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00:00:01,793 --> 00:00:04,793
--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,793
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:52,620 --> 00:00:55,344
Narrator: EGYPTIAN PHARAOHS
WERE LIKELY THE FIRST
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00:00:55,344 --> 00:00:59,172
TO HAVE MOLDS MADE OF THEIR
BODIES AND THE IMAGES CAST.
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00:00:59,172 --> 00:01:01,758
TODAY,
ANYONE CAN HAVE THIS DONE.
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00:01:01,758 --> 00:01:04,655
THE EXPERTS HAVE IT DOWN
TO A FINE ART.
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00:01:04,655 --> 00:01:07,413
IT'S CALLED LIFE CASTING,
OR BODY MOLDING,
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00:01:07,413 --> 00:01:10,655
AND IT'S IN DEMAND
BECAUSE EVERY BODY IS DIFFERENT.
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00:01:14,103 --> 00:01:16,275
NEED A BODY DOUBLE?
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00:01:16,275 --> 00:01:19,655
LIFE CASTING CREATES REPLICAS
OF BODY PARTS
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00:01:19,655 --> 00:01:23,655
THAT CAN BE USED AS PERSONAL
MEMENTOS OR MOVIE PROPS.
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00:01:27,310 --> 00:01:30,517
THEY START BY APPLYING
COLD CREAM TO THE BODY PART.
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00:01:30,517 --> 00:01:33,137
THE CREAM WILL SERVE
AS A RELEASE AGENT,
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00:01:33,137 --> 00:01:36,275
ALLOWING THE MOLD
TO BE REMOVED WHOLE.
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00:01:36,275 --> 00:01:39,655
THIS ORANGE GOOP
IS THE MOLDING MATERIAL.
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00:01:39,655 --> 00:01:42,896
IT'S A SEAWEED-BASED SUBSTANCE
CALLED ALGINATE.
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00:01:42,896 --> 00:01:46,896
IT'S THE SAME STUFF THE DENTIST
USES TO TAKE MOLDS OF TEETH,
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BUT IT'S FORMULATED
TO SET MORE SLOWLY.
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00:01:49,655 --> 00:01:52,827
THE LIFE CASTER
SPREADS THE ALGINATE LIBERALLY
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00:01:52,827 --> 00:01:56,551
ONTO THIS YOUNG ACTOR'S
CLENCHED FIST AND ARM.
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00:01:56,551 --> 00:01:59,724
ALGINATE CURES
IN FIVE OR SIX MINUTES,
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00:01:59,724 --> 00:02:02,000
SO THERE'S NO TIME TO WASTE.
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00:02:02,000 --> 00:02:04,655
HE WORKS AT A STEADY PACE.
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00:02:04,655 --> 00:02:09,482
HE APPLIES WET PLASTER BANDAGES
TO THE ALGINATE.
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00:02:12,448 --> 00:02:15,379
THE BANDAGES ADHERE
AND FORM A STIFF SHELL
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00:02:15,379 --> 00:02:18,000
SIMILAR TO A CAST
FOR A BROKEN LIMB.
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THE CAST-LIKE SHELL
SUPPORTS THE ALGINATE
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00:02:20,896 --> 00:02:23,793
AS IT CURES TO THE SHAPE
OF THE BOY'S FIST
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00:02:23,793 --> 00:02:25,482
TO PRODUCE A MOLD OF IT.
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WHEN CURED, THE ALGINATE HAS
A FIRM YET RUBBERY CONSISTENCY.
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00:02:31,517 --> 00:02:34,689
IT TAKES A FEW TUGS
TO PULL OFF THE MOLD,
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00:02:34,689 --> 00:02:37,655
BUT THE RUBBERY NATURE
OF THE ALGINATE
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MEANS IT CAN BE DONE
WITHOUT CRACKING OR CRUMPLING.
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00:02:41,655 --> 00:02:45,482
THE CASTING MATERIAL
IS DURABLE DENTAL PLASTER.
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00:02:45,482 --> 00:02:47,827
HE POURS IT INTO THE MOLD.
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00:02:51,517 --> 00:02:53,655
HE TIPS OUT A BIT
TO GET RID OF BUBBLES
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THAT HAVE ACCUMULATED
ON THE SURFACE.
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IT'S HANDS OFF NOW
AS THE PLASTER CURES
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00:02:59,724 --> 00:03:03,689
BECAUSE A CHEMICAL REACTION
MAKES IT DANGEROUSLY HOT.
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00:03:03,689 --> 00:03:06,724
A HALF-HOUR LATER,
THE PLASTER IS COOLED
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00:03:06,724 --> 00:03:10,137
AND HARDENED INTO THE SHAPE
OF THE BOY'S FIST.
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00:03:10,137 --> 00:03:14,517
THE PLASTER HAS PICKED UP
ALL THE LITTLE DETAILS,
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00:03:14,517 --> 00:03:17,724
INCLUDING
THE TINIEST OF CREASES.
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HE PICKS OUT BITS OF ALGINATE
LODGED IN THE CREASES.
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HE DEFINES THE FINGERNAILS
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AND CLEANS UP A FEW PITS
AND BUBBLES.
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THIS IS THE ACTOR'S REAL HAND,
AND THIS IS THE REPLICA.
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NEXT, THEY MAKE A MOLD
OF THE ACTOR'S FACE.
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THEY APPLY CREAM TO HIS HAIR
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TO PREVENT IT FROM
BECOMING STUCK IN THE ALGINATE.
