Ep 3. Angle Grinders

Angle Grinders are found in the hands of construction workers, metal workers, welders, and even do-it-yourself enthusiasts. They’re compact, light, and versatile power tools that can be used for tasks ranging from cutting through tough materials to polishing and deburring surfaces. But how are these tools made? That’s the subject of the third episode of How It’s Made season 28.

The episode starts with a brief introduction by the familiar narrator Brooks T. Moore, who sets the stage for the episode ahead by describing how angle grinders are used in various industries and how they are an essential tool for a range of tasks.

The first segment of the episode focuses on how the angle grinder’s motor is made. We learn that the motor is the heart of the tool and it’s essential to have a strong and reliable motor that can handle the high demands that angle grinders are required to meet. The process starts with a stator, which is a stationary coil that creates a magnetic field. The rotor, a rotating shaft with magnets attached to it, is then inserted into the stator, and connected to the rest of the motor components. We see how the motor is assembled piece by piece, with technicians carefully fitting each critical component, including the coils, bearings, and brushes.

Next, we dive into how the grinder’s casing is created. We see a team of workers at a molding plant pouring a powdered mixture of resin and fiberglass into a mold that’s been designed to create the shape of the casing. The mixture is then baked, and once it’s cured, the casing is released from the mold, and excess material is trimmed off. The final product is a shell that is both durable and lightweight.

The episode then moves on to how the gears in an angle grinder are made. Angle grinder gears are precision components that must be made to exacting standards to ensure the tool runs smoothly and with the necessary torque. We see how engineers use computer-aided design (CAD) software to create the gear design, and the machine shop team uses specialized tools, such as CNC mills, to cut the grooves in the gears.

Finally, the various components of the angle grinder, including the motor, gears, casing, and other small parts, are assembled. We see the final assembly process in action as workers pick up each piece and carefully screw them together. There’s a focus on how each piece is attached using specialized hardware and how everything must fit together like a puzzle to ensure the tool can be used safely and efficiently.

Throughout the episode, we don’t just learn how each component of the angle grinder is made - we learn why each component is designed the way it is. We hear from engineers, plant managers, and factory workers who explain how the various angles, shapes, and sizes of each piece contribute to the overall design of the tool. The result is a deep understanding of how angle grinders work and what makes them such versatile power tools.

All in all, this episode of How It’s Made is a fascinating exploration of industrial design, manufacturing, and engineering - with a focus on a tool that plays an essential role in so many industries. Whether you’re a construction worker, welder, or DIY enthusiast, you’ll gain a new appreciation for the angle grinder after watching this episode.