Ep 8. Gas Barbecues, Mattress Pads, and Ear Prostheses

How It's Made is a documentary-style television series that examines how various products and goods are manufactured and produced. The show takes a behind-the-scenes look at factories and assembly lines around the world, showcasing the intricate processes that go into creating everyday items. In season 17 episode 8, titled "Gas Barbecues, Mattress Pads, and Ear Prostheses," viewers are taken on a journey through the manufacturing of three very different products.

The episode begins with a look into the production of gas barbecues. The process of manufacturing a gas barbecue begins with the creation of a metal frame. The metal is cut and shaped into the necessary pieces using lasers, and then welded together to form the frame. The cooking grates are made from stainless steel, which is cut and formed into the correct shape using a high-pressure water jet. The grates are then polished and fitted onto the frame. The burners, which are the heart of the barbecue, are made from specially designed tubes that are coated with a heat-resistant material to ensure safe usage. The tubes are then cut, drilled, and assembled into the burner assembly. Finally, the grill is fitted with a propane tank and tested to ensure proper function.

Next, the episode explores the production of mattress pads, which are often used to protect mattresses from spills and stains. The process begins with the creation of padding material, which is made by layering different types of foam and fibers together. The padding is then cut into the desired size and shape using a large cutting machine. The outer fabric layer is created by weaving a specially designed thread into a quilt-like pattern. The fabric is cut to size, and then the padding is placed inside. The edges of the fabric are then sewn together, creating the final product.

The final segment of the episode is dedicated to the creation of ear prostheses, which are used to replace parts of the ear that have been damaged or lost due to injury or illness. The process begins by creating a mold of the patient's existing ear. This mold is used to create a model of the prosthetic ear, which is then crafted from medical-grade silicone. The silicone is mixed with a pigment to match the patient's skin tone, and then shaped to resemble a natural ear. Small details, such as the shape and position of the ear canal, are carefully modeled to ensure a natural appearance. Finally, the prosthetic ear is attached to the patient's existing ear using medical-grade adhesive.

Overall, season 17 episode 8 of How It's Made provides a fascinating look into the production processes behind gas barbecues, mattress pads, and ear prostheses. The episode highlights the intricate attention to detail required for the manufacturing of these products, and provides a new appreciation for the intricate processes that go into creating everyday items.