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Narrator:
"MILLEFIORI" IS ITALIAN
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FOR "A THOUSAND FLOWERS."
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00:00:55,137 --> 00:00:57,827
IT'S ALSO AN ELABORATE
GLASS-MAKING TECHNIQUE
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00:00:57,827 --> 00:00:59,758
DEVELOPED IN 15th-CENTURY ITALY
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IN WHICH PATTERN-COLORED
GLASS RODS ARE CUT,
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00:01:02,586 --> 00:01:04,551
GROUPED TO FORM FLORAL SHAPES,
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00:01:04,551 --> 00:01:06,931
ARRANGED
INTO INTRICATE PATTERNS,
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00:01:06,931 --> 00:01:08,931
THEN ENCASED IN CLEAR CRYSTAL.
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00:01:11,896 --> 00:01:14,551
IF A PICTURE'S WORTH
A THOUSAND WORDS,
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00:01:14,551 --> 00:01:16,862
THESE THOUSAND-FLOWER
PAPERWEIGHTS
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00:01:16,862 --> 00:01:18,310
SPEAK FOR THEMSELVES.
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00:01:18,310 --> 00:01:21,827
TWO CANADIAN ARTISTS CRAFT
THESE MILLEFIORI MASTERPIECES
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00:01:21,827 --> 00:01:24,896
JUST AS THE RENOWNED GLASS
MAKERS OF MURANO, ITALY, DID
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00:01:24,896 --> 00:01:26,275
CENTURIES AGO.
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A MIX CONTAINING SILICA SAND,
SODA ASH, AND LIME
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00:01:29,758 --> 00:01:32,620
IS HEATED
TO 2,400 DEGREES FAHRENHEIT,
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00:01:32,620 --> 00:01:35,655
MELTING IT
INTO LEAD-FREE LIQUID CRYSTAL.
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00:01:35,655 --> 00:01:37,413
WITH A MOLTEN-CRYSTAL POST,
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00:01:37,413 --> 00:01:41,758
THEY PICK UP
A DENSELY COLORED BAR OF GLASS.
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00:01:41,758 --> 00:01:44,655
THEY ROLL AND SHAPE
THE WHITE COLOR BAR
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00:01:44,655 --> 00:01:47,827
WHILE STABILIZING THE POST
WITH COLD WATER.
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00:01:50,206 --> 00:01:51,931
THEN WITH A TORCH,
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00:01:51,931 --> 00:01:55,551
THEY PREHEAT AN ALUMINUM MOLD
OF A FLOWER OR OTHER MOTIF.
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00:01:55,551 --> 00:01:59,310
PREHEATING THE MOLD HELPS THE
GLASS FLOW INTO IT MORE EASILY
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00:01:59,310 --> 00:02:02,758
AND ASSUME THE SHAPE
IN GREATER DETAIL.
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00:02:04,448 --> 00:02:06,724
ONCE THEY'VE MOLDED
THE COLORED GLASS,
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THEY RETURN TO THE FURNACE
TO ENCASE IT IN MOLTEN CRYSTAL.
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00:02:10,482 --> 00:02:13,000
THEN THEY REPEATEDLY HEAT
AND SHAPE THE CRYSTAL
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00:02:13,000 --> 00:02:16,344
WITH TOOLS AND WITH STEAM
ON A WAD OF WET NEWSPAPER
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UNTIL THE CRYSTAL ENCASES
THE FLOWER-SHAPED COLOR EVENLY.
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00:02:19,862 --> 00:02:21,206
AFTER REHEATING,
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THEY PUT SOME MOLTEN CRYSTAL
ON THE END OF ANOTHER ROD
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AND GRAB THE FREE END
OF THE CRYSTAL-ENCASED COLOR.
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00:02:27,448 --> 00:02:30,551
THEY WAIT UNTIL THE GLASS COOLS
TO A SPECIFIC CONSISTENCY.
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00:02:30,551 --> 00:02:32,793
THEN THEY BEGIN TO PULL.
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THEY SLOWLY STRETCH THE GLASS
INTO A THIN AND EVEN ROD,
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CAREFUL NOT TO TWIST IT,
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AS THAT WOULD DISTORT
THE FLOWER SHAPE
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OF THE COLORED GLASS INSIDE.
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THIS PRODUCES WHAT'S CALLED
A MURRINI CANE --
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A CLEAR CRYSTAL ROD WITH
A COLORED, FLOWER-SHAPED CENTER.
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ONCE THE MURRINI SOLIDIFIES,
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THEY NIP IT
INTO MANAGEABLE LENGTHS.
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00:02:54,034 --> 00:02:57,344
THEN THEY TAKE MURRINI
OF DIFFERENT COLORS AND DESIGNS,
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CUT THEM INTO SHORT RODS,
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AND BUNDLE THEM INTO A PATTERN
CALLED A COMPLEX MURRINI.
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00:03:02,551 --> 00:03:05,310
THEY PREHEAT THE COMPLEX MURRINI
IN A KILN
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00:03:05,310 --> 00:03:07,689
TO PREVENT
SHOCK-INDUCED CRACKING.
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00:03:07,689 --> 00:03:10,275
THEY NOW PICK IT UP
WITH A HOT CRYSTAL POST
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00:03:10,275 --> 00:03:12,689
AND, AFTER REMOVING
THE BUNDLING WIRES,
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HEAT AND WORK THE GROUP
OF GLASS RODS INTO ONE.