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THE TEAM COMPLETELY COATS
HIS FACE, EARS, AND UPPER CHEST
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WITH BLUE ALGINATE.
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IT MUST BE HARD NOT TO WINCE,
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00:03:50,689 --> 00:03:55,172
BUT HE CAN'T BUDGE IN ORDER
TO CREATE A GOOD IMPRESSION.
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THEY LEAVE THE BACK OF HIS HEAD
UNCOVERED FOR AN OPEN MOLD
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00:03:59,793 --> 00:04:02,965
AND CREATE TWO SMALL HOLES
FOR BREATHING.
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00:04:02,965 --> 00:04:06,517
THEY LAYER THE PLASTER BANDAGES
OVER THE ALGINATE
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00:04:06,517 --> 00:04:08,862
TO GIVE STRUCTURE TO THE MOLD.
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00:04:08,862 --> 00:04:11,655
IT ALSO MAKES HIM
LOOK MUMMIFIED.
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00:04:16,000 --> 00:04:19,241
AFTER SEVERAL MINUTES,
THE MOLD HAS SOLIDIFIED.
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00:04:19,241 --> 00:04:21,931
THE TEAM REMOVES IT
FROM THE SUBJECT.
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00:04:21,931 --> 00:04:25,724
NOW THAT HIS FEATURES HAVE BEEN
SUCCESSFULLY TRANSFERRED
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00:04:25,724 --> 00:04:28,413
TO THE ALGINATE,
HE CAN BREATHE EASY.
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00:04:28,413 --> 00:04:34,482
THE LIFE CASTER
TRIMS EXCESS ALGINATE,
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00:04:34,482 --> 00:04:36,862
THEN WRAPS FABRIC
AROUND THE MOLD
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TO BUILD A KIND OF WALL
TO CONTAIN SPILLS
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00:04:39,655 --> 00:04:41,862
AS HE FILLS IT WITH PLASTER.
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00:04:43,931 --> 00:04:46,896
THE PLASTER CASTING
MAY NOT BE THE FINAL ONE.
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00:04:46,896 --> 00:04:49,206
DEPENDING
ON THE CLIENT'S WISHES,
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00:04:49,206 --> 00:04:51,655
THEY MAY MAKE A MOLD
FROM THIS BUST
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00:04:51,655 --> 00:04:54,310
AND THEN CAST THE IMAGE
IN A MORE FLESH-LIKE MATERIAL
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LIKE SILICONE, FOAM, OR RUBBER.
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THE PLASTER IS CURED
AND THE WAIT IS OVER.
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00:05:00,931 --> 00:05:06,241
IT'S TIME TO PEEL OFF THE LAYERS
AND FIND THE FACE WITHIN.
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00:05:09,413 --> 00:05:12,482
IT'S A BIT LIKE
HE'S REMOVING AN INTRICATE MASK.
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00:05:14,862 --> 00:05:18,827
THE FACE BEHIND IT
IS INSTANTLY RECOGNIZABLE.
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00:05:22,482 --> 00:05:24,068
HE CLEANS OUT THE EYES
AND NOSE...
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...AND SCRUBS
THE ENTIRE PLASTER FACE.
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00:05:38,517 --> 00:05:43,000
HERE'S THE ACTOR
AND HIS PLASTER DOPPELGANGER.
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00:05:45,310 --> 00:05:48,000
THEY'LL USE IT
TO CREATE A SILICONE VERSION,
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00:05:48,000 --> 00:05:50,137
AND ONCE IT'S PAINTED
AND GIVEN HAIR,
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IT WILL BE READY FOR THE MOVIES.
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Narrator: IN CONTRAST
TO A BIG, TRADITIONAL HOOD,
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00:06:04,172 --> 00:06:05,793
WHICH IS SEPARATE
FROM THE STOVE,
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00:06:05,793 --> 00:06:08,931
A DOWNDRAFT SYSTEM VENTS SMOKE,
STEAM, AND COOKING ODORS
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00:06:08,931 --> 00:06:11,793
WITHOUT BEING CONSPICUOUS.
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00:06:11,793 --> 00:06:15,137
THE VENTILATION UNIT
IS ACTUALLY PART OF THE COOKTOP,
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00:06:15,137 --> 00:06:20,379
AND THAT OPENS UP A LOT
OF KITCHEN-DESIGN POSSIBILITIES.
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00:06:22,448 --> 00:06:25,448
INVENTED IN THE 1960s,
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00:06:25,448 --> 00:06:29,103
THE DOWNDRAFT COOKTOP
CAN SOLVE SOME DESIGN DILEMMAS.
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00:06:29,103 --> 00:06:32,931
INSTALLED IN A CENTER ISLAND,
IT OFFERS A CLEAR LINE OF VIEW
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00:06:32,931 --> 00:06:35,620
WHERE A TRADITIONAL HOOD
WOULD BLOCK IT.
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PRODUCTION STARTS
WITH THE BURNER BOX.
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00:06:40,275 --> 00:06:43,275
THEY'LL MAKE THREE
FROM THIS STEEL SHEET.
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00:06:43,275 --> 00:06:45,137
A COMPUTER GUIDES TOOLS
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00:06:45,137 --> 00:06:48,482
AS THEY CUT HOLES AND NOTCHES
IN THE STEEL.
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00:06:48,482 --> 00:06:51,896
IT ALSO ROUGHS OUT
THE SHAPE OF THE BOXES
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00:06:51,896 --> 00:06:54,586
AND MAKES SLOTS FOR THE
DOWNDRAFT VENTILATION INTAKE.
