Ep 13. Bicycle Helmets, Aluminum, Car Brakes, Lithium Batteries

How It's Made, a popular documentary television series, takes a look at the manufacturing processes behind some of the most common items we use in our daily lives. In season 1, episode 13, viewers are taken through an enlightening journey of how bicycle helmets, aluminum, car brakes, and lithium batteries are made.

The episode begins by exploring the making of bicycle helmets. The manufacturing process of these lifesaving accessories involves the use of expanded polystyrene material, which is molded into a helmet in a vacuum-sealed bag using high heat and steam. Viewers get to see the various stages involved in manufacturing a helmet, from the creation of the mold to the painting and labeling of the finished product. The episode also delves into the importance of wearing helmets and how they protect the head in the event of an accident.

Next up, the show covers how aluminum is made, which is one of the world's most versatile and widely used metals. The process for manufacturing aluminum involves combining alumina powder and cryolite in a large furnace, which is then heated to a temperature of over 950 degrees Celsius. The molten aluminum is then extracted from the furnace and cast into ingots, which can be used for a variety of purposes, including construction, transportation, and packaging.

The third segment of the episode takes a look at how car brakes are made. The process starts with the creation of metal blanks, which are then molded into brake pads using a hydraulic press. Viewers are shown how the brake pads are treated with resins and graphite to give them the desired properties, such as improved friction and durability. The episode also explores the different types of brake pads available in the market, including ceramic and metallic brake pads.

The final segment of the episode examines the production of lithium batteries, which are commonly used in electronic devices like smartphones, laptops, and electric cars. The manufacturing process for lithium batteries involves the creation of a cathode, anode, and electrolyte solution. These components are then assembled into a battery cell, and the final product is tested for performance and safety. The episode also delves into the importance of proper battery disposal and recycling.

Overall, the How It's Made season 1 episode 13 provides an insightful look into the manufacturing processes behind some of the most commonly used items in our daily lives. From lifesaving bicycle helmets to versatile aluminum, to the crucial car brakes, and finally to the ubiquitous lithium batteries, viewers get a chance to see how raw materials are transformed into the finished products we use every day. The show is a great resource for anyone interested in manufacturing, engineering, or how things work.