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00:03:16,827 --> 00:03:20,206
THEY NOW STRETCH
THIS COMPLEX MURRINI
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INTO WHAT'S KNOWN
AS COMPLEX MURRINI CANE.
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00:03:28,206 --> 00:03:30,241
ONCE THE CANE STABILIZES,
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THEY CUT IT
INTO YARDLONG LENGTHS,
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00:03:31,896 --> 00:03:34,655
THEN COOL THEM GRADUALLY
IN A KILN
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TO RELIEVE ANY STRESSES
IN THE GLASS.
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THEN THEY SLICE THE LENGTHS
INTO PIECES 2/10 OF AN INCH --
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THE SIZE REQUIRED
FOR THE MILLEFIORI PAPERWEIGHTS.
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00:03:45,896 --> 00:03:48,827
NOW, USING COMPLEX
MURRINI PIECES
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00:03:48,827 --> 00:03:51,068
OF DIFFERENT COLORS
AND PATTERNS,
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THEY ASSEMBLE
THE PAPERWEIGHT DESIGN,
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PLACING A UNIQUE,
HAND-CONSTRUCTED MURRINI
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IN THE CENTER.
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THIS ONE IS A TRILLIUM.
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00:04:00,689 --> 00:04:03,206
NEXT, THEY ENCIRCLE THE SETUP
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00:04:03,206 --> 00:04:05,275
WITH A HEAT-RESISTANT
GRAPHITE RING.
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00:04:05,275 --> 00:04:07,689
THIS HOLDS THE PIECES
IN POSITION.
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00:04:09,448 --> 00:04:11,758
AFTER A FINAL ADJUSTMENT,
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00:04:11,758 --> 00:04:14,551
THE ARTISTS PREHEAT A WHITE,
LACE-PATTERNED GLASS BASE
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00:04:14,551 --> 00:04:16,034
THEY PREPARED EARLIER.
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00:04:16,034 --> 00:04:18,448
THIS BASE WILL SERVE
AS A BLANK CANVAS
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FOR THE COLORFUL
PAPERWEIGHT PATTERN.
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THEY PUSH THE MOLTEN CRYSTAL
ONTO THE BASE.
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THE RING CONTAINS IT
TO THE BASE'S DIAMETER.
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00:04:30,931 --> 00:04:33,206
THEN THEY REHEAT THE BASE,
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00:04:33,206 --> 00:04:36,068
MAKING IT SMOOTH AND FREE
OF AIR POCKETS,
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00:04:36,068 --> 00:04:39,275
PREHEAT THE COMPLEX
MURRINI SETUP,
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00:04:39,275 --> 00:04:41,000
AND STICK THE BASE ONTO IT.
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00:04:41,000 --> 00:04:43,931
LIKE BEFORE,
THE RING CONTAINS THE SPREAD.
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00:04:43,931 --> 00:04:46,896
ANOTHER OVERALL REHEATING
SOFTENS THE GLASS
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00:04:46,896 --> 00:04:48,862
AND FULLY FUSES
ALL THE COMPONENTS.
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00:04:48,862 --> 00:04:52,724
THIS FILLS CREVICES
AND SMOOTHES THE SURFACE.
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00:04:52,724 --> 00:04:55,241
NOW THEY RETURN TO THE FURNACE
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00:04:55,241 --> 00:04:58,275
TO ENCASE THIS PAPERWEIGHT CORE
IN MOLTEN CRYSTAL.
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00:04:58,275 --> 00:05:00,793
USING STANDARD
GLASS-MAKING TECHNIQUES,
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00:05:00,793 --> 00:05:03,482
THEY WORK THE CRYSTAL
TO A BULBOUS SHAPE.
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00:05:03,482 --> 00:05:07,103
THEN ON THE BOTTOM,
THEY FORM A BREAK-OFF POINT.
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00:05:07,103 --> 00:05:11,310
A SHARP TAP ON THE ROD
CRACKS THE GLASS AT THAT POINT,
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00:05:11,310 --> 00:05:13,482
SEPARATING IT FROM THE ROD.
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00:05:13,482 --> 00:05:15,551
THEY HEAT THE BREAK-OFF POINT
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00:05:15,551 --> 00:05:19,206
AND INSERT A PIECE OF CANE
BEARING THE ARTIST'S INITIALS.
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00:05:19,206 --> 00:05:22,310
AFTER A 12-HOUR CONTROLLED
COOLING IN THE KILN,
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00:05:22,310 --> 00:05:24,034
THEY GRIND THE BASE LEVEL.
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00:05:24,034 --> 00:05:26,172
THEN THEY POLISH AWAY
THE SCRATCHES
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00:05:26,172 --> 00:05:27,724
LEFT BY THE GRINDING WHEEL.
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00:05:30,896 --> 00:05:32,758
AFTER A THOROUGH INSPECTION,
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00:05:32,758 --> 00:05:35,517
THESE MAGNIFICENT
MILLEFIORI PAPERWEIGHTS
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ARE READY TO BE SHIPPED
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00:05:37,068 --> 00:05:39,931
TO ART-GLASS COLLECTORS
WORLDWIDE.
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00:05:51,241 --> 00:05:53,620
Narrator: WHEN THE ROAD AHEAD
IS A SHEET OF ICE,
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ROCK SALT CAN MAKE THE PROBLEM
MELT AWAY.
