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--Captions by VITAC--
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
A RUBBER TREE'S LIFE-SPAN
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FOR NATURAL RUBBER PRODUCTION
IS LIMITED TO ABOUT 25 YEARS.
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BUT MAKING TOYS
OUT OF THEIR WOOD
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GIVES UNPRODUCTIVE TREES
A SECOND LIFE.
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THIS IDEA COMES
FROM SOUTHEASTERN ASIA,
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HOME TO MOST OF THE RUBBER
AND LATEX PRODUCTION WORLDWIDE.
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THIS COMPANY,
BASED IN THAILAND,
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MANUFACTURES TOYS
SUCH AS THIS SERIES
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OF ANIMAL-SHAPED RACERS MADE
OF LOCALLY FARMED RUBBERWOOD.
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THEY BUY OLD TREES
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THAT HAVE EXCEEDED
THEIR PRODUCTIVE LIFE.
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A WORKER FEEDS LUMBER
THROUGH A WOOD-ROUNDING MACHINE.
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THE MACHINE DRIVES THE LOG
THROUGH A MILL
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AND TURNS IT INTO A ROD.
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THE WORKER PLACES THE ROD
ON A TRAY
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ALONGSIDE OTHER PIECES
READY FOR CUTTING.
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A CUTTING MACHINE AUTOMATICALLY
MATCHES THE LENGTH OF THE RODS
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WHILE A ROUND SAW
CUTS OUT BLANKS,
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WHICH ACCUMULATE IN A CRATE.
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A ROUTER REMOVES THE SHARP EDGES
ON THE BLANKS.
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STACKED IN A FEEDER TUBE,
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THE BLANKS DROP DOWN ONE
BY ONE ON THE ROUTER TABLE.
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AN AUTOMATED FEEDING MECHANISM
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PUSHES EACH BLANK
AGAINST THE ROUTER HEAD.
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THE ROUTER BLADE BITES
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INTO THE BLANK
AND TRIMS OFF THE EDGE,
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LEAVING THE PIECES
READY FOR SANDING.
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AT ANOTHER STATION, A LATHE
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TURNS SPHERICAL SHAPES
OUT OF THE WOOD.
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SEVERAL BLADES MOVE IN SEQUENCE
TO FORM THE PIECE.
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WHEN A NEW LENGTH
OF WOOD COMES THROUGH,
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THE FRONT BLADE MOVES IN.
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ONCE IT BACKS AWAY,
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ANOTHER SET OF BLADES
SHAPES THE PIECE LATERALLY
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BEFORE A CUTTER BLADE
SEPARATES IT FROM THE ROD.
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A WORKER NOW POURS A NONTOXIC,
WATER-BASED PAINT
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OVER THE SANDED BLANKS.
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HE TRANSFERS THE BATCH
INTO A TUMBLING MACHINE.
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THE TUMBLING PROCESS
WILL EVEN OUT THE COLOR
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AND DRAIN THE EXTRA PAINT
TO ACCELERATE DRYING.
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THE WORKER CLOSES AND SECURES
THE LID OF THE TUMBLER
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BEFORE HE STARTS THE MACHINE.
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THE FACILITY CAN SIMULTANEOUSLY
PROCESS 40 BATCHES
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OF PAINTED PARTS
IN 30 MINUTES.
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THE PAINTED PARTS
NOW GO TO A PAD PRINTER.
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AN AUTOMATED ARM FEEDS THE PARTS
TO THE PRINTER,
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WHICH STAMPS EACH PIECE
WITH A NONTOXIC PAINT.
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A WORKER USES A TABLE SAW
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TO GROOVE ANOTHER SET
OF PAINTED PARTS.
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THE CUSTOM-MADE JIG ENSURES THAT
THE CUT IS STRAIGHT AND EVEN
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AND THAT THE BLADE
MAKES ONLY A NARROW
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AND SHALLOW GROOVE IN THE WOOD.
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THE WORKER PLACES
THE GROOVED PART
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ON A JIG AND BORES A HOLE
INTO THE PIECE WITH A DRILL.
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THE MACHINED PIECE
GOES TO ANOTHER PAD PRINTER.
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THE PAD PICKS UP PAINT
FROM A TRAY
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AND TRANSFERS IT TO THE WOOD.
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THIS PROCESS, CALLED
TAMPOGRAPHY, ALLOWS THE PRINTER
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TO REPRODUCE A DESIGN
ON AN IRREGULAR SURFACE,
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SUCH AS THIS WOOD PIECE.
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THE PRINTED PARTS
DRY AT ROOM TEMPERATURE.
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AS A LAST PAD PRINTER
PAINTS TWO DOTS ON THE WOOD,
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THE FACE OF THE ANIMAL RACER
SLOWLY TAKES SHAPE.
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THIS RED-COLORED POWDER
IS PROCESSED RUBBERWOOD SAWDUST
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ENTIRELY RECYCLED
FROM THE MACHINING OPERATIONS.
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A WORKER FILLS MOLDS
WITH THE REPROCESSED SAWDUST
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AND PREPARES THEM FOR CASTING.