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00:06:57,172 --> 00:07:01,034
AFTER THE SHEETS HAVE BEEN CUT
INTO INDIVIDUAL UNITS,
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00:07:01,034 --> 00:07:04,965
A WORKER SERVES THEM UP
TO A COMPUTERIZED BRAKE PRESS.
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00:07:04,965 --> 00:07:08,620
THE COMPUTER CONTROLS THE STOPS
102
00:07:08,620 --> 00:07:12,068
THAT POSITION THE SHEET
TO BE BENT AT THE CORRECT ANGLE.
103
00:07:12,068 --> 00:07:18,448
THIS TRANSFORMS THE STEEL SHEET
INTO A BOX.
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00:07:18,448 --> 00:07:23,965
THEY'RE NOW READY TO BUILD THE
DOWNDRAFT VENTILATION SYSTEM.
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00:07:26,793 --> 00:07:29,448
THE WORKER
INSERTS THE FAN BLOWER AND MOTOR
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00:07:29,448 --> 00:07:31,517
INTO AN ASSEMBLY FIXTURE.
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00:07:31,517 --> 00:07:36,068
HE THEN PLACES A METAL PART,
KNOWN AS THE PLENUM, OVER IT.
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00:07:36,068 --> 00:07:38,482
THE PLENUM IS THE INTAKE DUCT.
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00:07:38,482 --> 00:07:41,000
HE PLACES A MESH GUARD
OVER THE OPENING
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00:07:41,000 --> 00:07:44,000
THROUGH WHICH STEAM
AND COOKING FUMES WILL FLOW.
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00:07:44,000 --> 00:07:50,103
HE SECURES EVERYTHING
WITH FOUR NUTS AND STUDS.
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00:07:50,103 --> 00:07:55,206
HE CAPS THE NUTS WITH
RUBBER PLUGS TO SEAL THE GAPS.
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00:07:57,275 --> 00:08:00,758
HE NOW TRANSFERS THE FAN
AND DUCT ASSEMBLY
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00:08:00,758 --> 00:08:02,413
TO ANOTHER FIXTURE.
115
00:08:02,413 --> 00:08:06,068
IT ALLOWS HIM TO CORRECTLY
POSITION THE BURNER BOX
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00:08:06,068 --> 00:08:08,103
ON THE VENTILATION SYSTEM.
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00:08:11,896 --> 00:08:15,448
HE PLUGS THE BLOWER MOTOR
INTO A JUNCTION BOX.
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00:08:18,551 --> 00:08:21,137
HE PLACES A METAL FRAME
AROUND THE PLENUM
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00:08:21,137 --> 00:08:24,793
AND SCREWS IT IN PLACE TO SECURE
THE PLENUM TO THE BURNER BOX.
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00:08:27,103 --> 00:08:29,620
NEXT,
HE ASSEMBLES THE KNOB SWITCHES
121
00:08:29,620 --> 00:08:31,965
THAT TURN THE BURNERS ON
AND OFF.
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00:08:31,965 --> 00:08:36,137
HE ADDS RUBBER INSULATORS TO
KEEP WATER OUT OF THE SWITCHES.
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00:08:36,137 --> 00:08:38,689
HE COVERS THEM
WITH A METAL PLATE
124
00:08:38,689 --> 00:08:41,827
WITH HOLES
FOR THE KNOB SHAFTS TO PROTRUDE.
125
00:08:41,827 --> 00:08:46,379
HE INSTALLS THE LIGHTING SYSTEM
126
00:08:46,379 --> 00:08:49,448
THAT INDICATES WHETHER
THE BURNERS ARE ON OR OFF.
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00:08:52,448 --> 00:08:54,586
NEXT, AN EMPLOYEE
SLOTS THE SWITCH SYSTEM
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00:08:54,586 --> 00:08:57,620
INTO THE CERAMIC COOKTOP
THROUGH THE BACK.
129
00:08:57,620 --> 00:09:01,000
HE INSERTS
THE RADIANT HEATING ELEMENTS
130
00:09:01,000 --> 00:09:03,448
INTO THE HOLES IN THE COOKTOP.
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00:09:03,448 --> 00:09:07,310
THE ELEMENTS ARE DIFFERENT SIZES
TO ACCOMMODATE DIFFERENT POTS,
132
00:09:07,310 --> 00:09:10,068
AND THEY HAVE DIFFERENT
HEATING CAPACITIES.
133
00:09:10,068 --> 00:09:12,551
HE WIRES THE SWITCHES
TO THE ELEMENTS,
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00:09:12,551 --> 00:09:16,965
AND HE TIES THEM
TO THE MAIN POWER CORD.
135
00:09:19,862 --> 00:09:22,724
ANOTHER WORKER SCREWS
THE ELEMENTS TO A METAL BRACKET
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00:09:22,724 --> 00:09:26,655
THAT'S GLUED TO THE UNDERSIDE
OF THE CERAMIC COOKTOP,
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00:09:26,655 --> 00:09:29,931
AND HE COMPLETES
THE WIRING WORK.
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00:09:34,310 --> 00:09:36,344
THE CERAMIC COOKTOP IS COMPLETE
139
00:09:36,344 --> 00:09:40,068
AND READY TO BE JOINED TO
THE DOWNDRAFT VENTILATION UNIT.
140
00:09:40,068 --> 00:09:43,620
HE ALIGNS THE HOLE IN THE CENTER
WITH THE INTAKE DUCT.