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00:05:56,103 --> 00:05:58,965
SALT LOWERS THE MELTING POINT
OF WATER TO THAW ICE
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00:05:58,965 --> 00:06:00,827
AND ALSO PREVENTS ITS FORMATION.
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00:06:00,827 --> 00:06:03,827
SALT WAS FIRST USED TO DE-ICE
HIGHWAYS AND WALKWAYS
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00:06:03,827 --> 00:06:05,137
IN THE 1930s,
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00:06:05,137 --> 00:06:08,931
BUT IT WAS ONLY IN THE 1960s
THAT ITS USE SPREAD.
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00:06:12,793 --> 00:06:16,586
UNPROCESSED ROCK SALT
ACTUALLY LOOKS LIKE THE ICE
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00:06:16,586 --> 00:06:18,896
IT WILL EVENTUALLY BE USED
TO MELT.
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00:06:21,655 --> 00:06:25,137
THIS SALT COMES
FROM HUGE CRYSTALLINE CAVERNS
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00:06:25,137 --> 00:06:27,137
A THOUSAND FEET
BELOW THE EARTH'S SURFACE
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00:06:27,137 --> 00:06:28,758
ALONG THE CANADA/U.S. BORDER.
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00:06:28,758 --> 00:06:31,310
THAT'S 2/10 OF A MILE
UNDERGROUND.
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00:06:31,310 --> 00:06:33,344
THESE MASSIVE DEPOSITS
WERE FORMED
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HUNDREDS OF MILLIONS
OF YEARS AGO
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00:06:35,310 --> 00:06:38,517
WHEN SALTWATER LAKES DRIED UP.
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00:06:41,965 --> 00:06:46,137
THE CLARITY OF THIS ROCK SALT
IS A SIGN OF ITS PURITY.
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00:06:49,034 --> 00:06:53,206
THIS MINERAL IS 98%
SODIUM CHLORIDE, OR SALT.
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00:06:53,206 --> 00:06:56,000
THEY EXTRACT IT IN CHUNKS
FROM THE ROCK'S FACE
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00:06:56,000 --> 00:06:58,655
BY USING EXPLOSIVES
AND DRILLING.
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00:07:00,551 --> 00:07:03,827
THEN A LOADER SCOOPS UP
THE BROKEN PIECES OF SALT.
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00:07:03,827 --> 00:07:07,000
THIS IS CALLED
A LOW-PROFILE LOADER.
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00:07:07,000 --> 00:07:11,724
IT HAS A SHORTER HEIGHT TO FIT
INTO TIGHT SPACES UNDERGROUND.
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00:07:11,724 --> 00:07:16,827
IT TRANSFERS THE SALT
TO THE PRIMARY CRUSHER.
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00:07:16,827 --> 00:07:18,862
THIS CRUSHER IS
A SPIKED CYLINDER
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00:07:18,862 --> 00:07:21,206
THAT SPINS TO BREAK THE SALT
INTO PIECES
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00:07:21,206 --> 00:07:24,551
SMALL ENOUGH TO BE MOVED
ON A CONVEYOR.
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00:07:24,551 --> 00:07:28,034
THE CONVEYOR TAKES THE SALT
TO A PRODUCTION ELEVATOR
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00:07:28,034 --> 00:07:31,241
KNOWN AS A SKIP.
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00:07:31,241 --> 00:07:34,000
IT TAKES JUST A MINUTE
AND A HALF FOR THE SKIP
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00:07:34,000 --> 00:07:37,586
TO LIFT ITS HEAVY LOAD
ABOVEGROUND AND UP A TOWER.
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00:07:41,758 --> 00:07:46,931
WHEN IT STOPS, THE BOTTOM OPENS
TO EMPTY THE SALTY CARGO.
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00:07:49,793 --> 00:07:54,793
THE SALT FUNNELS INTO TWO CHUTES
AND LANDS ON VIBRATING SCREENS.
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00:07:56,379 --> 00:08:00,965
THESE SCREENS ARE ESSENTIALLY
BIG AUTOMATED SALT SHAKERS.
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00:08:00,965 --> 00:08:04,586
AS THEY PULSATE, THEY SHAKE OUT
THE SMALLER BITS,
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00:08:04,586 --> 00:08:07,896
WHILE LARGER CHUNKS MOVE ON
TO BE CRUSHED AGAIN.
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00:08:07,896 --> 00:08:10,517
THEN IT'S ON
TO MORE SHAKING SIFTERS.
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00:08:10,517 --> 00:08:12,965
THESE SCREEN OUT
THE VERY FINE PARTICLES,
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00:08:12,965 --> 00:08:15,724
AND WHAT'S LEFT WILL BE USED
AS DE-ICING SALT.
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00:08:19,000 --> 00:08:23,241
THERE ARE SEVERAL SIFTERS
IN THIS ROOM.
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00:08:23,241 --> 00:08:25,379
THEY ALSO SIFT OUT PARTICLES
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00:08:25,379 --> 00:08:27,689
THAT ARE ABOUT 4/10 OF AN INCH
IN SIZE
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00:08:27,689 --> 00:08:30,034
TO BE USED
AS WATER-SOFTENING PRODUCT.
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00:08:30,034 --> 00:08:31,379
AND FOR THIS PURPOSE,
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00:08:31,379 --> 00:08:33,896
THE DARKER BITS ARE SEEN
AS UNDESIRABLE,
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00:08:33,896 --> 00:08:35,172
SO THEY REMOVE THOSE
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00:08:35,172 --> 00:08:37,724
WITH SOMETHING CALLED
AN OPTICAL SORTER.
