROM EACH PRODUCTION RUN

TO A 6 1/2-FOOT-DROP TEST
AND A RIM-IMPACT TEST.

THE SAMPLE MUSTN'T BREAK, CHIP,
OR CRACK...

ALL TO ENSURE
THIS STYLISH DINNERWARE

WILL WITHSTAND WHATEVER
YOUR HOUSEHOLD CAN DISH OUT.

Narrator: SHEARS ARE TYPICALLY
LARGER THAN SCISSORS

FOR HEAVIER-DUTY CUTTING.

AND YOU CAN INSERT
UP TO THREE FINGERS

IN THE HANDLE'S FINGER RING.

USING MORE FINGERS
GIVES YOU A STRONGER GRASP,

WHICH TRANSLATES INTO MORE
CONTROL AND MORE CUTTING FORCE.

THESE HIGH-END SHEARS

EFFORTLESSLY
SLICE THROUGH PRODUCE,

SNIP FRESH HERBS,
AND OPEN PACKAGING.

OUTSIDE THE KITCHEN,
THEY EASILY CUT MANY MATERIALS,

INCLUDING THIN ALUMINUM
AND GALVANIZED STEEL.

THE SECRET TO THEIR STRENGTH?

BLADES MADE OF STAINLESS STEEL,

WHICH CONTAINS
A MINUTE AMOUNT OF CARBON.

TO MAKE THEM,

WORKERS FEED A BAR OF THIS
HIGH-CARBON STAINLESS STEEL

INTO A PRESS.

IT STAMPS OUT BLADE SHAPES
CALLED BLANKS.

STAINLESS STEEL
CAN BE HEAT-TREATED

TO MAKE IT MORE DURABLE
AND CORROSION-RESISTANT.

BUT FIRST, A FURNACE SOFTENS THE
BLANKS FOR THE FORGING PROCESS

THAT TRANSFORMS THEM
INTO BLADES.

EACH BLANK
GOES ONTO A FORGING DYE

THAT HAS TWO
BLADE-SHAPED CAVITIES.

ONE STRIKE IN EACH,
AND THE BLANK IS A BLADE.

ONCE IT COOLS,

A TRIMMING PRESS
CUTS OFF ALL THE EXCESS METAL

AROUND THE PERIMETER.

HEATING AND FORGING
TEND TO WARP STEEL,

SO ANOTHER PRESS MAKES THE BLADE
PERFECTLY FLAT

AND STRAIGHT AGAIN.

TRIMMING THE EXCESS METAL
LEAVES SOME ROUGH AREAS,

SO THE NEXT STEP IS TO SMOOTH
THE SURFACE WITH A SANDING BELT.

TO MAKE THE HOLE FOR THE BOLT
ON WHICH THE BLADES PIVOT,

THEY DRILL A ROUND HOLE
PARTWAY THROUGH...

THEN PIERCE A RECTANGULAR HOLE
THROUGH THE REST.

YOU'LL SEE WHY LATER ON.

NOW THE BLADES
UNDERGO HEAT TREATMENT --

FIRST, TO HARDEN THEM, A SLOW
HEATING AND RAPID COOLING,

THEN, TO MAKE THEM
TOUGH AND DURABLE,

A REHEAT AND SLOW COOLING.

A GRINDER SHAPES THE ROUND AREA
NEXT TO THE TANG,

THE TERM FOR THE METAL CORE
OF THE HANDLE.

WITH A SANDING BELT,

THEY SMOOTH OUT AND BLEND
THE ADJACENT CORNERS.

HERE, TWO POLISHING WHEELS
GIVE THE SURFACE

AN UPSCALE SATIN FINISH.

THEN AN ETCHING MACHINE USES
ELECTRICALLY ACTIVATED CHEMICALS

TO IMPRINT THE COMPANY'S NAME
INTO THE THUMB-OPERATED BLADE.

JUST ONE FINAL STEP
BEFORE THE BLADES ARE FINISHED.

A COMPUTER-OPERATED GRINDER

SERRATES THE INSIDE EDGE
OF THE THUMB-OPERATED BLADE.

WORKERS NOW LOAD
SIX BLADES AT A TIME

INTO AN INJECTION-MOLDING
MACHINE.

THE MACHINE SHOOTS MOLTEN
PLASTIC INTO THE CAVITIES,

THEN RAPIDLY COOLS THE MATERIAL
UNTIL IT SOLIDIFIES.

EACH BLADE EXITS THE MACHINE
WITH A MOLDED HANDLE

FIRMLY ENCASING THE TANG.

NOW FOR THE FINAL ASSEMBLY --

FIRST THEY DRIVE A BOLT
WITH A RECTANGULAR HEAD

INTO THE PIVOT HOLE
OF THE FINGER-OPERATED BLADE.

THEN THEY ADD
THE THUMB-OPERATED BLADE

AND PRESS THE BOLT AGAIN
INTO ITS FINAL POSITION.

A SELF-LOCKING, HEXAGONAL NUT

SECURES THE BOLT
FROM UNDERNEATH.

AN AUTOMATIC TIGHTENER
DOES THE INITIAL FASTENING.

THEN WORKERS DO THE FINAL
TENSION ADJUSTMENT MANUALLY.

THE FINAL STEP

IS TO GRIND THE EXCESS PLASTIC
OFF THE HANDLE STOPS.

THIS ENABLES THE BLADE TO CLOSE
FULLY AND IN PERFECT ALIGNMENT.

SO, WHY THE RECTANGULAR BOLT?

WATCH CLOSELY.

IT ALLOWS YOU,
WITH JUST ONE SIMPLE TWIST,

TO SEPARATE THE BLADES
FOR CLEANING

AND THEN REASSEMBLE THEM.

NOW, THAT'S CUTTING-EDGE DESIGN.

IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,

OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,

DROP US A LINE AT...

--Captions by VITAC--
www.vitac.com

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