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00:09:43,620 --> 00:09:46,068
HE FEEDS THE WIRES
FROM THE COOKTOP
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00:09:46,068 --> 00:09:50,137
THROUGH HOLES IN THE BURNER BOX
TO THE JUNCTION BOX.
143
00:09:50,137 --> 00:09:54,689
HE SCREWS THE JUNCTION BOX
TO THE BOTTOM OF THE BURNER BOX.
144
00:09:54,689 --> 00:09:59,206
HE PULLS THE MAIN POWER HARNESS
THROUGH A HOLE IN THE BURNER BOX
145
00:09:59,206 --> 00:10:03,275
AND SECURES IT TO THE BOX
WITH A METAL BRACKET AND SCREWS.
146
00:10:07,862 --> 00:10:09,758
HE ADJUSTS THE CERAMIC COOKTOP,
147
00:10:09,758 --> 00:10:13,000
WHICH MOVED OUT OF ALIGNMENT
A BIT DURING THE WIRING,
148
00:10:13,000 --> 00:10:15,413
AND THEN EQUIPS THE COOKTOP
WITH KNOBS
149
00:10:15,413 --> 00:10:17,965
WHICH FIT SNUGLY
TO THE PROTRUDING PINS.
150
00:10:19,103 --> 00:10:21,275
AND IT'S OVER TO A TEST STATION.
151
00:10:21,275 --> 00:10:25,103
THE OPERATOR CONNECTS A COMPUTER
TO THE DOWNDRAFT COOKTOP.
152
00:10:25,103 --> 00:10:26,620
SHE TURNS THE KNOBS,
153
00:10:26,620 --> 00:10:30,620
AND THE COMPUTER MEASURES THE
POWER CONSUMED BY THE ELEMENTS.
154
00:10:30,620 --> 00:10:34,241
SOME ELEMENTS ARE THE SAME SIZE
BUT DIFFERENT WATTAGES.
155
00:10:34,241 --> 00:10:35,448
THE TEST CONFIRMS
156
00:10:35,448 --> 00:10:38,275
THAT THE ELEMENTS
ARE IN THE CORRECT SLOTS
157
00:10:38,275 --> 00:10:41,724
AND THAT ALL BURNERS
ARE OPERATIONAL.
158
00:10:41,724 --> 00:10:46,793
IT'S TAKEN 25 MINUTES TO
ASSEMBLE THIS DOWNDRAFT COOKTOP.
159
00:10:46,793 --> 00:10:49,448
THE DOWNDRAFT VENTILATION UNIT
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00:10:49,448 --> 00:10:52,931
WILL GET RID OF MOISTURE
AND ODORS DISCREETLY.
161
00:10:52,931 --> 00:10:55,310
IT'S NOW TIME
TO TURN UP THE HEAT
162
00:10:55,310 --> 00:10:57,724
WITH NO WORRIES
ABOUT THE FALLOUT.
163
00:11:09,586 --> 00:11:11,689
Narrator:
IF YOU'VE GOT VARICOSE VEINS,
164
00:11:11,689 --> 00:11:14,689
LEG FATIGUE, ANKLE SWELLING,
OR OTHER CIRCULATION DISORDERS,
165
00:11:14,689 --> 00:11:17,103
YOUR DOCTOR MAY PRESCRIBE
COMPRESSION HOSIERY,
166
00:11:17,103 --> 00:11:19,310
PRESSURED STOCKINGS
THAT SQUEEZE YOUR LEGS
167
00:11:19,310 --> 00:11:20,896
PRIMARILY AT THE ANKLE
168
00:11:20,896 --> 00:11:23,655
AND, TO A LESSER EXTENT,
IN OTHER AREAS
169
00:11:23,655 --> 00:11:28,068
TO HELP THE BLOOD IN YOUR VEINS
TRAVEL BACK TO THE HEART.
170
00:11:28,068 --> 00:11:31,724
THEY DON'T LOOK LIKE
UGLY OLD-LADY STOCKINGS ANYMORE.
171
00:11:31,724 --> 00:11:35,413
TODAY'S COMPRESSION HOSIERY
COMES IN A RANGE OF COLORS
172
00:11:35,413 --> 00:11:38,931
AND PANTYHOSE, THIGH-HIGH,
AND KNEE-HIGH VERSIONS.
173
00:11:38,931 --> 00:11:42,551
THE DOCTOR PRESCRIBES THE
COMPRESSION STRENGTH YOU NEED.
174
00:11:42,551 --> 00:11:46,586
THAT'S THE PRESSURE AT THE ANKLE
IN MILLIMETERS MERCURY,
175
00:11:46,586 --> 00:11:50,620
THE SAME MEASURING UNIT
USED IN BLOOD-PRESSURE READINGS.
176
00:11:50,620 --> 00:11:52,275
THE HOSIERY IS KNITTED
177
00:11:52,275 --> 00:11:55,862
OUT OF STRETCHY SPANDEX
AND NYLON YARNS.
178
00:11:55,862 --> 00:11:58,310
THE COMPUTERIZED
KNITTING MACHINE
179
00:11:58,310 --> 00:12:01,862
INTERLOCKS YARN STRANDS
VERTICALLY AND HORIZONTALLY.
180
00:12:01,862 --> 00:12:05,896
THIS TWO-DIRECTION KNIT GIVES
THE STOCKING A TWO-WAY STRETCH.
181
00:12:05,896 --> 00:12:09,000
HOWEVER, IT'S
THE HORIZONTAL YARN IN THE KNIT
182
00:12:09,000 --> 00:12:12,275
THAT PROVIDES THE DOCTOR'S
STRENGTH PRESCRIPTION.