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00:08:37,724 --> 00:08:41,413
THE OPTICAL SORTER BOUNCES LIGHT
OFF THE SALT PARTICLES,
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00:08:41,413 --> 00:08:43,034
AND A COMPUTER
READS THE REFLECTION
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00:08:43,034 --> 00:08:44,793
TO DETERMINE
IF THEY'RE LIGHT OR DARK.
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00:08:48,482 --> 00:08:51,689
JETS OF COMPRESSED AIR
THEN TARGET THE DARK BITS
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00:08:51,689 --> 00:08:53,103
AND BLAST THEM DOWNWARD,
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00:08:53,103 --> 00:08:57,137
WHILE THE WHITE PARTICLES
CONTINUE FORWARD.
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00:08:57,137 --> 00:09:00,517
A CLOSER LOOK CONFIRMS
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00:09:00,517 --> 00:09:05,034
THAT THE OPTICAL SORTER
HAS DONE ITS JOB EFFECTIVELY.
156
00:09:05,034 --> 00:09:08,965
THE SALT MEANT FOR WATER
SOFTENING IS PURE WHITE,
157
00:09:08,965 --> 00:09:13,344
WHILE A FEW DARKER SPECKLES
IS ACCEPTABLE FOR ROAD SALT.
158
00:09:13,344 --> 00:09:15,275
OUTSIDE IN THE HOLDING AREA,
159
00:09:15,275 --> 00:09:18,965
THE SALT ACCUMULATES IN PILES
THAT LOOK LIKE HUGE SNOW DRIFTS.
160
00:09:18,965 --> 00:09:21,344
IF THE WINTER IS HARSH,
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00:09:21,344 --> 00:09:25,793
ROAD CREWS WILL USE IT
AS FAST AS IT PILES UP.
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00:09:25,793 --> 00:09:28,827
WHEN IT COMES
TO BULK PURCHASING,
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00:09:28,827 --> 00:09:31,034
ORDERS DON'T COME
MUCH BIGGER THAN THIS.
164
00:09:31,034 --> 00:09:32,724
HIGHWAY MAINTENANCE DEPARTMENTS
165
00:09:32,724 --> 00:09:34,965
BUY DE-ICING SALT
BY THE TRUCKLOAD
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00:09:34,965 --> 00:09:36,896
AND CREATE THEIR OWN STOCKPILES
167
00:09:36,896 --> 00:09:39,172
TO BE PREPARED
FOR STORMY WEATHER.
168
00:09:39,172 --> 00:09:41,620
BUT INDIVIDUAL CONSUMERS,
OF COURSE,
169
00:09:41,620 --> 00:09:44,034
BUY DE-ICING SALT BY THE BAG.
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00:09:45,206 --> 00:09:46,724
IN THE PACKAGING DEPARTMENT,
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00:09:46,724 --> 00:09:50,137
AUTOMATED TRAYS RELAY PLASTIC
BAGS TO GRIPPERS OVERHEAD,
172
00:09:50,137 --> 00:09:53,965
AND THE SYSTEM
MOVES THEM FORWARD.
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00:09:59,758 --> 00:10:03,793
SUCTIONING ROBOT ARMS
PRY EACH BAG OPEN.
174
00:10:05,827 --> 00:10:08,517
A PUFF OF AIR INFLATES THE BAG,
175
00:10:08,517 --> 00:10:11,103
WHILE A NOZZLE PIPES MEASURED
AMOUNTS OF THE DE-ICING SALT
176
00:10:11,103 --> 00:10:13,931
INTO THE BAG.
177
00:10:13,931 --> 00:10:15,965
ONCE THE BAG IS FULL,
178
00:10:15,965 --> 00:10:18,103
THE SYSTEM MOVES IT
FORWARD AGAIN,
179
00:10:18,103 --> 00:10:21,689
AND NOT A GRAIN OF SALT
IS SPILLED.
180
00:10:21,689 --> 00:10:23,344
FINALLY, A HEAT SEALER
181
00:10:23,344 --> 00:10:26,551
MELTS THE PLASTIC
TO CLOSE THE PACKAGE.
182
00:10:26,551 --> 00:10:30,689
IT'S TAKEN ABOUT AN HOUR
FOR THIS ROCK SALT
183
00:10:30,689 --> 00:10:34,655
TO BE MINED, CRUSHED,
SIFTED, AND PACKAGED.
184
00:10:34,655 --> 00:10:37,482
AND NOW THEY'RE READY TO TAKE IT
TO THE STREET.
185
00:10:50,482 --> 00:10:52,103
Narrator:
THE FIRST NUTCRACKERS
186
00:10:52,103 --> 00:10:54,620
WERE PLAIN,
PURELY FUNCTIONAL DEVICES.
187
00:10:54,620 --> 00:10:56,000
BY THE 15th CENTURY,
188
00:10:56,000 --> 00:10:58,344
EUROPEAN WOODCARVERS
BEGAN CRAFTING
189
00:10:58,344 --> 00:11:01,413
BEAUTIFUL NUTCRACKERS
SHAPED LIKE ANIMALS AND PEOPLE.
