♪♪
Narrator: ceramic is one
of the best insulation materials
In the world.
Grills made with ceramic bodies
can bake, roast, smoke,
And, of course, grill food.
Ceramic grills retain more heat
than metal ones,
Resulting in a juicier,
more flavorful meal.
Ceramic grills
use natural-lump charcoal.
Natural charcoal is made
by carbonizing wood
Through a specialized
heating process.
Cooking with natural charcoal
Is just like cooking
over a campfire.
At this factory,
they begin by making a slurry.
The main ingredients
are water, clay, feldspar,
And other raw materials.
When the slurry is fired
at a high temperature,
It hardens
into ceramic material.
Another team assembles
the two-part plaster mold
To cast the base of the grill.
After cleaning off residue
from the previous casting,
They clamp the parts together.
The mold has two funnels.
One funnel pumps
the slurry into the mold.
The other allows air to exit
as the slurry fills the gap
Between the two parts
of the mold.
They let the slurry set
for several hours.
The plaster mold absorbs 80%
of the water,
Leaving a firm but damp casting.
They remove the top part
of the mold
And trim off
any excess material.
They cut out a rectangular hull
for the sliding draft door.
The door allows cold air
to enter the grill.
Then a worker uses a vacuum
attached to a hoist
To remove the heavy grill base
from the mold.
They repeat this casting process
For the other ceramic parts
of the grill,
Including the top called
the dome and the fire box,
Which sits inside the base
and holds the charcoal.
After each casting,
They scrape and sand
away the excess material.
They roll the cast parts
into a dryer
To remove
the remaining moisture.
For the next 30 hours,
Blowers circulate air
That's heated to
After the parts cool,
the base and dome
Undergo a final touch up to
perfect their exterior surfaces.
Next, the parts are taken
to an automated glazing station.
A conveyor spins the parts
under a shower of ceramic glaze.
A worker checks the coverage
And sprays a touch up
where required.
The glaze dries
in about 20 seconds.
Workers vacuum up the excess...
...then temporarily assemble
the grill for firing.
They place the fire box
inside the base,
The base plate
at the bottom of the fire box,
And the dome on top of the base.
They fire the grills
in a huge kiln for 24 hours.
They gradually increase
the temperature
To more than
Hold it there for a set time,
then gradually cool it down.
This firing process
triggers a chemical reaction
That transforms
the clay-based slurry
Into hard, heat-resistant
ceramic.
It also turns the glaze
on the surface into black glass.
After firing,
They attach the stainless steel
draft door to the base.
They spread adhesive
on the top edge of the base...
...and apply a gasket
made of heat-resistant material.
This creates an air seal
between the base and the dome.
Then they attach the two parts
with a hinge.
They insert the fire box
and stamp it.
Then they glue a gasket
around the neck of the dome
And install the top vent.
They place the cast-iron grate
that holds the charcoal
And the porcelain-coated cooking
grates inside the grill.
The cast-iron grate
holds the charcoal.
The porcelain-coated grate
is for cooking.
Finally,
they install the thermometer.
After lighting the charcoal,
Grillers can adjust the air flow
with the draft door
And top vent.
The draft door and top vent
Must be fully closed
to shut off the grill.
This cuts off the air supply
and extinguishes the fire.
Narrator: many factories
Use punching machines
to make the parts they need.
Older punching machines
consisted of a large press
Powered by a separate hydraulic
or pneumatic system.
Today's smaller
punching machines
Contain both of these components
in a single device.
These punching machines
are used in factories
That make aluminum window
and door frames.
A factory worker inserts
A strip of extruded aluminum
in the machine
And presses a foot pedal.
The punch strikes the die,
making the required cut.
They construct the machine
out of steel and aluminum,
Both of which arrive
at the factory as solid bars.
First they saw the bars
into smaller pieces
So they can make the machine's
various components.
They place the aluminum pieces
In a computer-guided
milling machine.
