32x03 - Orthodontic Retainers; Orange Juice; Retractable Saunas; Sawmill Knives

[bunniefuu]

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Narrator: today,
on "how it's made,"

Orthodontic retainers...

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...orange juice...

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...retractable saunas...

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...and sawmill
blade knives.

After spending a fortune on
braces to straighten your teeth,

You don't want that
new beautiful smile

To shift back to
its original position.

So, orthodontists recommend
wearing a retainer

For several months
after the braces come off,

To avoid any shifting.

Oftentimes, an orthodontist
advises their patients

To wear a retainer
for about a year

After their braces
are removed.

Retainers are custom-made
for each person

Using a model
of the patient's mouth.

The orthodontist scans
the patient's teeth and palate,

And sends the 3-d images
to a lab.

A 3-d printer
builds each model

By printing approximately


Which takes about


The printer prints resin
and a support material.

The support material
prevents the model from shifting

During the
printing process,

And provides structural support
for the resin in complex areas.

The support material
is water-soluble.

Once a model is printed,

They soak it in water
for 10 minutes,

Then remove the material
with a pressure washer.

A technician places the model
in a vice.

Using preformed clasp
made of stainless-steel wire,

She fits the wire
around the first molar,

Bending it with pliers
to fit snugly around the tooth.

Then, she bends the end
in a specific shape.

This step will help
to anchor the wire

In the retainer's acrylic palate
at a later time.

She clips off
excess wire,

And repeats these steps
for the opposite side.

Once both clasps
are in position,

The technician secures them
with sticky wax.

Next, she assembles
the front of the retainer,

Called the "labial bow."

To do so, she bends a piece
of wire against a form.

Then, she marks
where to bend the wire

To create an adjustment loop
on each side.

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The labial bow is secured to
the model with wax.

Using a pulse welder,
a technician

Tacks the labial bow
and the clasps together.

He applies flux, a chemical that
preps an area for soldering.

He also applies
a heat-shielding product

To prevent the wires
from overheating.

Next, the labial bow
is soldered to the clasps

With a silver-based solder
that's safe to wear.

He steams off the wax,

Removes the finished retainer
wire from the model,

And polishes
the solder joint.

The retainer's palate
is made of acrylic,

And comes in
multiple colors.

A technician waxes the wire
onto the model,

Then, applies
the acrylic to the palate,

Embedding the ends
of the wire.

The acrylic is made up
of liquid and powder,

Which react when mixed.

She applies about three layers
of each the the palate,

Producing an 1/8-inch
thick mold.

The excess acrylic
is trimmed off with a knife.

Then, she the model is placed
into a pressure cooker

For 10 minutes.

The pressure removes air bubbles
in the acrylic,

While the heat
speeds up the curing.

When the acrylic is ready,
the technician uses a steam g*n

To melt the wax
holding the wire to the model.

She removes the fully formed
retainer off the model.

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She trims the acrylic
with a grinding wheel

To smooth out rough areas
and refine the shape.

With a hand tool,
she smoothes the entire surface,

So it won't irritate
the patient's mouth.

Another technician
runs the acrylic palate

Against a muslin-rag wheel
with pumice, a natural abrasive.

This makes
the surface glossy.

He applies a greaseless
polishing compound

To another
muslin-rag wheel,

And polishes the acrylic
to a high shine.

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Finally,
he drops the retainer

Into an ultrasonic
cleaning machine

Containing mild acid.

The combination of acid
and sonic waves

Removes the pumice
and polish residues.

Once the retainer has been
rinsed with water and dried,

It's placed it in
a storage case.

Now, it's ready to be shipped
to the orthodontist.

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Narrator:
no one knows who came up with
the idea of squeezing oranges

To make juice.

The popularity of orange juice
increased dramatically

In the middle
of the 20th century,

As techniques were developed
to extend its shelf life.

Today, many people start their
day with a tall glass of o.j.

In its purest form,
orange juice fresh-squeezed

And made with no preservatives
or other additives.

The appeal
is indisputable.

Fresh-squeezed o.j.
Contains vitamin c,

And the flavor
is authentic.

Orange juice production
starts in groves.

The trees take several months
to bear fruit,

And are harvested
in early november.

Picking oranges a job
that's done entirely by hand.

An automated picking system

Could damage
both the trees and the fruit.

The picker uses a bag
made of vinyl composite

That's lightweight
and heavy-duty.

There are multiple types
of juicing oranges.

This one is called
"the hamlin."

Hamlin oranges
are small and juicy,

The trees they grow on
are productive

And resilient to cold.