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THE MACHINE COMPRESSES
THE SAWDUST IN A DIE
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AND TURNS IT INTO A SOLID
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AND COMPACT MATERIAL
CALLED PLANWOOD.
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A WORKER STARTS ASSEMBLING
THE PLANWOOD PIECES
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TO FORM THE BODY OF THE RACERS.
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SHE APPLIES A THIN COAT
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OF NONTOXIC,
FORMALDEHYDE-FREE GLUE
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AND PRESSES TWO CORRESPONDING
PLANWOOD PIECES TOGETHER.
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SHE REMOVES THE EXCESS GLUE
WITH HER FINGER
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BEFORE SHE HAMMERS A DOWEL
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INTO THE ASSEMBLED
PLANWOOD BODY.
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TO FINISH THE HEAD
OF THE RACER,
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SHE INSERTS A FELT PIECE
INTO THE GROOVE
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MACHINED ON TOP
AND PRESSES THE HEAD
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INTO THE RACER'S BODY
USING A PNEUMATIC PRESS.
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THE WORKER THEN DRIVES THE AXLES
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THROUGH HOLES
IN THE PLANWOOD ASSEMBLY.
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SHE TAKES PAINTED
AND PAD-PRINTED WHEELS
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AND APPLIES A DROP
OF FAST-HARDENING GLUE
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INSIDE EACH WHEEL HUB.
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SHE THEN HAMMERS THE WHEELS
INTO THE AXLES
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00:05:33,689 --> 00:05:35,275
AND TAKES THE ASSEMBLED TOY
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TO A CUSTOMIZED MACHINE DESIGNED
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TO PRESS THE WHEELS
FIRMLY INTO THE AXLES.
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THIS FINISHED CHICKEN RACER
IS ONE OF A WIDE VARIETY
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OF RUBBERWOOD TOYS
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MANUFACTURED WITH
ENVIRONMENT-FRIENDLY PROCESSES
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AND MATERIALS.
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Narrator: WHETHER YOUR PREFERRED
SHADE IS LIGHT, MEDIUM, OR DARK,
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OWNING A RELIABLE ELECTRIC
TOASTER THAT EVENLY HEATS
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00:06:09,551 --> 00:06:11,793
AND BROWNS BOTH SIDES
OF YOUR BREAD JUST THE WAY
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YOU LIKE IT IS ONE
OF LIFE'S SMALL PLEASURES.
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AND IF THAT TOASTER
ADDS SOME STYLE TO YOUR KITCHEN,
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ALL THE BETTER.
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00:06:23,896 --> 00:06:27,206
MAKING RETRO-STYLE TOASTERS
IS THIS BRITISH COMPANY'S
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00:06:27,206 --> 00:06:28,586
BREAD AND BUTTER.
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WHILE SOME OF ITS MODELS
ARE NEW DESIGNS
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IN A VINTAGE STYLE,
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THIS ONE IS AUTHENTICALLY RETRO,
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IN CONTINUOUS PRODUCTION
SINCE THE 1960s.
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THE MANUFACTURING EQUIPMENT,
HOWEVER, IS MODERN.
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A COMPUTER-GUIDED LASER CUTTER
CUTS OUT MANY COMPONENTS
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00:06:46,103 --> 00:06:50,689
FROM SHEET STEEL COATED WITH
ZINC FOR CORROSION RESISTANCE.
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THEY STAMP THE COMPANY LOGO
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00:06:53,172 --> 00:06:54,758
AND THEN USE THE SAME PRESS
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TO BEGIN FORMING
A RECTANGULAR BOX.
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THEY BEND THREE SIDES
ON THIS PRESS...
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THEN BEND THE FOURTH
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ON A MACHINE
CALLED A BOX FOLDER.
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THEY RIVET THE BODY CLOSED, THEN
SPRAY ON A THICK LAYER
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OF PAINT POWDER
KNOWN AS POWDER COAT.
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THEN, THEY RUN THE BODY
THROUGH A TUNNEL OVEN
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FOR 10 MINUTES
TO BAKE THE FINISH.
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THE COMPUTER-GUIDED
LASER CUTTER ALSO
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CUTS OUT SEVERAL TOASTER TOPS
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FROM A SHEET OF STAINLESS STEEL.
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THIS MODEL
IS A FOUR-SLICE TOASTER,
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SO THE MACHINE
CUTS FOUR SLOTS PER TOP.
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TO MAKE THE MANUAL BREAD EJECTOR
THAT POPS UP THE HOT TOAST,
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THEY WELD STEEL STRIPS
TO A ROUND STEEL BAR.
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00:07:49,482 --> 00:07:52,620
MOVING THE TOASTER'S
EJECTOR KNOB LIFTS THIS BAR,
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00:07:52,620 --> 00:07:54,965
RAISING THE TOP
OF THE TOAST OUT OF THE SLOT.
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THEY BEND THE STRIPS,
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CREATING A CRADLE
TO STABILIZE THE BREAD
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00:07:59,310 --> 00:08:01,379
SO THAT IT DOESN'T WOBBLE
AND GET CAUGHT
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00:08:01,379 --> 00:08:05,758
WHILE MOVING UP AND DOWN
WITHIN THE SLOT.