190
00:11:01,413 --> 00:11:03,034
GERMAN ARTISANS BECAME KNOWN
191
00:11:03,034 --> 00:11:05,862
FOR THEIR MAJESTIC NUTCRACKER
KINGS AND SOLDIERS,
192
00:11:05,862 --> 00:11:09,586
JUST LIKE THE ONE
IN TCHAIKOVSKY'S FAMOUS BALLET.
193
00:11:11,379 --> 00:11:13,241
THIS GERMAN COMPANY
194
00:11:13,241 --> 00:11:16,172
HAS BEEN CRAFTING CHARACTER
NUTCRACKERS SINCE 1928.
195
00:11:16,172 --> 00:11:18,275
LIKE PORCELAIN FIGURINES,
196
00:11:18,275 --> 00:11:21,689
THESE NUTCRACKERS SELL
AS LIMITED-EDITION COLLECTIBLES.
197
00:11:21,689 --> 00:11:23,620
AT HUNDREDS OF DOLLARS EACH,
198
00:11:23,620 --> 00:11:27,000
PEOPLE DON'T ACTUALLY USE THEM
FOR THE INTENDED PURPOSE.
199
00:11:30,620 --> 00:11:33,137
BUT THEY CAN AND DO
PERFORM THE JOB.
200
00:11:33,137 --> 00:11:34,931
YOU SIMPLY MANIPULATE A LEVER
201
00:11:34,931 --> 00:11:38,137
TO OPEN, THEN CLOSE THE MOUTH
TO CRACK THE NUTSHELL.
202
00:11:38,137 --> 00:11:41,793
ON THE FACTORY FLOOR, THEY USE
A MULTIBLADE CIRCULAR SAW
203
00:11:41,793 --> 00:11:44,379
TO CUT ALL THE BODY PARTS
OUT OF LINDEN WOOD.
204
00:11:44,379 --> 00:11:48,172
LINDEN IS IDEAL BECAUSE IT'S
LIGHTWEIGHT, EASY TO CARVE,
205
00:11:48,172 --> 00:11:51,379
AND ITS COLOR IS PALE ENOUGH
TO MIMIC SKIN.
206
00:11:54,724 --> 00:11:57,620
THESE BLOCKS ARE ON THEIR WAY
TO BECOMING NUTCRACKER TORSOS.
207
00:12:01,206 --> 00:12:03,724
FIRST, THEY GO THROUGH A PLANER.
208
00:12:03,724 --> 00:12:06,103
IT TRIMS THE FOUR SIDES
OF EACH BLOCK,
209
00:12:06,103 --> 00:12:07,896
FORMING AN OCTAGONAL SHAPE...
210
00:12:19,827 --> 00:12:23,413
...FROM SQUARE TO OCTAGONAL
AND NEXT TO ROUND.
211
00:12:23,413 --> 00:12:26,448
BUT FIRST, WORKERS
USE A CIRCULAR SAW
212
00:12:26,448 --> 00:12:29,000
TO CUT THE BLOCKS
INTO TORSO-LENGTH PIECES.
213
00:12:31,586 --> 00:12:34,172
A CONVEYOR FEEDS THE PIECES
ONE BY ONE
214
00:12:34,172 --> 00:12:36,862
INTO AN AUTOMATIC,
MULTI-STATION LATHE.
215
00:12:36,862 --> 00:12:39,172
THE FIRST STATION
ROUNDS OUT THE OCTAGON,
216
00:12:39,172 --> 00:12:42,137
THEN FORMS
THE BASIC TORSO SHAPE.
217
00:12:43,206 --> 00:12:45,793
THE SECOND STATION
FINALIZES THE SHAPE.
218
00:12:45,793 --> 00:12:48,862
THEN THE NEXT FOUR STATIONS
SAND THE WOOD SMOOTH
219
00:12:48,862 --> 00:12:51,758
SO THAT THE WOOD STAIN
THEY'LL APPLY LATER ON
220
00:12:51,758 --> 00:12:54,275
WILL PENETRATE WELL AND EVENLY.
221
00:12:54,275 --> 00:12:57,310
THEN THE TORSOS GO
THREE AT A TIME
222
00:12:57,310 --> 00:13:00,103
INTO A VERTICAL ROUTER.
223
00:13:00,103 --> 00:13:03,413
IT CUTS A NOTCH IN EACH ONE
224
00:13:03,413 --> 00:13:07,275
FOR THE LEVER THAT OPENS AND
CLOSES THE NUTCRACKER'S MOUTH.
225
00:13:12,896 --> 00:13:15,034
NEXT STOP IS A DRILLING MACHINE,
226
00:13:15,034 --> 00:13:18,344
WHICH SIMULTANEOUSLY DRILLS
ALL THE HOLES REQUIRED
227
00:13:18,344 --> 00:13:22,448
TO ATTACH THE BODY PARTS,
AS WELL AS THE LEVER'S AXLE.
228
00:13:22,448 --> 00:13:25,241
NOW THEY DRESS THE TORSO
IN A COAT,
229
00:13:25,241 --> 00:13:29,517
WHICH THEY CREATE SIMPLY BY
STAINING THE WOOD A DARK COLOR.
230
00:13:29,517 --> 00:13:30,931
ONCE THE STAIN DRIES,
231
00:13:30,931 --> 00:13:34,448
THEY SPRAY ON TWO COATS
OF SEMIGLOSS LACQUER.