183
00:12:12,275 --> 00:12:14,655
THEY PROGRAM
THE KNITTING MACHINE
184
00:12:14,655 --> 00:12:18,206
TO PRODUCE A RUN OF A SPECIFIC
SIZE AND PRESCRIPTION.
185
00:12:18,206 --> 00:12:21,586
IT AUTOMATICALLY VARIES
THE STITCH AND YARN TENSION
186
00:12:21,586 --> 00:12:24,827
TO APPLY 100% OF THE PRESCRIBED
PRESSURE AT THE ANKLE,
187
00:12:24,827 --> 00:12:29,206
65% AT THE CALF,
AND 30% AT THE THIGH.
188
00:12:29,206 --> 00:12:32,137
STRONGER PRESSURE
AT THE BOTTOM POINT
189
00:12:32,137 --> 00:12:35,137
FORCES BLOOD UPWARD
TOWARD THE HEART.
190
00:12:35,137 --> 00:12:38,379
THE MACHINE
OUTPUTS STOCKING-LENGTH TUBES,
191
00:12:38,379 --> 00:12:42,482
WHICH SEWERS SKILLFULLY
TRANSFORM INTO THE FINAL SHAPE.
192
00:12:42,482 --> 00:12:45,448
THE FIRST SEWER
TURNS THE TUBE INSIDE OUT
193
00:12:45,448 --> 00:12:47,448
AND STITCHES THE TOE CLOSED.
194
00:12:47,448 --> 00:12:49,965
THEN SHE STRETCHES
THOSE STITCHES
195
00:12:49,965 --> 00:12:53,827
TO FLATTEN THE SEAM SO IT'LL BE
COMFORTABLE ON THE FOOT.
196
00:12:53,827 --> 00:12:57,275
IF THEY'RE MAKING PANTYHOSE,
ANOTHER SEWER SLITS THAT TUBE
197
00:12:57,275 --> 00:12:59,448
PARTWAY DOWN
THE INSIDE OF THE LEG
198
00:12:59,448 --> 00:13:03,103
SO IT CAN BE JOINED
TO ANOTHER LEG.
199
00:13:03,103 --> 00:13:05,655
THE NEXT SEWER TAKES A LEG
200
00:13:05,655 --> 00:13:08,551
AND STITCHES IT
TO A TRIANGULAR COTTON GUSSET,
201
00:13:08,551 --> 00:13:11,137
WHICH FORMS THE CROTCH
OF THE PANTYHOSE.
202
00:13:13,172 --> 00:13:15,241
THESE ARE MATERNITY HOSE,
203
00:13:15,241 --> 00:13:18,965
SO SHE ALSO SEWS IN
A STRETCHY STOMACH PANEL.
204
00:13:24,862 --> 00:13:28,896
THEN SHE SEWS A BIG
U-SHAPED SEAM AT THE FRONT,
205
00:13:28,896 --> 00:13:31,379
JOINING THE SECOND LEG
TO THE OTHER PARTS.
206
00:13:31,379 --> 00:13:34,827
WHETHER IT'S
A MULTIPLE-COMPONENT PANTYHOSE
207
00:13:34,827 --> 00:13:38,827
OR A SIMPLE SINGLE THIGH-HIGH
OR KNEE-HIGH STOCKING,
208
00:13:38,827 --> 00:13:42,931
THE PRODUCTION STEPS
FROM THIS POINT ON ARE THE SAME.
209
00:13:42,931 --> 00:13:47,379
WORKERS SLIDE EACH STOCKING
ONTO A HEATED ALUMINUM LEG FORM
210
00:13:47,379 --> 00:13:50,793
IN THE SIZE THEY'RE PRODUCING
IN THIS RUN.
211
00:13:50,793 --> 00:13:53,137
LASER LINES SHOW
EXACTLY WHERE TO ALIGN THE HEEL
212
00:13:53,137 --> 00:13:55,413
AND OTHER PARTS ON THE FORM.
213
00:13:55,413 --> 00:13:56,931
THEN, ONE BY ONE,
214
00:13:56,931 --> 00:13:59,862
THE FORMS ENTER
A PRESSURIZED STEAM CHAMBER
215
00:13:59,862 --> 00:14:01,551
FOR ABOUT FOUR SECONDS.
216
00:14:01,551 --> 00:14:04,862
THIS QUICK STEAM TREATMENT
IS ENOUGH
217
00:14:04,862 --> 00:14:07,827
TO PERMANENTLY LOCK
THE FORM'S SHAPE INTO THE NYLON.
218
00:14:10,965 --> 00:14:13,068
THE FORM THEN ENTERS A DRYER,
219
00:14:13,068 --> 00:14:15,862
WHERE IT STOPS
FOR ABOUT 15 SECONDS.
220
00:14:15,862 --> 00:14:19,931
THE HOT FORCED AIR EVAPORATES
THE STEAM-INFUSED MOISTURE.
221
00:14:19,931 --> 00:14:23,206
WHEN THE STOCKING
FINALLY COMES OFF THE FORM,
222
00:14:23,206 --> 00:14:25,827
IT'S DRY AND LEG-SHAPED.
223
00:14:27,344 --> 00:14:30,896
WORKERS NOW GROUP THE STOCKINGS
INTO 10-PAIR STACKS,
224
00:14:30,896 --> 00:14:33,827
PUT EACH STACK
INSIDE A SPECIFIC COLOR BAG
225
00:14:33,827 --> 00:14:36,758
TO IDENTIFY ITS STYLE AND SIZE,
226
00:14:36,758 --> 00:14:41,482
THEN LOAD THE BAGS
IN THIS HIGH-TECH DYE MACHINE.