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THIS MACHINE MAKES
THE TOASTER'S GUARD WIRES
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OUT OF COPPER-COATED STEEL.
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THE GUARD WIRES ARE BARRIERS
THAT PREVENT THE BREAD
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00:08:13,310 --> 00:08:16,724
FROM TOUCHING
THE TOASTER'S HEATING ELEMENTS.
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00:08:16,724 --> 00:08:19,586
THE MACHINE FIRST WELDS
CUT HORIZONTAL WIRES
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00:08:19,586 --> 00:08:22,034
TO FOUR CONTINUOUS
VERTICAL ONES.
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THEN, A BLADE
CHOPS THE VERTICAL WIRES
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00:08:24,206 --> 00:08:29,758
EVERY 12 INCHES, PRODUCING
TWO SIDE-BY-SIDE GUARD WIRES.
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00:08:29,758 --> 00:08:32,620
WORKERS CUT THEM APART
ON A GUILLOTINE, THEN,
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00:08:32,620 --> 00:08:36,206
WITH A HAND PRESS,
FOLD OVER THE TOP OF EACH ONE.
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THIS PREVENTS THE BREAD
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00:08:37,551 --> 00:08:41,137
FROM CATCHING ON THE TOP
OF THE GUARD WIRES.
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NOW THEY TAKE
THE TOASTING COMPARTMENT
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00:08:43,137 --> 00:08:45,034
AND INSERT
THE EIGHT GUARD WIRES,
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00:08:45,034 --> 00:08:48,172
ONE FOR EACH SIDE
OF THE FOUR BREAD SLOTS.
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00:08:51,793 --> 00:08:55,931
THEN, THEY INSTALL
THE BREAD EJECTOR.
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NEXT, THE HEATING ELEMENTS.
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BEING A HIGH-END TOASTER,
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00:08:59,241 --> 00:09:02,655
THE ELEMENTS ARE SHEETS
OF PURE MICA,
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00:09:02,655 --> 00:09:06,517
A MINERAL THAT'S HEAT-RESISTANT
UP TO 1,800 DEGREES FAHRENHEIT.
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THEY CONNECT THEM WITH
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ELECTRICALLY
CONDUCTIVE COPPER LINKS.
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THEY MOUNT THE SWITCH
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THAT SELECTS THE NUMBER
OF BREAD SLICES TO TOAST.
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00:09:16,172 --> 00:09:18,793
THEN, THEY INSTALL A RED NEON
LIGHT THAT ILLUMINATES
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00:09:18,793 --> 00:09:21,103
WHEN YOU START THE TOASTER
AND TURNS OFF
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00:09:21,103 --> 00:09:23,931
WHEN THE TOAST TIME HAS ELAPSED.
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THE TIMER SWITCH HAS A BELL
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00:09:25,551 --> 00:09:28,172
THAT SOUNDS WHEN
THE TOAST TIME IS UP,
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00:09:28,172 --> 00:09:32,517
AT WHICH POINT THE SWITCH CUTS
THE CURRENT TO THE ELEMENTS.
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00:09:32,517 --> 00:09:35,241
THEY ATTACH THE DIALS
FOR THE SLICE SELECTOR
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00:09:35,241 --> 00:09:36,931
AND TIMER SWITCHES
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00:09:36,931 --> 00:09:39,344
AND CONNECT THEIR WIRES
TO THE MAIN POWER CORD.
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00:09:41,758 --> 00:09:43,551
THEN, THEY PLACE
THE TOASTER COMPARTMENT
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00:09:43,551 --> 00:09:47,482
INTO THE BODY AND SCREW ON
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00:09:47,482 --> 00:09:49,655
THE TOASTER'S
STAINLESS STEEL TOP,
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THE PROTECTIVE FILM NOW REMOVED.
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THEY FLIP THE TOASTER
UPSIDE DOWN
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00:09:59,586 --> 00:10:01,413
AND WIRE UP THE ELEMENTS.
175
00:10:05,689 --> 00:10:07,517
THEY INSTALL THE EJECTOR KNOB,
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00:10:07,517 --> 00:10:11,482
POSITIONING ITS SPRING
AGAINST THE BREAD EJECTOR.
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00:10:11,482 --> 00:10:15,068
WHEN THE BELL RINGS,
INDICATING YOUR TOAST IS READY,
178
00:10:15,068 --> 00:10:19,896
YOU MOVE THE KNOB TO RAISE
AND RETRIEVE YOUR SLICES.
179
00:10:19,896 --> 00:10:22,827
A TECHNICIAN TESTS THE TOASTER
THOROUGHLY, ENSURING
180
00:10:22,827 --> 00:10:25,206
THAT ALL OF THE ELEMENTS HEAT
TO THE CORRECT TEMPERATURE,
181
00:10:25,206 --> 00:10:28,034
THAT ONLY THE SELECTED
SLOTS HEAT UP,
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00:10:28,034 --> 00:10:29,965
THAT THE TIMER IS ACCURATE,
183
00:10:29,965 --> 00:10:34,448
AND THAT THE BELL RINGS
WHEN THE SELECTED TIME ELAPSES.
