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These are the user uploaded subtitles that are being translated: 1 00:00:01,793 --> 00:00:04,793 --Captions by VITAC-- www.vitac.com 2 00:00:04,793 --> 00:00:07,793 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 3 00:00:52,620 --> 00:00:55,344 Narrator: EGYPTIAN PHARAOHS WERE LIKELY THE FIRST 4 00:00:55,344 --> 00:00:59,172 TO HAVE MOLDS MADE OF THEIR BODIES AND THE IMAGES CAST. 5 00:00:59,172 --> 00:01:01,758 TODAY, ANYONE CAN HAVE THIS DONE. 6 00:01:01,758 --> 00:01:04,655 THE EXPERTS HAVE IT DOWN TO A FINE ART. 7 00:01:04,655 --> 00:01:07,413 IT'S CALLED LIFE CASTING, OR BODY MOLDING, 8 00:01:07,413 --> 00:01:10,655 AND IT'S IN DEMAND BECAUSE EVERY BODY IS DIFFERENT. 9 00:01:14,103 --> 00:01:16,275 NEED A BODY DOUBLE? 10 00:01:16,275 --> 00:01:19,655 LIFE CASTING CREATES REPLICAS OF BODY PARTS 11 00:01:19,655 --> 00:01:23,655 THAT CAN BE USED AS PERSONAL MEMENTOS OR MOVIE PROPS. 12 00:01:27,310 --> 00:01:30,517 THEY START BY APPLYING COLD CREAM TO THE BODY PART. 13 00:01:30,517 --> 00:01:33,137 THE CREAM WILL SERVE AS A RELEASE AGENT, 14 00:01:33,137 --> 00:01:36,275 ALLOWING THE MOLD TO BE REMOVED WHOLE. 15 00:01:36,275 --> 00:01:39,655 THIS ORANGE GOOP IS THE MOLDING MATERIAL. 16 00:01:39,655 --> 00:01:42,896 IT'S A SEAWEED-BASED SUBSTANCE CALLED ALGINATE. 17 00:01:42,896 --> 00:01:46,896 IT'S THE SAME STUFF THE DENTIST USES TO TAKE MOLDS OF TEETH, 18 00:01:46,896 --> 00:01:49,655 BUT IT'S FORMULATED TO SET MORE SLOWLY. 19 00:01:49,655 --> 00:01:52,827 THE LIFE CASTER SPREADS THE ALGINATE LIBERALLY 20 00:01:52,827 --> 00:01:56,551 ONTO THIS YOUNG ACTOR'S CLENCHED FIST AND ARM. 21 00:01:56,551 --> 00:01:59,724 ALGINATE CURES IN FIVE OR SIX MINUTES, 22 00:01:59,724 --> 00:02:02,000 SO THERE'S NO TIME TO WASTE. 23 00:02:02,000 --> 00:02:04,655 HE WORKS AT A STEADY PACE. 24 00:02:04,655 --> 00:02:09,482 HE APPLIES WET PLASTER BANDAGES TO THE ALGINATE. 25 00:02:12,448 --> 00:02:15,379 THE BANDAGES ADHERE AND FORM A STIFF SHELL 26 00:02:15,379 --> 00:02:18,000 SIMILAR TO A CAST FOR A BROKEN LIMB. 27 00:02:18,000 --> 00:02:20,896 THE CAST-LIKE SHELL SUPPORTS THE ALGINATE 28 00:02:20,896 --> 00:02:23,793 AS IT CURES TO THE SHAPE OF THE BOY'S FIST 29 00:02:23,793 --> 00:02:25,482 TO PRODUCE A MOLD OF IT. 30 00:02:27,241 --> 00:02:31,517 WHEN CURED, THE ALGINATE HAS A FIRM YET RUBBERY CONSISTENCY. 31 00:02:31,517 --> 00:02:34,689 IT TAKES A FEW TUGS TO PULL OFF THE MOLD, 32 00:02:34,689 --> 00:02:37,655 BUT THE RUBBERY NATURE OF THE ALGINATE 33 00:02:37,655 --> 00:02:41,655 MEANS IT CAN BE DONE WITHOUT CRACKING OR CRUMPLING. 34 00:02:41,655 --> 00:02:45,482 THE CASTING MATERIAL IS DURABLE DENTAL PLASTER. 35 00:02:45,482 --> 00:02:47,827 HE POURS IT INTO THE MOLD. 36 00:02:51,517 --> 00:02:53,655 HE TIPS OUT A BIT TO GET RID OF BUBBLES 37 00:02:53,655 --> 00:02:56,689 THAT HAVE ACCUMULATED ON THE SURFACE. 38 00:02:56,689 --> 00:02:59,724 IT'S HANDS OFF NOW AS THE PLASTER CURES 39 00:02:59,724 --> 00:03:03,689 BECAUSE A CHEMICAL REACTION MAKES IT DANGEROUSLY HOT. 40 00:03:03,689 --> 00:03:06,724 A HALF-HOUR LATER, THE PLASTER IS COOLED 41 00:03:06,724 --> 00:03:10,137 AND HARDENED INTO THE SHAPE OF THE BOY'S FIST. 42 00:03:10,137 --> 00:03:14,517 THE PLASTER HAS PICKED UP ALL THE LITTLE DETAILS, 43 00:03:14,517 --> 00:03:17,724 INCLUDING THE TINIEST OF CREASES. 