232
00:13:34,448 --> 00:13:37,758
EVERY NUTCRACKER STANDS
ON A WOODEN BASE,
233
00:13:37,758 --> 00:13:40,206
UNDER WHICH THEY BURN
THE COMPANY'S LOGO.
234
00:13:40,206 --> 00:13:44,482
IT'S A MARK OF AUTHENTICITY
FOR COLLECTORS.
235
00:13:44,482 --> 00:13:47,896
THE AUTOMATIC LATHE ALSO SHAPES
THE OTHER BODY PARTS,
236
00:13:47,896 --> 00:13:49,241
INCLUDING THE HEAD.
237
00:13:49,241 --> 00:13:51,379
WORKERS ATTACH A NOSE,
238
00:13:51,379 --> 00:13:54,586
THEN, USING A ROUTER,
CUT HOLES FOR THE EYES.
239
00:13:54,586 --> 00:13:57,931
THEN THEY LIGHTLY SPRAY ON
A TOUCH OF RED PAINT
240
00:13:57,931 --> 00:14:01,068
TO SIMULATE A SUN-KISSED NOSE
AND ROSY CHEEKS.
241
00:14:03,379 --> 00:14:05,551
THEN, WITH A STEADY HAND,
242
00:14:05,551 --> 00:14:08,000
THEY PAINT THE WHITES
OF THE EYES...
243
00:14:11,413 --> 00:14:13,344
...AND THE EYEBROWS.
244
00:14:15,965 --> 00:14:17,482
ONCE THE PAINT DRIES,
245
00:14:17,482 --> 00:14:20,724
THEY APPLY SOME GLUE
TO THE CENTER OF EACH EYE,
246
00:14:20,724 --> 00:14:24,068
THEN AFFIX AN IRIS AND PUPIL
MADE OF ENAMELED TIN.
247
00:14:26,448 --> 00:14:29,413
NOW THEY ALIGN THE HEAD
WITH THE TORSO
248
00:14:29,413 --> 00:14:31,965
AND SCREW THE PARTS TOGETHER.
249
00:14:33,344 --> 00:14:36,103
AFTER DECORATING THE COAT
WITH BUTTONS AND A BUCKLE,
250
00:14:36,103 --> 00:14:39,344
THEY GLUE A STRIP OF RABBIT-FUR
HAIR TO THE HEAD...
251
00:14:42,758 --> 00:14:44,275
...A RABBIT-FUR BEARD
252
00:14:44,275 --> 00:14:46,965
TO CAMOUFLAGE THE NOTCH
FOR THE LEVER,
253
00:14:46,965 --> 00:14:49,793
THEN THEY MOUNT THE TORSO
ONTO THE LEGS,
254
00:14:49,793 --> 00:14:53,517
WHICH WEAR PAINTED-ON BOOTS
AND STAND ON THE BASE.
255
00:14:53,517 --> 00:14:57,034
THEN THIS NUTCRACKER
PERCUSSIONIST GETS HIS DRUM,
256
00:14:57,034 --> 00:15:00,310
ALONG WITH ARMS AND DRUMSTICKS.
257
00:15:04,655 --> 00:15:07,689
THEY TOP HIM OFF WITH A HAT
MADE OF SPRAY-PAINTED WOOD.
258
00:15:12,379 --> 00:15:14,206
MOST OF THE NUTCRACKER'S PARTS
259
00:15:14,206 --> 00:15:17,000
JOIN TOGETHER
WITH WOODEN DOWELS.
260
00:15:17,000 --> 00:15:20,344
A LARGE DOWEL RUNNING
ACROSS THE NOTCH IN THE TORSO
261
00:15:20,344 --> 00:15:23,448
IS THE AXLE
ON WHICH THE LEVER ROTATES.
262
00:15:30,206 --> 00:15:32,758
THIS EXTENSIVE CAST
OF NUTCRACKER CHARACTERS
263
00:15:32,758 --> 00:15:34,586
COMES IN VARIOUS SIZES,
264
00:15:34,586 --> 00:15:38,206
AND YOU CAN EVEN SPECIAL-ORDER
A LIFE-SIZED VERSION.
265
00:15:50,689 --> 00:15:54,172
Narrator: CAR DOORS HAVE COME A
LONG WAY OVER THE LAST CENTURY.
266
00:15:54,172 --> 00:15:57,000
THEY'RE LIGHTER
FOR IMPROVED FUEL EFFICIENCY
267
00:15:57,000 --> 00:16:00,413
AND STRONGER TO BETTER WITHSTAND
THE FORCE OF AN IMPACT.
268
00:16:00,413 --> 00:16:03,413
THEY ALSO CONTAIN A LOT
OF ELECTRONIC GADGETRY,
269
00:16:03,413 --> 00:16:05,379
LIKE SPEAKERS AND POWER WINDOWS,
270
00:16:05,379 --> 00:16:07,931
ALL OF WHICH ENHANCE
THE DAILY COMMUTE.
271
00:16:12,000 --> 00:16:14,068
A CAR DOOR IS ONE
OF THE FIRST THINGS
272
00:16:14,068 --> 00:16:16,448
MANY PEOPLE REACH FOR
AS THEY START THEIR DAY,
273
00:16:16,448 --> 00:16:20,068
SO LET'S UNLOCK THE MYSTERY
OF HOW IT'S MADE.
274
00:16:20,068 --> 00:16:22,620
IT ALL STARTS WITH CARBON STEEL,
275
00:16:22,620 --> 00:16:25,241
AN ALLOY THAT'S STRONG,
YET MALLEABLE.