184
00:10:35,793 --> 00:10:38,068
THEY INSTALL THE REMOVABLE
CRUMB TRAY,
185
00:10:38,068 --> 00:10:40,068
THEN CLOSE UP THE BOTTOM
OF THE TOASTER
186
00:10:40,068 --> 00:10:42,724
WITH A VENTILATED BASE PLATE.
187
00:10:42,724 --> 00:10:46,206
NYLON FEET ELEVATE
THE TOASTER FOR VENTILATION
188
00:10:46,206 --> 00:10:48,344
AND TO PREVENT THE SCREWS
ATTACHING THE BASE
189
00:10:48,344 --> 00:10:50,655
FROM SCRATCHING
YOUR KITCHEN COUNTER.
190
00:10:50,655 --> 00:10:53,551
THE STYLE MAY BE RETRO,
191
00:10:53,551 --> 00:10:57,310
BUT THIS 1960s-DESIGN TOASTER
WAS AHEAD OF ITS TIME
192
00:10:57,310 --> 00:10:59,862
WITH ITS ENERGY-SAVING
SLICE-SELECTOR FEATURE
193
00:10:59,862 --> 00:11:02,068
THAT STOPS THE TOASTER'S
EMPTY SLOTS
194
00:11:02,068 --> 00:11:04,448
FROM HEATING UP UNNECESSARILY.
195
00:11:17,379 --> 00:11:18,896
Narrator: LABORATORY FURNACES
196
00:11:18,896 --> 00:11:20,896
ARE SMALL
BUT POWERFUL APPLIANCES.
197
00:11:20,896 --> 00:11:22,586
THEY CAN REACH TEMPERATURES
198
00:11:22,586 --> 00:11:25,172
OF 3,000 DEGREES
FAHRENHEIT OR MORE.
199
00:11:25,172 --> 00:11:27,862
THESE INCREDIBLE FURNACES
ARE OFTEN USED TO TEST
200
00:11:27,862 --> 00:11:32,034
THE QUALITY OF THINGS
LIKE FUEL OIL, GREASES, COAL,
201
00:11:32,034 --> 00:11:35,344
AND TO CONFIRM THE STRENGTH
OF STRUCTURAL MATERIALS.
202
00:11:39,344 --> 00:11:43,310
EXPOSED TO THE RED-HOT INTENSITY
OF A LABORATORY FURNACE,
203
00:11:43,310 --> 00:11:44,620
THIS PIECE OF STEEL
204
00:11:44,620 --> 00:11:48,034
SHOULD ENDURE AND EVEN
BE STRENGTHENED BY THE EXPOSURE.
205
00:11:48,034 --> 00:11:52,137
IT'S THE ULTIMATE TEST
OF THE STEEL'S INTEGRITY.
206
00:11:52,137 --> 00:11:56,172
MAKING A LABORATORY FURNACE
STARTS WITH THIS LASER CUTTER.
207
00:11:56,172 --> 00:12:00,172
IT CARVES OUT STEEL PANELS
FOR THE LOWER CABINET.
208
00:12:00,172 --> 00:12:02,655
A PRESS BRAKE FOLDS THE PANELS
WITH PRECISION
209
00:12:02,655 --> 00:12:06,793
TO MAKE THREE-SIDED PIECES
OF CABINETRY.
210
00:12:06,793 --> 00:12:10,241
A WORKER STACKS THEM UP.
211
00:12:10,241 --> 00:12:12,206
THE NEXT WORKER
APPLIES A POWDER COAT
212
00:12:12,206 --> 00:12:16,689
TO THE METAL PARTS
USING A COMPRESSED-AIR SPRAYER.
213
00:12:16,689 --> 00:12:22,310
WHEN BAKED ON, THE POWDER FORMS
A TOUGH THERMOPLASTIC SKIN.
214
00:12:22,310 --> 00:12:24,034
AT THE NEXT STATION, A WORKER
215
00:12:24,034 --> 00:12:26,241
TUCKS THE END
OF AN IRON ALLOY WIRE
216
00:12:26,241 --> 00:12:29,172
INTO A LATHE.
217
00:12:29,172 --> 00:12:30,724
AS THE LATHE SPINS,
218
00:12:30,724 --> 00:12:33,103
IT WINDS THE WIRE
AROUND A MANDREL,
219
00:12:33,103 --> 00:12:35,517
PRODUCING A TIGHT COIL.
220
00:12:35,517 --> 00:12:37,344
THIS COILED WIRE WILL SERVE
221
00:12:37,344 --> 00:12:41,517
AS ONE OF THE FURNACE'S
TWO HEATING ELEMENTS.
222
00:12:41,517 --> 00:12:44,241
AFTER STRETCHING THE COIL
TO WIDEN THE GAPS
223
00:12:44,241 --> 00:12:47,034
AND BENDING IT
TO CREATE PARALLEL ROWS,
224
00:12:47,034 --> 00:12:51,310
THE TECHNICIAN
ATTACHES ELECTRICAL CLIPS.