The picker plucks the fruit
from the trees

Before they turn orange.

They may be green
on the outside,

But they are still sweet
on the inside.

The fruits' size and condition
are indications

Of maturity and flavor.

As the picker empties the bag
into a bin,

He examines the oranges.

Anything with tears
or punctures

May also have
internal degradation,

But superficial flaws won't
affect the quality of the juice.

The oranges are taken
to a processing facility,

And transferred to
a sloped chute.

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The gradient of the chute
prevents damage

As the oranges tumble
into a wash station.

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A sprayer rains soapy water
onto the oranges

As spiraling nylon brushes
scrub and clean,

While simultaneously
moving them forward.

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After the wash,
another sprayer rinses them off

As the spiraling brushes
continue scrubbing.

The oranges transition to
a roller conveyor

That takes them up
and under drying fans.

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As the oranges exit the dryer,
an inspector checks them

For any missed damage.

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The oranges then travel
across more revolving brushes.

The bristles on these brushes
are gentler

Than on the first group.

They buff the skin of the fruit,
and remove any residual dirt.

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Finally, the oranges fall off
the conveyor line into a bin.

Now cleaned,
the oranges can be juiced

With no contaminants

That could spoil either the
product or juicing machinery.

As a final precaution,

The juicing operator
performs one last inspection.

If she's completely satisfied
with their cleanliness

And general condition,

She loads the oranges
into the extractor.

There's no need to slice them
beforehand.

She feeds them to
the juicing machine whole.

The system feeds the oranges
one at a time to the extractor.

The extractor
punctures the fruit,

And metal teeth
peel away the skin.

It squeezes out the juice

While simultaneously
filtering out the seeds

And the membrane between
the flesh of the orange

And the skin.

The juice
flows into a vat.

A screen in the vat
filters the pulp

To the desired
consistency.

There are different filters
for different amounts of pulp.

The juice is bottled
in jugs.

The plastic jugs
will accommodate

Any expansion of
the unpasteurized juice

Due to fermentation.

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Instead of pasteurizing
this fresh-squeezed juice,

It is chilled
immediately.

The unpasteurized
orange juice

Won't have
an extended shelf life,

But the trade-off is
an unaltered flavor and color.

Refrigeration will preserve
the juice for a few days --

And after all,
fresh-squeezed orange juice

Is a drink
that's best served cold.

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Narrator: there's nothing
more relaxing

Than sitting in
a hot sauna.

Our ancestors figured that out
at least 1,000 years ago.

Today, saunas are a substantial
part of finnish culture,

But they also have
a long history

In other parts of the world,
especially in korea.

When you live in a city,

It's hard to find the space
to fit a sauna.

Luckily, this retractable
indoor sauna solves the problem.

The manufacturer
uses high-strength laminates

From sustainably sourced
wood products.

Laminate wood
is not only strong,

It's torsion-resistant,
which is an important factor

When you're
constructing something

That will undergo significant
shifts in temperature.

To cut the laminate,
a craftsman uses a chop saw,

Which contains
a computerized system

That positions
the fenced tolerances

Within a tenth
of a millimeter.

At the next station,

The craftsman
positions the laminate

So that a cnc machine
can drill end holes

Before assembling
a pair of dowels.

Meanwhile, another craftsman
preps several wood components

For assembly.

After placing them
on an edge,

He fills a set of open holes
with high-strength glue.

He assembles
the laminate

By inserting dowels
into openings

And gently hammering
everything into position.

This part will form
the framework

For one of the highly engineered
insulated panels.

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The framework is placed
into a press

That exerts a calibrated
amount of pressure

To every side.

This steps ensures
a solid and durable connection

At all points.

This is high-performance
insulating material.

Thanks to
specialized engineering,

It insulates
more effectively

Than many other
sauna materials.

This material also
allows the manufacturer

To maintain the sleek design
of the sauna system.

With the insulation
in place,

A craftsman feeds the panels
into a precision planer,

To ensure the wood contains
a uniform thickness.

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A technician
begins a process

Called
"frame-stability construction,"

This method adds a series
of layers to each panel,

Including exterior sheathing,
insulation material,

A vapor barrier,
and interior plywood paneling.

These will add up to a thickness
of only 30 millimeters,

Achieving a
high-insulating value

While remaining
lightweight.

A specialized adhesive is
applied to attach each layer.

Then, a customized press
applies heat and pressure

To bond all the layers
securely together.

After a quick
inspection check,

A technician
carries the panels

To a cnc
milling machine,

Where they position it
for trimming.