It uses a series of tools
to shape the metal
Into a specific component.
This piece is called
a punch guide.
Its job is to align
the punch tool
So that it strikes the die
correctly.
A worker grinds the edges
of the part
Until they're smooth.
A different milling machine
cuts more resilient parts
Out of steel bars.
It, too, is computer guided
And follows
technical specifications.
This steel component
is the punch tool.
It strikes through a steel die
manufactured the same way.
Every machine part
Undergoes a meticulous
quality-control inspection.
This computer-guided sensor
checks each piece.
Once all the parts
have passed testing,
Workers begin assembling.
The machine's base houses
the air cylinder.
They position the die
on top of the base
And screw it in place.
Then they install the punch,
Carefully centering it
over the die.
A worker hooks up hoses
to the air cylinder.
He tests everything
To make sure it's properly
aligned with the die,
Then he fastens it with screws.
They install the floor
of the machine's second level.
A machine can hold up
to three different dies
On three separate levels.
They position the second die
on the guide pins,
Then install the ceiling
of the second level.
They glue the punches
to the ceiling.
This level has several punches,
Allowing the machine
to make different cuts
Using the same die.
The cuts can be simultaneous
or continuous.
They install a punch selector
Which allows users to activate
or deactivate each punch.
Once installation is complete,
They test the alignment
of the punches.
Then they mount safety covers
on the machine.
They prevent workers' hands
From accidentally getting caught
between a punch and die.
Next, they make the pneumatic
system that powers the machine.
First, they attach air hoses
to the foot pedal.
The operator will step on
the pedal
To punch out the metal.
Then they hook up the other end
of the hoses
To the compressed air-supply
line.
Now the pneumatic
punching machine
Is ready to be used
at the window-and-door factory.
A worker inserts a strip
of extruded aluminum
Into the first die
to notch the end,
Then into the second die
To punch three holes
to join the window-frame parts.
Finally, the third die
punches three screw holes
On the opposite side.
The machine saves time
Because they don't have
to switch dies between each cut.
Narrator: water is essential
to life on earth.
We need it to survive,
But we also use it
for entertainment.
Water-jet fountains
captivate audiences
With incredible displays.
Some even use lights
to change the appearance
Of the water's color.
♪♪
These water-jet fountains
send spiraling ribbons of color
Into the air.
The effect is magical.
Production starts
with this cast-bronze part.
Computerized tools
Transform it it into a flange
that will be installed on-site.
The flange is designed
to prevent leaks where the pipe
Meets the concrete pool.
The next part
is a stainless-steel faceplate
For the fountain.
An employee places it
on a template,
Closes a u.v.-Light shield,
and activates a laser.
The laser etches
product information
Into the steel.
This branding is permanent
and won't wear off.
Next, a technician assembles
the colored l.e.d. Lights.
He connects the circuitry
to a cable,
Then slides the bulb and its
housing on to the circuitry.
He screws a metal ring
on to the base
To keep the light watertight.
He immerses the light
in a clear water tank
To test it.
He switches on a vacuum
to suck air out of the tank,
Simulating underwater pressure.
He checks for bubbles
around the light,
Which would indicate a leak.
He programs the light
For the water show so that
different colors flash on cue.
The next employee
prepares an epoxy sealant.
He pours the epoxy
Into the solenoid controller
for the water-fountain jets.
It takes two hours to dry.
Once solidified,
It will protect the components
from water damage.
Then he assembles the carriage
for the fountain jets.
He places the carriage
on a spring-loaded slide
And secures
it with long-threaded rods.
The worker applies sealant
to the ends of the rods
And screws on the nuts.
He installs a plastic
nozzle cup.
He secures it to the carriage
With a center pin
that has a swiveling mechanism.
He transfers
the carriage assembly
To a water-distribution manifold
And screws it in place.
He tests the carriage
And confirms that it
slides freely on the springs.
Then he runs plastic tubing
From the water-distribution
manifold
To the spouts
of the nozzle cups.