225
00:12:51,310 --> 00:12:52,620
HE FLIPS A SWITCH.
226
00:12:52,620 --> 00:12:55,206
AND ELECTRICITY
SURGES THROUGH THE COIL.
227
00:12:55,206 --> 00:12:57,413
THIS RELIEVES STRESSES
IN THE METAL CAUSED
228
00:12:57,413 --> 00:12:59,344
BY THE WINDING AND BENDING.
229
00:13:01,896 --> 00:13:05,482
HE NOW INSERTS TWO COILS
INTO THE RIDGES OF THE MOLD.
230
00:13:05,482 --> 00:13:10,586
HE TRANSFERS IT TO A VAT FILLED
WITH A CERAMIC FIBER MIXTURE.
231
00:13:10,586 --> 00:13:13,965
A POWERFUL VACUUM PUMP
PULLS THE MIXTURE INTO THE MOLD,
232
00:13:13,965 --> 00:13:15,793
FILLING ALL THE CREVICES.
233
00:13:15,793 --> 00:13:18,620
THE VACUUM THEN
DRAWS OUT THE MOISTURE.
234
00:13:18,620 --> 00:13:22,793
THE COILS ARE NOW EMBEDDED
IN A CERAMIC CAKE.
235
00:13:22,793 --> 00:13:24,758
THIS CAKE BAKES
IN AN OVEN OVERNIGHT
236
00:13:24,758 --> 00:13:26,137
AND SOLIDIFIES,
237
00:13:26,137 --> 00:13:30,206
ENCASING AND INSULATING
THE HEATING COILS.
238
00:13:30,206 --> 00:13:33,827
A WORKER CUTS THE SOLID
CERAMIC-FIBER BLOCK IN TWO,
239
00:13:33,827 --> 00:13:36,586
CREATING
TWO SEPARATE HEATING MODULES.
240
00:13:36,586 --> 00:13:40,275
HE TRIMS THEM SO THEY FIT NEATLY
IN THE FURNACE CHAMBER.
241
00:13:40,275 --> 00:13:43,379
A COMPUTERIZED ROUTER
CUTS OUT OTHER INSULATION PIECES
242
00:13:43,379 --> 00:13:47,000
TO FIT THE REST
OF THE FURNACE CHAMBER.
243
00:13:47,000 --> 00:13:51,172
THIS CERAMIC BRICK
IS A THRESHOLD INSULATOR.
244
00:13:51,172 --> 00:13:54,034
THIS PIECE IS A SURROUND
FOR THE FURNACE DOOR.
245
00:13:54,034 --> 00:13:57,068
A TEAM NOW PUTS ALL THE CERAMIC
FIBER PIECES TOGETHER
246
00:13:57,068 --> 00:14:00,379
IN A METAL FRAMEWORK.
247
00:14:00,379 --> 00:14:02,586
THE HEATING ELEMENT BLOCKS
FORM THE SIDES
248
00:14:02,586 --> 00:14:04,551
OF THE FURNACE CHAMBER.
249
00:14:04,551 --> 00:14:06,551
THEY THREAD THE WIRES
FROM THE COILS
250
00:14:06,551 --> 00:14:08,896
THROUGH THE BACK PANEL.
251
00:14:08,896 --> 00:14:10,862
THEY INSERT THE SIDE
AND BACK PANELS
252
00:14:10,862 --> 00:14:12,931
IN THE FRAMEWORK.
253
00:14:12,931 --> 00:14:15,137
THEY ASSEMBLE THE OTHER
CERAMIC FIBER PARTS
254
00:14:15,137 --> 00:14:18,413
TO FORM AN INSULATED CHAMBER.
255
00:14:18,413 --> 00:14:20,551
THEY SCREW THE FRAMEWORK TIGHT,
256
00:14:20,551 --> 00:14:22,655
AND THIS NESTLES
THE CERAMIC-FIBER WALLS
257
00:14:22,655 --> 00:14:26,206
MORE CLOSELY TOGETHER.
258
00:14:26,206 --> 00:14:29,586
THEY TUCK THE THRESHOLD
INSULATOR INTO PLACE,
259
00:14:29,586 --> 00:14:32,724
COMPLETING THE LABORATORY
FURNACE'S HEATED CHAMBER.
260
00:14:35,482 --> 00:14:38,275
A TECHNICIAN NOW PLACES
THE FURNACE'S
261
00:14:38,275 --> 00:14:41,896
ELECTRIC HEATING CONTROL PANEL
IN THE LOWER CABINET.
262
00:14:41,896 --> 00:14:46,241
HE FASTENS IT TO THE METAL
CABINET WITH SCREWS.
263
00:14:46,241 --> 00:14:49,827
HE WIRES THE TEMPERATURE-CONTROL
BOARD TO A TOUCH SCREEN
264
00:14:49,827 --> 00:14:53,551
AND CONNECTS THE POWER SUPPLY
FOR THE TOUCH SCREEN.
265
00:14:53,551 --> 00:14:58,793
HE INSTALLS A STAINLESS STEEL
SHELF ON TOP, TOWARDS THE FRONT.
