Ep 26. Ball Bearings, Electrical Wires, Lost Wax Process Casting, Automated Machines

In season 1 episode 26 of How It's Made, viewers are taken on a journey through the manufacturing processes of four different products: ball bearings, electrical wires, lost wax process casting, and automated machines. Each segment provides an in-depth look at the intricate processes required to create these essential components.

The first segment focuses on ball bearings, which are essential components of many mechanical devices including engines, conveyor belts, and appliances. Viewers learn how steel wire is cut, formed, and hardened to create the outer ring of the ball bearing. The inner sphere is then formed, and thousands of tiny steel balls are inserted within the space between the inner and outer rings. The ball bearing must undergo rigorous testing before it is deemed suitable for use in its intended application.

Next, viewers are taken through the manufacturing process of electrical wires, which are used in nearly all electronic devices. The segment starts with the creation of copper wire by taking bundles of copper rods and heating and extruding them through a series of dies to create the desired thickness. The wire is then coated in a thin layer of insulating material to prevent electricity from escaping. Finally, the wires are spooled onto large reels for use in manufacturing.

The third segment explores the lost wax process casting, which is used to create intricate metal parts with a high level of precision. Viewers are taken through the process of first creating a highly detailed wax model of the desired part, which is then coated in a ceramic shell. The wax is then melted out, leaving a negative space in the ceramic shell. Molten metal is poured into the ceramic shell, filling the space left by the wax. After the metal cools, the ceramic shell is broken away, leaving the finished metal part.

The final segment focuses on automated machines, which are designed to streamline manufacturing processes and increase efficiency. Viewers learn about the design process of these machines, which involve extensive testing and programming to ensure that they operate correctly and safely. The machines are capable of completing complex tasks in a fraction of the time that it would take a human worker, and their precision and accuracy reduce the chances of errors occurring during the manufacturing process.

Overall, season 1 episode 26 of How It's Made offers a fascinating look into the manufacturing processes of four essential products, each with its own unique set of challenges and intricacies. From the creation of ball bearings to the manufacturing of automated machines, viewers are sure to come away with a newfound appreciation for the art and science of manufacturing.