227
00:14:42,862 --> 00:14:45,758
THEY KEY IN THE PROGRAM
WHICH AUTOMATICALLY CONTROLS
228
00:14:45,758 --> 00:14:48,068
EVERY ASPECT
OF DYEING THE STOCKINGS
229
00:14:48,068 --> 00:14:51,172
FROM WATER LEVELS AND
TEMPERATURE TO DYE INJECTION.
230
00:14:51,172 --> 00:14:55,275
FOR ONE HOUR, THE MACHINE
WASHES THE STOCKINGS.
231
00:14:55,275 --> 00:14:59,241
THEN, OVER THE NEXT FIVE HOURS,
IT DYES THEM,
232
00:14:59,241 --> 00:15:03,034
ADDING CHEMICALS
TO MAKE THE WATER ACIDIC,
233
00:15:03,034 --> 00:15:06,137
WHICH DRAWS THE DYE
LIKE A SPONGE
234
00:15:06,137 --> 00:15:08,896
PERMANENTLY
INTO THE YARN FIBERS.
235
00:15:08,896 --> 00:15:13,034
THE COMPRESSION STOCKINGS KNIT,
SEWN, SHAPED, AND DYED
236
00:15:13,034 --> 00:15:16,413
ARE NOW READY
TO BE INSPECTED AND PACKAGED.
237
00:15:16,413 --> 00:15:20,620
THE FACTORY PULLS A SET NUMBER
OF RANDOM SAMPLES PER DAY
238
00:15:20,620 --> 00:15:22,103
FROM THE PRODUCTION LINE
239
00:15:22,103 --> 00:15:24,551
AND TESTS THEM
ON THIS EXTENSION MACHINE.
240
00:15:24,551 --> 00:15:27,551
IT STRETCHES THE HOSE
TO TEST THE TENSILE STRENGTH,
241
00:15:27,551 --> 00:15:29,310
AND IT MEASURES THE COMPRESSION
242
00:15:29,310 --> 00:15:32,172
AT THE DIFFERENT POINTS
OF THE LEG.
243
00:15:32,172 --> 00:15:34,482
EVERY SINGLE PAIR OF STOCKINGS
244
00:15:34,482 --> 00:15:39,206
UNDERGOES A VISUAL INSPECTION
PRIOR TO PACKAGING.
245
00:15:41,862 --> 00:15:45,793
THEN THE PACKAGER NEATLY FOLDS
IT AROUND A CARDBOARD INSERT,
246
00:15:45,793 --> 00:15:49,000
SLIPS IT INSIDE
AN ADHESIVE-SEALED PLASTIC BAG,
247
00:15:49,000 --> 00:15:52,103
AND INSERTS IT
INTO THE RETAIL BOX.
248
00:15:52,103 --> 00:15:56,758
COMPRESSION STOCKINGS ARE
CLASSIFIED AS A MEDICAL DEVICE.
249
00:15:56,758 --> 00:15:59,344
THE SEALED BAG
ASSURES THE CUSTOMER
250
00:15:59,344 --> 00:16:02,724
THAT THE STOCKINGS
ARE A BRAND-NEW, UNUSED PAIR,
251
00:16:02,724 --> 00:16:04,413
AND THEREFORE, HYGIENIC.
252
00:16:17,172 --> 00:16:18,931
Narrator:
LOOKING TO DRIVE MOTORCYCLE
253
00:16:18,931 --> 00:16:21,448
WITHOUT EVER HAVING TO STOP
FOR A FILL-UP, CHANGE THE OIL,
254
00:16:21,448 --> 00:16:22,758
TOP OFF THE FLUIDS,
255
00:16:22,758 --> 00:16:25,620
OR REPAIR A TRANSMISSION,
CLUTCH, AND COOLING SYSTEM?
256
00:16:25,620 --> 00:16:27,379
AND DO YOU WANT A QUIET MOTOR
257
00:16:27,379 --> 00:16:29,931
THAT DOESN'T CONTRIBUTE
TO AIR POLLUTION?
258
00:16:29,931 --> 00:16:31,620
THEN AN ELECTRIC MOTORCYCLE
259
00:16:31,620 --> 00:16:35,931
MAY BE JUST THE SET OF WHEELS
YOU'RE LOOKING FOR.
260
00:16:35,931 --> 00:16:39,793
AN ELECTRIC MOTORCYCLE
LENDS A WHOLE NEW MEANING
261
00:16:39,793 --> 00:16:42,068
TO THE TERM "PLUG AND PLAY."
262
00:16:42,068 --> 00:16:45,655
YOU CHARGE THE BIKE'S BATTERY
BY PLUGGING IN
263
00:16:45,655 --> 00:16:49,758
TO A STANDARD 120-VOLT
HOUSEHOLD ELECTRICAL OUTLET.
264
00:16:49,758 --> 00:16:53,206
A FULL CHARGE TAKES EIGHT HOURS,
BUT YOU CAN BUY AN ADD-ON DEVICE
265
00:16:53,206 --> 00:16:55,724
TO CUT THAT CHARGING TIME
IN HALF.
266
00:16:55,724 --> 00:16:58,689
THE BIKE'S JOURNEY BEGINS
ON A SKETCH PAD.