The worker secures the joints
with plastic zip ties.
Then he trims the ties
using a special g*n.
He attaches the solenoid
controller to the carriage
And connects the controller
to the various air tubes
That lead to the waterspouts.
He places the water-jet assembly
On the back
of a steel mounting plate
And secures it with screws.
He inserts two l.e.d. Lights
in specially designed slots,
Then screws them in place.
This water-jet fountain
is now complete.
He hooks it up to a compressed
air source for a dry-bench test.
He confirms that the compressed
air moves the carriage correctly
In the programmed sequence.
He also connects the water jet
to a mechanical sequencer
To verify that it's functional.
After it passes the tests,
He seals the perimeter
of the jet with a rubber gasket
And the faceplate.
This water-jet fountain
is ready for installation.
When combined
with other fountains,
It will put on quite a show.
Onlookers will be so engaged,
They won't mind
getting a little wet.
Narrator: people have been
surfing on wooden boards
For thousands of years.
These early surfboards
Were heavy because they were
made of solid wood.
Today, surfers
are taking this classic material
And giving it a modern twist,
Creating beautiful,
lightweight boards
From sustainable resources.
When most people
think of surfboards,
They picture
brightly colored boards
Made of foam and fiberglass.
But wooden surfboards are making
a not-so-surprising comeback.
Every waterborne vessel
was originally made from trees
Because,
no matter what, wood floats.
They start by gluing two planks
of poplar to a strip of oak.
Using a template,
A craftsman draws the shape
he wants for the surfboard.
He uses a japanese pull saw
to cut the shape out by hand.
This is the basic outline
of the surfboard.
A cnc router
quickly and accurately cuts
The inner support framework
from poplar plywood.
The builder sources wood
From suppliers who use
sustainable forestry practices.
Using his pull saw,
the craftsman
Carefully frees the pieces
of the support framework.
Then he smoothes the edges
with a block sander.
He begins fitting the pieces
together to form the framework.
For the spine, the builder
uses fast-drying superglue.
It bonds powerfully and quickly,
allowing him to work fast.
After completing the spine,
He starts gluing
and inserting the ribs.
The finished frame resembles
the skeleton of a large fish.
Once the support structure
has dried, the craftsman
Places it on the bottom skin
of the surfboard.
He positions it carefully
And securely clamps it in place
on a purpose-built jig.
Then he traces the lines
of the frame on to the skin.
He measures and marks
a set distance
From the end of each rib.
He squeezes a bead
Of epoxy-based glue
over the network of lines
Before lifting the frame
into position on the skin.
He clamps everything down
and lets it dry overnight.
The sides of the surfboard,
called the rails,
Consist of 12 strips of wood
glued and clamped together.
The rails take several days
to make.
After that process is complete,
The builder lays a bead
of polyurethane glue
On the frame and rails.
Then he lowers the surfboard's
top skin into position
And secures it with dozens
of clamps.
He lets the fully assembled
board dry overnight.
Now the board is ready for
the last phase of production.
First, the craftsman shapes
and smoothes the wood
To give the object
its final shape.
He trims the excess wood
off the sides using the rails
As a cutting guide.
He rounds the top edges
of the board
With a small,
japanese-made wood plane.
The builder also uses
a special tool called a saw rasp
To finish the edges.
He uses a square
to make sure the bottom and top
Are even
when shaping the nose and tail.
The saw rasp allows him
to quickly and efficiently
Bring the board
to its final shape.
Next, the craftsman
uses a sanding block
With increasingly finer
grits of sandpaper
To create a smooth surface.
He signs the bottom of the board
with a pencil,
Then burns it into the wood with
a tool called a pyrography pen.
He adds a layer
of fiberglass and epoxy
To give the wood
a tough outer shell.
Customers can choose
to have a fin box
With a removable fin
Or they can opt
for a permanent wooden one.
Traditional material
plus an innovative design
Results in wooden surfboards
that are built to last.
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