266
00:14:58,793 --> 00:15:00,103
HE SCREWS THE FRONT PANEL
267
00:15:00,103 --> 00:15:04,655
THAT HOUSES THE TOUCH SCREEN
TO THE CABINET.
268
00:15:04,655 --> 00:15:05,827
HE ADDS THE TOP PANEL
269
00:15:05,827 --> 00:15:09,103
THAT THE FURNACE CHAMBER
WILL SIT ON.
270
00:15:09,103 --> 00:15:11,620
HE ASSEMBLES THE METAL SURROUND
FOR THE FURNACE CHAMBER
271
00:15:11,620 --> 00:15:14,034
TO THE CONTROL CABINET,
272
00:15:14,034 --> 00:15:16,793
THEN SLIDES THE FURNACE CHAMBER
INTO PLACE.
273
00:15:19,724 --> 00:15:22,793
MOVING TO THE OPEN BACK,
HE WIRES THE HEATING ELEMENTS
274
00:15:22,793 --> 00:15:25,827
FOR POWER AND INSERTS
A TEMPERATURE SENSOR
275
00:15:25,827 --> 00:15:28,448
INTO A HOLE IN THE CENTER
OF THE CHAMBER.
276
00:15:31,241 --> 00:15:33,034
HE ASSEMBLES A CONNECTOR BLOCK,
277
00:15:33,034 --> 00:15:34,793
WHICH WILL RELAY
THE SENSOR SIGNAL
278
00:15:34,793 --> 00:15:38,137
TO THE CONTROLLER.
279
00:15:38,137 --> 00:15:42,172
HE ENCLOSES THE BACK
WITH ANOTHER METAL PANEL.
280
00:15:42,172 --> 00:15:45,758
THE NEXT TECHNICIAN HINGES
THE DOOR TO THE METAL SURROUND.
281
00:15:45,758 --> 00:15:47,620
THE DOOR IS A METAL STRUCTURE
282
00:15:47,620 --> 00:15:52,172
THAT'S FILLED WITH MANY LAYERS
OF CERAMIC-FIBER INSULATION.
283
00:15:52,172 --> 00:15:53,689
HE LOWERS AND RAISES THE DOOR
284
00:15:53,689 --> 00:15:56,517
TO CONFIRM
THAT IT OPERATES SMOOTHLY.
285
00:15:56,517 --> 00:16:01,344
THIS METAL COVER
IS THE FINISHING TOUCH.
286
00:16:01,344 --> 00:16:07,172
HE SNAPS IT ONTO THE DOOR
AND SECURES IT WITH SCREWS.
287
00:16:07,172 --> 00:16:10,000
THE LABORATORY FURNACE'S
THICK, INSULATED CHAMBER
288
00:16:10,000 --> 00:16:12,241
IS READY TO CONTAIN
THE EXTREME HEAT
289
00:16:12,241 --> 00:16:14,689
AND MAINTAIN IT.
290
00:16:14,689 --> 00:16:16,068
AND THESE TORRID CONDITIONS
291
00:16:16,068 --> 00:16:18,862
ARE IDEAL
FOR QUALITY-CONTROL TESTING.
292
00:16:31,965 --> 00:16:34,793
Narrator: AEROGELS ARE
THE LIGHTEST SOLID MATERIALS
293
00:16:34,793 --> 00:16:36,172
ON EARTH.
294
00:16:36,172 --> 00:16:38,965
THEY HAVE NANOSIZED PORES
THAT MAKE IT DIFFICULT
295
00:16:38,965 --> 00:16:41,448
FOR COLD OR HOT AIR
TO PENETRATE.
296
00:16:41,448 --> 00:16:44,586
USED TO INSULATE THE ELECTRONICS
OF THE MARS ROVERS
297
00:16:44,586 --> 00:16:46,551
AND TO CAPTURE COMET DUST,
298
00:16:46,551 --> 00:16:50,000
AEROGELS ARE AMONG THE MOST
FASCINATING MATERIALS.
299
00:16:52,241 --> 00:16:56,034
AEROGELS IN SHAPED FORMS
LOOK ALMOST LIKE HOLOGRAMS.
300
00:16:56,034 --> 00:16:58,310
YET THEY FEEL LIKE HARD FOAM.
301
00:16:58,310 --> 00:17:03,068
IT'S WHY THEY ARE OFTEN CALLED
FROZEN SMOKE OR SOLID SMOKE.
302
00:17:03,068 --> 00:17:05,310
MAKING THEM STARTS
WITH FOUR INGREDIENTS --
303
00:17:05,310 --> 00:17:08,068
A CHEMICAL CALLED
TMOS, METHANOL,
304
00:17:08,068 --> 00:17:10,551
CONCENTRATED AMMONIA, AND WATER.
305
00:17:13,379 --> 00:17:17,103
THE TECHNICIAN ADDS MEASURED
AMOUNTS OF TMOS AND METHANOL
306
00:17:17,103 --> 00:17:19,241
TO A BEAKER
THAT HAS A MAGNETIC STIR BEAD
307
00:17:19,241 --> 00:17:20,551
AT THE BOTTOM.