267
00:16:58,689 --> 00:17:02,275
AN INDUSTRIAL DESIGNER
DRAWS AN ARTISTIC CONCEPTION,
268
00:17:02,275 --> 00:17:05,724
CREATING THE AESTHETICS
SUCH AS LINES AND COLORS
269
00:17:05,724 --> 00:17:10,034
AS WELL AS THE ERGONOMICS, SUCH
AS SEAT AND MIRROR POSITIONING.
270
00:17:10,034 --> 00:17:12,689
THE DESIGNER
TRANSFORMS THE SKETCHES
271
00:17:12,689 --> 00:17:14,275
INTO A COMPUTER MODEL
272
00:17:14,275 --> 00:17:17,931
TO WHICH ENGINEERS
THEN ADD THE MECHANICS.
273
00:17:17,931 --> 00:17:22,103
THE MOTORCYCLE'S BATTERY
CONTAINS FOUR CELL BOXES.
274
00:17:22,103 --> 00:17:27,344
TO LINK ALL THE CELL BOXES, THEY
INSTALL TWO INTERCONNECT BOARDS.
275
00:17:27,344 --> 00:17:29,103
THEN, INTO EACH BOARD,
276
00:17:29,103 --> 00:17:32,689
THEY PLUG THE CONNECTORS
FROM TWO CELL BOXES.
277
00:17:32,689 --> 00:17:36,379
THEY USE LOTS OF GREASE
TO WATERPROOF THE BATTERY
278
00:17:36,379 --> 00:17:40,965
AND PROTECT IT AGAINST CORROSION
CAUSED BY ROAD SALT OR SEA AIR.
279
00:17:43,620 --> 00:17:47,103
NEXT, THEY PLUG WIRES COMING
FROM THE TWO INTERCONNECT BOARDS
280
00:17:47,103 --> 00:17:49,206
INTO A CIRCUIT BOARD.
281
00:17:49,206 --> 00:17:51,793
THIS CIRCUIT BOARD
IS THE BATTERY'S BRAIN.
282
00:17:51,793 --> 00:17:54,689
IT REGULATES THE VOLTAGES
OF THE INDIVIDUAL CELLS
283
00:17:54,689 --> 00:17:56,965
TO PREVENT OVERHEATING.
284
00:17:56,965 --> 00:17:59,758
THEN THE CHARGING COMPONENTS.
285
00:18:01,896 --> 00:18:05,310
TECHNICIANS NOW CLOSE UP
THE FULLY ASSEMBLED BATTERY
286
00:18:05,310 --> 00:18:09,034
WITH PROTECTIVE COVERS AND
RUN IT THROUGH A FUNCTION TEST.
287
00:18:09,034 --> 00:18:12,103
THE TEST SIMULATES
THE DISCHARGE OF THE BATTERY
288
00:18:12,103 --> 00:18:14,620
THAT HAPPENS
WHEN YOU RIDE THE BIKE,
289
00:18:14,620 --> 00:18:17,551
THEN THE RECHARGE THAT OCCURS
WHEN YOU PLUG IN.
290
00:18:17,551 --> 00:18:21,172
ALL THE CELL VOLTAGES
MUST BALANCE IN THE PROCESS.
291
00:18:21,172 --> 00:18:24,551
THE MOTORCYCLE FRAME
IS MADE OF HIGH-STRENGTH,
292
00:18:24,551 --> 00:18:26,827
LIGHTWEIGHT,
AIRCRAFT-GRADE ALUMINUM.
293
00:18:26,827 --> 00:18:30,344
AT THE TAIL END,
THEY INSTALL THE CONTROLLER,
294
00:18:30,344 --> 00:18:33,206
THE LINK BETWEEN THE BATTERY
AND THE THROTTLE,
295
00:18:33,206 --> 00:18:36,137
WHICH CONTROLS THE ELECTRICITY
FLOW TO THE MOTOR.
296
00:18:36,137 --> 00:18:38,310
THEY MOUNT
THE SUSPENSION SYSTEM,
297
00:18:38,310 --> 00:18:39,620
AN ALUMINUM SWINGARM
298
00:18:39,620 --> 00:18:42,241
THAT ATTACHES
TO THE REAR WHEEL ON ONE END
299
00:18:42,241 --> 00:18:44,068
AND TO THE FRAME ON THE OTHER
300
00:18:44,068 --> 00:18:46,448
VIA A SPRING-SHAPED
SHOCK ABSORBER,
301
00:18:46,448 --> 00:18:49,068
WHICH EXPANDS
AND CONTRACTS TO DAMPEN BOUNCE
302
00:18:49,068 --> 00:18:52,103
AS THE WHEEL MOVES UP AND DOWN
OVER BUMPS IN THE ROAD.
303
00:18:54,206 --> 00:18:55,482
THEY MOUNT THE MOTOR.
304
00:18:55,482 --> 00:18:57,310
THE BATTERY'S ELECTRICAL CURRENT
305
00:18:57,310 --> 00:18:59,586
ROTATES THE MOTOR
VIA THE CONTROLLER,
306
00:18:59,586 --> 00:19:03,000
WHICH TURNS THE DRIVE BELT,
SPINNING THE BIKE'S REAR WHEEL.
307
00:19:05,482 --> 00:19:07,172
THIS BELT'S MAINTENANCE-FREE
308
00:19:07,172 --> 00:19:09,827
BECAUSE IT'S MADE
OF HIGH-STRENGTH RUBBER,
309
00:19:09,827 --> 00:19:11,310
FURTHER REINFORCED
WITH THE MATERIAL USED
310
00:19:11,310 --> 00:19:14,034
TO MAKE BULLETPROOF VESTS.