The cnc machine gauges
the dimensions of the panel,

And runs a bit
around the perimeter,

Trimming the edges to
a uniform width at high speed.

Once complete, the panels
advance on conveyor belts.

An automated machine
uses an adhesive

To add a veneer
to the perimeter

Then, it applies heat
and pressure to secure the bond.

The process is known
as "zero joints,"

Because it covers up
the panel's visible joinery.

The machine can apply
a range of different veneers,

Depending on
customers' specifications.

The control panel allows users
to customize the temperature

And duration
of a sauna session.

Customers can also
choose from

A variety of
pre-installed programs.

Two drive buttons
control the extension

And retraction
of the sauna.

To extend and retract,

The manufacturer custom-made
this track-wheel system,

The system includes
durable guides,

Self-lubricating
components,

And industrial-strength
ball bearings.

A craftsman carefully joins
the structured wall,

Ceiling, and floor panels.

Thanks to precision machining,
they fit together perfectly,

Making it easy
to assemble the parts

Wherever a customer
wants their sauna.

Then, the craftsman installs
the heart of the sauna.

The manufacturer has engineered
this compact powerful heater

With a specialized finish

That makes the usual
safety guard unnecessary.

Retractable saunas --

For the most efficient
sweat possible.

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Narrator: after years of
carving wood into lumber,

Sawmill blades eventually
lose their cutting edge.

So, craftsmen are salvaging
the discarded carbon steel,

And making them into knives
for hunting and outdoor use.

When it comes to
sustainability,

This is a new kind
of cutting edge.

What was once an old
sawmill blade is now a sleek,

New brush-cutting knife --

Proof that the future
doesn't have to be dull

For discarded
mill blades.

A sawmill blade
lasts 5 to 10 years.

But when it jagged edges
wear thin,

It can't cut logs anymore.

Luckily, the carbon steel
can be salvaged.

A computerized
high-pressure water tool

Cuts into a stack
of three sawmill blades.

In doing so, it carves out
numerous knife blade blanks.

The computerized tool also cuts
holes for the handles

And a tab
for attaching the knife sheath.

Next, the blades are transferred
to a vibratory tumbler.

The tumbler is filled
with triangular ceramic stones

And a soapy solution.

For several hours,
the vibrating stones

Smooth and clean
the blades.

Once complete,
a technician secures the blades

In a fixture
with screws.

The screws hold the blades
down flat,

And lock them in position
for the next step.

This tool's spiral bit
carves into the steel

To shave small amounts
from around the edges.

This improves
the shape of the knife

And ensures
that the knife handle

Will fit perfectly
on the tang.

The trimming also
removes the lines

Left by
the water-jet cutting.

One of the blades is placed
in a fixture

That holds the knife

With the cutting edge
in an upward position.

A technician ignites
an automated torch.

The torch follows the blade,
exposing it to intense heat.

The torch doesn't touch
the blade's spine.

This selective heat treatment
hardens only the blade.

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An operator places the blade
into a bucket of quenching oil.

This rapid cooldown
completes the hardening process.

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Next, the cutting edge
is beveled,

And the entire blade is coated
with a thermoplastic polymer,

Which provides a hard finish
and prevents rust.

Then, the knives are transferred
to a laser-emblazoning chamber.

Another technician
closes the chamber doors

And activates the laser.

The computerized laser
etches the company logo,

The knives' model number,

And other information
into the steel.

At the next station,
a technician moves a blade

Against and abrasive belt

Held in by a special fixture
along a track.

This angles the blade
precisely to the abrasive belt

To grind the cutting edge
and complete the bevel.

This brush-cutting blade
is now almost razor-sharp.

He sharpens
the tip of the knife

By gentling pressing it
against another abrasive belt.

Next, he applies an abrasive
compound to a buffing wheel.

He presses the cutting edge
of the knife against the wheel,

And the abrasive compound
works its magic,

Honing the edge
to its final sharpness.

He presses threaded fittings
into the tang of the knife.

He installs them
so that the fittings protrude

From both sides
of the tang.

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The fittings in the tang
have been spaced

To match holes
in a handle.

This handle is made of
composite glass and resin.

There are two parts,
one for each side of the tang.

Due to
the precision prep work,

The two parts fit together
perfectly as one.

Screws hold
the handle parts together.

He dips the tips
in a thread-lock solution.

When the thread-lock
solution cures,

It stabilizes the screws.

With multiple
thread-locked screws,

The composite handle
now has a solid handgrip.

It's taken several hours

To transform
a blunt sawmill blade

Into a sharp
brush-cutting knife.

Through recycling,
steel that lost its edge

Now has a new one.