44 00:03:17,724 --> 00:03:22,344 HE PICKS OUT BITS OF ALGINATE LODGED IN THE CREASES. 45 00:03:22,344 --> 00:03:24,275 HE DEFINES THE FINGERNAILS 46 00:03:24,275 --> 00:03:27,344 AND CLEANS UP A FEW PITS AND BUBBLES. 47 00:03:27,344 --> 00:03:33,275 THIS IS THE ACTOR'S REAL HAND, AND THIS IS THE REPLICA. 48 00:03:33,275 --> 00:03:36,241 NEXT, THEY MAKE A MOLD OF THE ACTOR'S FACE. 49 00:03:36,241 --> 00:03:39,655 THEY APPLY CREAM TO HIS HAIR 50 00:03:39,655 --> 00:03:42,655 TO PREVENT IT FROM BECOMING STUCK IN THE ALGINATE. 51 00:03:42,655 --> 00:03:45,965 THE TEAM COMPLETELY COATS HIS FACE, EARS, AND UPPER CHEST 52 00:03:45,965 --> 00:03:48,655 WITH BLUE ALGINATE. 53 00:03:48,655 --> 00:03:50,689 IT MUST BE HARD NOT TO WINCE, 54 00:03:50,689 --> 00:03:55,172 BUT HE CAN'T BUDGE IN ORDER TO CREATE A GOOD IMPRESSION. 55 00:03:55,172 --> 00:03:59,793 THEY LEAVE THE BACK OF HIS HEAD UNCOVERED FOR AN OPEN MOLD 56 00:03:59,793 --> 00:04:02,965 AND CREATE TWO SMALL HOLES FOR BREATHING. 57 00:04:02,965 --> 00:04:06,517 THEY LAYER THE PLASTER BANDAGES OVER THE ALGINATE 58 00:04:06,517 --> 00:04:08,862 TO GIVE STRUCTURE TO THE MOLD. 59 00:04:08,862 --> 00:04:11,655 IT ALSO MAKES HIM LOOK MUMMIFIED. 60 00:04:16,000 --> 00:04:19,241 AFTER SEVERAL MINUTES, THE MOLD HAS SOLIDIFIED. 61 00:04:19,241 --> 00:04:21,931 THE TEAM REMOVES IT FROM THE SUBJECT. 62 00:04:21,931 --> 00:04:25,724 NOW THAT HIS FEATURES HAVE BEEN SUCCESSFULLY TRANSFERRED 63 00:04:25,724 --> 00:04:28,413 TO THE ALGINATE, HE CAN BREATHE EASY. 64 00:04:28,413 --> 00:04:34,482 THE LIFE CASTER TRIMS EXCESS ALGINATE, 65 00:04:34,482 --> 00:04:36,862 THEN WRAPS FABRIC AROUND THE MOLD 66 00:04:36,862 --> 00:04:39,655 TO BUILD A KIND OF WALL TO CONTAIN SPILLS 67 00:04:39,655 --> 00:04:41,862 AS HE FILLS IT WITH PLASTER. 68 00:04:43,931 --> 00:04:46,896 THE PLASTER CASTING MAY NOT BE THE FINAL ONE. 69 00:04:46,896 --> 00:04:49,206 DEPENDING ON THE CLIENT'S WISHES, 70 00:04:49,206 --> 00:04:51,655 THEY MAY MAKE A MOLD FROM THIS BUST 71 00:04:51,655 --> 00:04:54,310 AND THEN CAST THE IMAGE IN A MORE FLESH-LIKE MATERIAL 72 00:04:54,310 --> 00:04:56,896 LIKE SILICONE, FOAM, OR RUBBER. 73 00:04:56,896 --> 00:05:00,931 THE PLASTER IS CURED AND THE WAIT IS OVER. 74 00:05:00,931 --> 00:05:06,241 IT'S TIME TO PEEL OFF THE LAYERS AND FIND THE FACE WITHIN. 75 00:05:09,413 --> 00:05:12,482 IT'S A BIT LIKE HE'S REMOVING AN INTRICATE MASK. 76 00:05:14,862 --> 00:05:18,827 THE FACE BEHIND IT IS INSTANTLY RECOGNIZABLE. 77 00:05:22,482 --> 00:05:24,068 HE CLEANS OUT THE EYES AND NOSE... 78 00:05:29,689 --> 00:05:32,793 ...AND SCRUBS THE ENTIRE PLASTER FACE. 79 00:05:38,517 --> 00:05:43,000 HERE'S THE ACTOR AND HIS PLASTER DOPPELGANGER. 80 00:05:45,310 --> 00:05:48,000 THEY'LL USE IT TO CREATE A SILICONE VERSION, 81 00:05:48,000 --> 00:05:50,137 AND ONCE IT'S PAINTED AND GIVEN HAIR, 82 00:05:50,137 --> 00:05:52,517 IT WILL BE READY FOR THE MOVIES. 83 00:06:01,965 --> 00:06:04,172 Narrator: IN CONTRAST TO A BIG, TRADITIONAL HOOD, 84 00:06:04,172 --> 00:06:05,793 WHICH IS SEPARATE FROM THE STOVE, 85 00:06:05,793 --> 00:06:08,931 A DOWNDRAFT SYSTEM VENTS SMOKE, STEAM, AND COOKING ODORS 86 00:06:08,931 --> 00:06:11,793 WITHOUT BEING CONSPICUOUS. 