311
00:19:14,034 --> 00:19:16,724
THEY INSTALL
THE UPPER TRIPLE CLAMP,
312
00:19:16,724 --> 00:19:19,758
WHICH CARRIES THE DASH, HORN,
TURN SIGNALS,
313
00:19:19,758 --> 00:19:22,034
AND IGNITION SWITCH.
314
00:19:22,034 --> 00:19:24,275
THEN THE HANDLEBARS.
315
00:19:24,275 --> 00:19:27,448
THERE ARE SEVERAL COMPONENTS
ALREADY MOUNTED TO THEM,
316
00:19:27,448 --> 00:19:30,275
INCLUDING THE FRONT BRAKE LEVER,
THE THROTTLE,
317
00:19:30,275 --> 00:19:31,620
AND CONTROL SWITCHES.
318
00:19:31,620 --> 00:19:34,586
THEN TECHNICIANS
SLIDE THE BATTERY INTO THE FRAME
319
00:19:34,586 --> 00:19:37,931
AND CONNECT IT TO THE MOTOR
AND CONTROLLER.
320
00:19:37,931 --> 00:19:41,448
THIS MOTORCYCLE
HAS NO TRANSMISSION, NO GEARS,
321
00:19:41,448 --> 00:19:45,310
NO CLUTCH, NO COOLING SYSTEM
TO MAINTAIN OR REPAIR.
322
00:19:45,310 --> 00:19:49,137
THE MOTOR'S FINS ADEQUATELY
DISSIPATE HEAT BUILDUP.
323
00:19:50,344 --> 00:19:54,172
NEXT, TWO ALUMINUM FORKS
TO HOLD THE FRONT WHEEL AXLE.
324
00:19:54,172 --> 00:19:57,827
WORKERS POSITION THEM
INSIDE THE UPPER TRIPLE CLAMP
325
00:19:57,827 --> 00:20:00,655
AND A SECOND TRIPLE CLAMP
LOWER DOWN.
326
00:20:00,655 --> 00:20:04,103
BUT THEY DON'T INSTALL
THE FRONT WHEEL JUST YET.
327
00:20:04,103 --> 00:20:06,275
THEY FIRST MOUNT THE REAR WHEEL.
328
00:20:06,275 --> 00:20:07,827
IT HAS A RUBBER TIRE,
329
00:20:07,827 --> 00:20:10,896
HYDRAULIC BRAKES
ACTIVATED BY A FOOT LEVER,
330
00:20:10,896 --> 00:20:13,620
AND A SPROCKET
FOR THE DRIVE BELT.
331
00:20:13,620 --> 00:20:16,896
THEY PLACE THE DRIVE BELT
AROUND THE SPROCKET.
332
00:20:16,896 --> 00:20:20,206
NOW, WHEN THE MOTOR RUNS,
THE REAR WHEEL TURNS.
333
00:20:20,206 --> 00:20:22,344
AFTER MOUNTING THE FRONT WHEEL,
334
00:20:22,344 --> 00:20:25,448
THEY INSTALL
THE BIKE'S PLASTIC BODY PARTS.
335
00:20:25,448 --> 00:20:27,241
THERE'S A STORAGE AREA
336
00:20:27,241 --> 00:20:31,034
WHERE GAS MOTORCYCLES
WOULD HAVE THEIR FUEL TANK.
337
00:20:31,034 --> 00:20:35,206
THERE ARE FOUR CHARGERS
LOCATED UNDERNEATH THE BATTERY.
338
00:20:35,206 --> 00:20:38,448
THEIR WIRING CULMINATES
IN A SINGLE PORT
339
00:20:38,448 --> 00:20:41,034
IN WHICH YOU PLUG A CABLE
TO RECHARGE.
340
00:20:41,034 --> 00:20:46,137
EVERY MOTORCYCLE
THIS FACTORY PRODUCES
341
00:20:46,137 --> 00:20:50,172
UNDERGOES AN EXTENSIVE INDOOR
ROAD TEST ON A DYNAMOMETER,
342
00:20:50,172 --> 00:20:51,689
A DRIVING SIMULATOR
343
00:20:51,689 --> 00:20:54,689
THAT ASSESSES THE PERFORMANCE
OF EVERY COMPONENT.
344
00:20:54,689 --> 00:20:56,241
ALTHOUGH VERY QUIET,
345
00:20:56,241 --> 00:21:00,310
THE BIKE'S AS POWERFUL AS A
MIDSIZE, GASOLINE-RUN MOTORCYCLE
346
00:21:00,310 --> 00:21:03,862
AND CAN REACH SPEEDS
OF UP TO 100 MILES PER HOUR.
347
00:21:03,862 --> 00:21:06,758
WHEN THE BATTERY
NEEDS A QUICK RECHARGE,
348
00:21:06,758 --> 00:21:07,965
YOU CAN PULL OVER
349
00:21:07,965 --> 00:21:10,655
AT A ROADSIDE ELECTRIC-VEHICLE
CHARGING STATION
350
00:21:10,655 --> 00:21:12,965
AND FILL HER UP
IN LESS THAN AN HOUR.
351
00:21:21,793 --> 00:21:23,827
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW
352
00:21:23,827 --> 00:21:26,275
OR YOU'D LIKE TO SUGGEST TOPICS
FOR FUTURE SHOWS,
353
00:21:26,275 --> 00:21:28,379
DROP US A LINE AT...
29140
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