308
00:17:20,551 --> 00:17:21,965
HE TRANSFERS THE BEAKER
309
00:17:21,965 --> 00:17:25,827
TO A DEVICE THAT GENERATES
A ROTATING MAGNETIC FIELD.
310
00:17:25,827 --> 00:17:27,413
THIS CAUSES THE BEAD
IN THE BOTTLE
311
00:17:27,413 --> 00:17:29,896
TO EVENLY MIX THE INGREDIENTS.
312
00:17:29,896 --> 00:17:32,482
HE POURS THE MIXTURE
INTO A LARGER BEAKER
313
00:17:32,482 --> 00:17:35,103
AND ADDS SPECIFIC AMOUNTS
OF WATER,
314
00:17:35,103 --> 00:17:38,344
ADDITIONAL METHANOL,
AND AMMONIA HYDROXIDE.
315
00:17:38,344 --> 00:17:43,586
AS THE INGREDIENTS ARE BLENDED,
A CHEMICAL REACTION OCCURS.
316
00:17:43,586 --> 00:17:47,206
THE TMOS AND WATER
REACT TO FORM SILICA.
317
00:17:47,206 --> 00:17:48,586
THE CHEMICAL REACTION
318
00:17:48,586 --> 00:17:52,137
WILL ALSO CAUSE THE MIXTURE
TO BECOME A GEL.
319
00:17:52,137 --> 00:17:56,103
BUT BEFORE THAT HAPPENS,
HE QUICKLY PREPARES THE MOLDS.
320
00:17:56,103 --> 00:17:59,862
HE POURS PURE METHANOL
OVER A PLASTIC GRID
321
00:17:59,862 --> 00:18:03,379
AND ARRANGES RECTANGULAR MOLDS
OVER THE GRID.
322
00:18:03,379 --> 00:18:06,275
HE INJECTS PRECISE AMOUNTS
OF THE SILICA GEL MIX
323
00:18:06,275 --> 00:18:07,862
INTO THE MOLDS
324
00:18:07,862 --> 00:18:09,931
AND LEAVES THEM TO GEL.
325
00:18:09,931 --> 00:18:12,862
DURING THIS PROCESS,
THE METHANOL UNDER THE GRID
326
00:18:12,862 --> 00:18:17,379
EVAPORATES, PREVENTING
EXCESSIVE DRYING OF THE GELS.
327
00:18:17,379 --> 00:18:20,586
THE MIXTURE COAGULATES
IN JUST MINUTES,
328
00:18:20,586 --> 00:18:22,034
BUT IT TAKES ABOUT A DAY
329
00:18:22,034 --> 00:18:25,275
FOR THE GELS
TO FULLY STRENGTHEN.
330
00:18:25,275 --> 00:18:28,724
HE THEN SOAKS THE SILICA GELS
IN METHANOL BATHS REPEATEDLY
331
00:18:28,724 --> 00:18:31,689
OVER A PERIOD OF SEVERAL DAYS.
332
00:18:31,689 --> 00:18:34,068
THE METHANOL SEEPS
IN THE GEL'S PORES
333
00:18:34,068 --> 00:18:36,931
TO FLUSH OUT IMPURITIES.
334
00:18:36,931 --> 00:18:39,551
THE GEL PORES ARE SO MINUSCULE
335
00:18:39,551 --> 00:18:42,758
THEY CAN'T BE SEEN
WITH THE NAKED EYE.
336
00:18:42,758 --> 00:18:47,241
THE TECHNICIAN DECANTS THE USED
METHANOL INTO A CONTAINER.
337
00:18:47,241 --> 00:18:50,241
HE'LL SEND IT TO A RECYCLER
TO REMOVE IMPURITIES,
338
00:18:50,241 --> 00:18:52,344
AND THIS WILL ALLOW IT
TO BE USED AGAIN
339
00:18:52,344 --> 00:18:56,275
IN THE AEROGEL PRODUCTION
PROCESS.
340
00:18:56,275 --> 00:18:58,586
AFTER SEVERAL DAYS
OF SOAKING IN METHANOL,
341
00:18:58,586 --> 00:19:01,379
THE SILICA GELS ARE PURIFIED.
342
00:19:01,379 --> 00:19:05,896
THEY'RE READY FOR A PROCESS
KNOWN AS SUPERCRITICAL DRYING.
343
00:19:05,896 --> 00:19:11,034
IT'S A PROCESS THAT WILL CONVERT
THESE SILICA GELS INTO AEROGELS.
344
00:19:11,034 --> 00:19:14,172
A TECHNICIAN PLACES THE GELS
IN A PRESSURE VESSEL.
345
00:19:14,172 --> 00:19:18,068
HE LOCKS THE HEAVY STEEL LID
WITH 12 LARGE BOLTS AND NUTS
346
00:19:18,068 --> 00:19:20,275
SO IT WILL HOLD TIGHT
AGAINST A PRESSURE
347
00:19:20,275 --> 00:19:25,827
THAT'S 100 TIMES GREATER THAN
THAT OF THE NORMAL ATMOSPHERE.