87 00:06:11,793 --> 00:06:15,137 THE VENTILATION UNIT IS ACTUALLY PART OF THE COOKTOP, 88 00:06:15,137 --> 00:06:20,379 AND THAT OPENS UP A LOT OF KITCHEN-DESIGN POSSIBILITIES. 89 00:06:22,448 --> 00:06:25,448 INVENTED IN THE 1960s, 90 00:06:25,448 --> 00:06:29,103 THE DOWNDRAFT COOKTOP CAN SOLVE SOME DESIGN DILEMMAS. 91 00:06:29,103 --> 00:06:32,931 INSTALLED IN A CENTER ISLAND, IT OFFERS A CLEAR LINE OF VIEW 92 00:06:32,931 --> 00:06:35,620 WHERE A TRADITIONAL HOOD WOULD BLOCK IT. 93 00:06:37,448 --> 00:06:40,275 PRODUCTION STARTS WITH THE BURNER BOX. 94 00:06:40,275 --> 00:06:43,275 THEY'LL MAKE THREE FROM THIS STEEL SHEET. 95 00:06:43,275 --> 00:06:45,137 A COMPUTER GUIDES TOOLS 96 00:06:45,137 --> 00:06:48,482 AS THEY CUT HOLES AND NOTCHES IN THE STEEL. 97 00:06:48,482 --> 00:06:51,896 IT ALSO ROUGHS OUT THE SHAPE OF THE BOXES 98 00:06:51,896 --> 00:06:54,586 AND MAKES SLOTS FOR THE DOWNDRAFT VENTILATION INTAKE. 99 00:06:57,172 --> 00:07:01,034 AFTER THE SHEETS HAVE BEEN CUT INTO INDIVIDUAL UNITS, 100 00:07:01,034 --> 00:07:04,965 A WORKER SERVES THEM UP TO A COMPUTERIZED BRAKE PRESS. 101 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. 104 00:07:18,448 --> 00:07:23,965 THEY'RE NOW READY TO BUILD THE DOWNDRAFT VENTILATION SYSTEM. 105 00:07:26,793 --> 00:07:29,448 THE WORKER INSERTS THE FAN BLOWER AND MOTOR 106 00:07:29,448 --> 00:07:31,517 INTO AN ASSEMBLY FIXTURE. 107 00:07:31,517 --> 00:07:36,068 HE THEN PLACES A METAL PART, KNOWN AS THE PLENUM, OVER IT. 108 00:07:36,068 --> 00:07:38,482 THE PLENUM IS THE INTAKE DUCT. 109 00:07:38,482 --> 00:07:41,000 HE PLACES A MESH GUARD OVER THE OPENING 110 00:07:41,000 --> 00:07:44,000 THROUGH WHICH STEAM AND COOKING FUMES WILL FLOW. 111 00:07:44,000 --> 00:07:50,103 HE SECURES EVERYTHING WITH FOUR NUTS AND STUDS. 112 00:07:50,103 --> 00:07:55,206 HE CAPS THE NUTS WITH RUBBER PLUGS TO SEAL THE GAPS. 113 00:07:57,275 --> 00:08:00,758 HE NOW TRANSFERS THE FAN AND DUCT ASSEMBLY 114 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 116 00:08:06,068 --> 00:08:08,103 ON THE VENTILATION SYSTEM. 117 00:08:11,896 --> 00:08:15,448 HE PLUGS THE BLOWER MOTOR INTO A JUNCTION BOX. 118 00:08:18,551 --> 00:08:21,137 HE PLACES A METAL FRAME AROUND THE PLENUM 119 00:08:21,137 --> 00:08:24,793 AND SCREWS IT IN PLACE TO SECURE THE PLENUM TO THE BURNER BOX. 120 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. 122 00:08:31,965 --> 00:08:36,137 HE ADDS RUBBER INSULATORS TO KEEP WATER OUT OF THE SWITCHES. 123 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. 127 00:08:52,448 --> 00:08:54,586 NEXT, AN EMPLOYEE SLOTS THE SWITCH SYSTEM 128 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. 131 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, 134 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 136 00:09:22,724 --> 00:09:26,655 THAT'S GLUED TO THE UNDERSIDE OF THE CERAMIC COOKTOP, 137 00:09:26,655 --> 00:09:29,931 AND HE COMPLETES THE WIRING WORK. 138 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. 141 00:09:43,620 --> 00:09:46,068 HE FEEDS THE WIRES FROM THE COOKTOP 142 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 160 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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