276
00:16:26,551 --> 00:16:29,931
MACHINERY UNCOILS
AND STRAIGHTENS IT.
277
00:16:29,931 --> 00:16:32,310
A LARGE BLADE SLICES IT
TO THE DESIRED LENGTH,
278
00:16:32,310 --> 00:16:34,655
PRODUCING SHEETS CALLED BLANKS.
279
00:16:34,655 --> 00:16:36,758
THEN IT'S OVER
TO A POWERFUL PRESS.
280
00:16:36,758 --> 00:16:38,965
THIS PARTICULAR ONE
IS A TRIAL PRESS,
281
00:16:38,965 --> 00:16:41,344
WHICH OFFERS A BETTER VIEW
OF THE PROCESS
282
00:16:41,344 --> 00:16:43,103
THAN THE ONE
ON THE PRODUCTION LINE.
283
00:16:43,103 --> 00:16:45,620
THE PRESS FORCES THE BLANK
INTO A DIE,
284
00:16:45,620 --> 00:16:48,206
GIVING IT THE BASIC SHAPE
OF TWO CAR DOORS.
285
00:16:48,206 --> 00:16:50,586
IT'S A DESIGN
THAT'S BEEN ENGINEERED
286
00:16:50,586 --> 00:16:54,137
FOR BOTH AERODYNAMICS
AND STRENGTH.
287
00:16:54,137 --> 00:16:56,482
BACK ON THE PRODUCTION LINE,
288
00:16:56,482 --> 00:16:59,655
THE MAIN PRESS IS
CHURNING OUT CAR DOORS.
289
00:16:59,655 --> 00:17:01,482
AN AUTOMATED DEVICE WITH FINGERS
290
00:17:01,482 --> 00:17:03,517
THEN GRIPS
THE NEWLY SHAPED STEEL
291
00:17:03,517 --> 00:17:06,034
AND TRANSFERS IT
TO A PUNCH CUTTER.
292
00:17:06,034 --> 00:17:07,448
IT SEPARATES THE TWO DOORS
293
00:17:07,448 --> 00:17:12,103
AND TRIMS THE EXCESS METAL
FROM THE EDGES.
294
00:17:12,103 --> 00:17:14,689
WITH THE OUTER DOOR PANELS
NOW COMPLETE,
295
00:17:14,689 --> 00:17:18,482
A HANDLER INSPECTS THEM
FOR BUMPS, DENTS, OR SCRATCHES.
296
00:17:18,482 --> 00:17:21,689
HE APPROVES ONLY THOSE
THAT ARE ABSOLUTELY FLAWLESS.
297
00:17:21,689 --> 00:17:24,379
THE NEXT WORKER ARRANGES
THE WINDOW FRAME,
298
00:17:24,379 --> 00:17:26,655
A REINFORCING PLATE
FOR THE HINGE,
299
00:17:26,655 --> 00:17:28,241
AND THE INNER DOOR PANEL,
300
00:17:28,241 --> 00:17:30,551
ALL ON A SPECIAL
CLAMPING FIXTURE.
301
00:17:30,551 --> 00:17:33,931
ITS FINGERS GRIP THE PARTS
TO HOLD THEM IN POSITION
302
00:17:33,931 --> 00:17:35,448
AS THE FIXTURE ROTATES
303
00:17:35,448 --> 00:17:38,517
AND TWO ROBOTS MOVE IN
TO WELD THEM TOGETHER.
304
00:17:40,620 --> 00:17:42,068
AT THE NEXT STATION,
305
00:17:42,068 --> 00:17:46,206
THE WORKER ARRANGES STEEL BARS
AND TUBES ON A ROBOTIC PLATFORM.
306
00:17:46,206 --> 00:17:47,758
THEY ADD STRENGTH TO THE DOOR
307
00:17:47,758 --> 00:17:50,931
SO IT WILL BETTER WITHSTAND
ANY IMPACT.
308
00:17:50,931 --> 00:17:54,793
HE PLACES THE INNER DOOR PANEL
OVER THE BARS AND TUBES.
309
00:17:54,793 --> 00:17:58,655
THE ROBOTIC PLATFORM
ANGLES THE PARTS FOR WELDING.
310
00:18:01,758 --> 00:18:04,034
ANOTHER ROBOT APPLIES ADHESIVE
311
00:18:04,034 --> 00:18:05,724
TO THE RIM
OF THE OUTER DOOR PANEL.
312
00:18:05,724 --> 00:18:10,344
MORE ROBOTS DAB ADHESIVE
AT STRATEGIC LOCATIONS.
313
00:18:13,482 --> 00:18:16,965
THOSE DABS MATCH UP TO THE TUBES
AND BARS ON THE INNER PANEL
314
00:18:16,965 --> 00:18:20,586
AS THEY MATE IT
TO THE OUTER ONE.
315
00:18:20,586 --> 00:18:24,172
A SPECIAL PRESS THEN FOLDS
THE LIP OF THE OUTER PANEL
316
00:18:24,172 --> 00:18:25,586
OVER THE INNER ONE.
317
00:18:25,586 --> 00:18:29,379
THIS HEMMING GIVES THE ASSEMBLED
CAR DOOR A NEATER EDGE.