348
00:19:25,827 --> 00:19:27,931
HE CONNECTS THE HOSE
THAT DELIVERS LIQUID
349
00:19:27,931 --> 00:19:31,241
AND CARBON DIOXIDE
TO THE VESSEL.
350
00:19:31,241 --> 00:19:34,137
THE LIQUID CARBON DIOXIDE
REPLACES THE METHANOL
351
00:19:34,137 --> 00:19:36,103
IN THE GEL'S PORES.
352
00:19:36,103 --> 00:19:38,689
THEY THEN HEAT
AND PRESSURIZE THE GELS
353
00:19:38,689 --> 00:19:42,448
UNTIL THE CARBON DIOXIDE
IN THEM BECOMES SUPERCRITICAL.
354
00:19:42,448 --> 00:19:44,689
IT'S SEMILIQUID, SEMIGAS.
355
00:19:47,206 --> 00:19:49,275
THE SUPERCRITICAL CARBON DIOXIDE
356
00:19:49,275 --> 00:19:54,724
DIFFUSES OUT WITHOUT COLLAPSING
THE GELS' SOLID SKELETONS.
357
00:19:54,724 --> 00:19:56,965
THIS TRANSFORMS THE SILICA GELS
358
00:19:56,965 --> 00:20:00,000
INTO TRANSPARENT SOLIDS
THAT ARE MOSTLY AIR.
359
00:20:04,689 --> 00:20:06,793
TO DEMONSTRATE
THE INSULATING PROPERTIES
360
00:20:06,793 --> 00:20:08,586
OF THE NANOSIZED PORES,
361
00:20:08,586 --> 00:20:11,310
THEY AIM A BLOWTORCH
UNDER AN AEROGEL
362
00:20:11,310 --> 00:20:13,206
WITH A PEANUT BUTTER CUP
ON THE TOP.
363
00:20:13,206 --> 00:20:16,310
IT DOESN'T MELT.
364
00:20:16,310 --> 00:20:19,586
A TECHNICIAN THEN
PLACES THE AEROGEL ON A SCALE
365
00:20:19,586 --> 00:20:22,172
TO CONFIRM ITS INCREDIBLE
LOW DENSITY.
366
00:20:22,172 --> 00:20:26,034
THIS AEROGEL WEIGHS LESS
THAN A NICKEL.
367
00:20:26,034 --> 00:20:27,896
NEXT, USING A SCOOPULA,
368
00:20:27,896 --> 00:20:30,068
WHICH IS A TOOL
WITH A V-SHAPED DENT,
369
00:20:30,068 --> 00:20:33,758
SHE BREAKS AN AEROGEL
INTO LITTLE PIECES.
370
00:20:33,758 --> 00:20:35,034
SHE INSERTS THE BITS
371
00:20:35,034 --> 00:20:39,689
INTO A GLASS TUBE
WITH A BULB AT THE BASE.
372
00:20:39,689 --> 00:20:41,896
SHE TRANSFERS THE TUBE
TO A MACHINE
373
00:20:41,896 --> 00:20:44,137
THAT MEASURES
HOW MUCH NITROGEN GAS
374
00:20:44,137 --> 00:20:47,137
THE AEROGEL BITS TAKE UP
AT DIFFERENT PRESSURES
375
00:20:47,137 --> 00:20:48,931
TO DETERMINE THE SIZE
OF THE PORES
376
00:20:48,931 --> 00:20:52,034
AND THE SURFACE AREA.
377
00:20:52,034 --> 00:20:55,172
AEROGELS CAN HAVE
OTHER MAGICAL PROPERTIES.
378
00:20:55,172 --> 00:20:56,655
TO DEMONSTRATE,
379
00:20:56,655 --> 00:21:02,103
SHE RUBS SPECIALLY TREATED
AEROGEL PARTICLES ON HER HANDS.
380
00:21:02,103 --> 00:21:05,000
SHE THEN PLUNGES HER HANDS
INTO WATER.
381
00:21:05,000 --> 00:21:08,172
THE AEROGEL PARTICLES
ACT LIKE WATERPROOF GLOVES
382
00:21:08,172 --> 00:21:11,379
AND REPEL THE WATER.
383
00:21:11,379 --> 00:21:14,310
THIS WATER RESISTANCE
MAKES AEROGELS USEFUL
384
00:21:14,310 --> 00:21:16,655
FOR A VARIETY OF APPLICATIONS.
385
00:21:16,655 --> 00:21:17,965
THEY CAN BE ADDED TO PAINT
386
00:21:17,965 --> 00:21:20,137
OR OTHER THINGS
TO MAKE THEM WATERPROOF
387
00:21:20,137 --> 00:21:23,310
AND ADD INSULATING PROPERTIES.
388
00:21:23,310 --> 00:21:27,931
SCIENTISTS CONTINUE TO EXPLORE
THE POTENTIAL OF AEROGELS.
389
00:21:27,931 --> 00:21:30,793
A GOSSAMER SYNTHETIC MATERIAL
THAT WEIGHS ALMOST NOTHING,
390
00:21:30,793 --> 00:21:33,758
THERE'S A LOT MORE
TO THEM THAN IT MAY SEEM.
31008
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