318
00:18:33,482 --> 00:18:36,482
WITH THE INNER AND OUTER PANELS
NOW JOINED,
319
00:18:36,482 --> 00:18:39,448
THE CAR DOOR UNDERGOES
RUSTPROOFING, PAINT,
320
00:18:39,448 --> 00:18:41,724
AND OTHER PROTECTIVE TREATMENTS.
321
00:18:41,724 --> 00:18:43,931
NOW, OVER ON THE ASSEMBLY LINE,
322
00:18:43,931 --> 00:18:46,551
A WORKER FITS THE HANDLE
INTO ITS NICHE
323
00:18:46,551 --> 00:18:50,724
AND BOLTS IT TO THE DOOR
FROM THE OTHER SIDE.
324
00:18:50,724 --> 00:18:54,793
CHROME TRIM
IS CLIPPED INTO PLACE.
325
00:18:54,793 --> 00:18:56,137
MOVING DOWN THE LINE,
326
00:18:56,137 --> 00:18:58,620
A WORKER INSTALLS
A SMALL, FIXED WINDOW
327
00:18:58,620 --> 00:19:00,655
IN THE GROOVE OF THE FRAME.
328
00:19:00,655 --> 00:19:03,896
HE USES A PLASTIC PROTECTOR
TO PREVENT SCRATCHES
329
00:19:03,896 --> 00:19:07,379
AS HE SLIDES THE LARGER WINDOW
INTO ITS SLOT IN THE DOOR
330
00:19:07,379 --> 00:19:10,793
AND LINKS IT TO A POWER-LIFTING
MECHANISM INSIDE.
331
00:19:16,103 --> 00:19:19,793
HE SEPARATES THE TWO WINDOWS
WITH A METAL DIVIDER.
332
00:19:19,793 --> 00:19:21,241
AT THE NEXT STATION,
333
00:19:21,241 --> 00:19:24,379
THIS CAR DOOR GETS
AN AUTOMATED SIDE-VIEW MIRROR.
334
00:19:25,965 --> 00:19:29,000
THEY'RE NOW READY FOR THE INNER
PANEL AND ITS WORKINGS.
335
00:19:29,000 --> 00:19:31,379
THE EMPLOYEE WIRES
THE PANEL TO THE DOOR
336
00:19:31,379 --> 00:19:34,172
AND SNAPS IT INTO PLACE.
337
00:19:34,172 --> 00:19:37,862
HE TESTS THE POWER WINDOWS,
AND THEY CLOSE TO A TIGHT SEAL,
338
00:19:37,862 --> 00:19:40,517
INDICATING
A SUCCESSFUL INSTALLATION.
339
00:19:40,517 --> 00:19:44,068
A SPECIAL ELEVATOR NOW LOWERS
THE COMPLETED CAR DOORS
340
00:19:44,068 --> 00:19:47,103
6 1/2 YARDS
TO THE NEXT STATION.
341
00:19:47,103 --> 00:19:49,413
A WORKER UNLOADS EACH DOOR
342
00:19:49,413 --> 00:19:51,448
WITH THE HELP
OF A PNEUMATIC ARM.
343
00:19:51,448 --> 00:19:54,034
THIS DEVICE SHOULDERS
THE WEIGHT OF THE PART
344
00:19:54,034 --> 00:19:56,931
AND CORRECTLY POSITIONS THE DOOR
FOR INSTALLATION.
345
00:20:00,827 --> 00:20:04,586
HE DRIVES BOLTS INTO HINGES
TO ATTACH THE DOOR TO THE CAR.
346
00:20:04,586 --> 00:20:05,862
ON THE DOOR SIDE,
347
00:20:05,862 --> 00:20:08,241
THE HEAVY-DUTY
REINFORCEMENT PLATE
348
00:20:08,241 --> 00:20:10,931
SURROUNDS THE HINGES
AND SUPPORTS THEM.
349
00:20:10,931 --> 00:20:12,310
THE WHOLE WEIGHT OF THE DOOR
350
00:20:12,310 --> 00:20:15,551
WILL HANG ON THIS PLATE
AS IT SWINGS OPEN AND SHUT.
351
00:20:17,413 --> 00:20:19,517
WITH ALL THE PANELS INSTALLED,
352
00:20:19,517 --> 00:20:21,448
IT'S TIME
FOR THE FINAL ADJUSTMENTS.
353
00:20:21,448 --> 00:20:23,482
THEY CALL THIS FINESSING.
354
00:20:23,482 --> 00:20:25,344
THEY EXAMINE EACH PANEL
355
00:20:25,344 --> 00:20:28,689
TO CONFIRM THAT IT'S FLUSH
TO THE REST OF THE CAR BODY,
356
00:20:28,689 --> 00:20:32,310
AND THEY TWEAK THE INSTALLATION
JOB WHERE NEEDED.
357
00:20:32,310 --> 00:20:35,758
FINALLY, THEY'RE SATISFIED
THE ASSEMBLY IS AIRTIGHT,
358
00:20:35,758 --> 00:20:39,758
SO IT'S TIME TO CLOSE THE DOOR
ON THIS PRODUCTION.
359
00:20:39,758 --> 00:20:42,758
--Captions by VITAC--
www.vitac.com
360
00:20:42,758 --> 00:20:45,758
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
361
00:20:51,379 --> 00:20:53,896
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
362
00:20:53,896 --> 00:20:56,517
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
363
00:20:56,517 --> 00:20:58,379
DROP US A LINE AT...
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