Ep 8. Racing Pulley Systems, Inductors, and Medicine Balls

How It's Made is a popular television series that puts the manufacturing process under the spotlight and educates its audience on how everyday items are produced. Season 30 episode 8 features a range of interesting and diverse products: Racing Pulley Systems, Inductors, and Medicine Balls.

The episode takes us behind the scenes of a popular and exciting motorsport to discover how the essential Racing Pulley System is produced. We are shown how crucial the timing of the engine and the transmission needs to be, and how the pulley system affects this. The pulleys themselves are made of steel and have to be carefully machined to ensure they meet the exact specifications needed to perform efficiently, and be FDA compliant. We see the intricate and precise assembly process, from cutting the steel to grinding it and assembling the individual components. The workers use a range of specialised machinery and equipment, including remarkable robotic arms that can precisely place and attach parts at incredibly fast speeds.

Next, the series takes us on a journey into the world of electrical engineering, where we learn about the manufacturing process of Inductors. Inductors are highly technical components used in electrical circuits to store energy and filter out unwanted signals. We are shown how the small coiled structures that make up the inductor are wound from incredibly thin copper wire and how the coiled wire is then formed into the shells that hold the inductor's core. The manufacturing process requires technicians with a high level of skill, as the coils of wire have to be wound by hand, while keeping track of the number of turns, and while making precise adjustments to the wire's tension and position. The end result is an incredibly small and intricate component capable of performing complex electrical functions.

The episode concludes with a fascinating look at how one of the most common pieces of fitness equipment, the medicine ball, is produced. Medicine balls are balls that are used for strength training and typically weigh between two and twenty pounds. They have been used for centuries, and they are still a ubiquitous piece of workout equipment in gyms and homes worldwide. The segment uncovers the manufacturing process from start to finish, starting with a large block of solid rubber and finishing with a perfectly weighted and sized medicine ball. We see the rubber being shaved and cut into shape and the careful addition of the weight inserts that give each ball its heft. We even get to see the rigorous testing and quality control process, including a drop test, where each ball is dropped from a height to ensure it can withstand the stresses of being used for exercise.

Overall, this episode of How It's Made offers a fascinating insight into the manufacturing process for three completely different products. From the highly precise racing pulley systems, to the intricate and delicate inductors, to the ubiquitous and practical medicine ball, we are taken behind the scenes of the manufacturing process to see the skill, expertise and technology that goes into producing them. The show manages to make what could be dry, technical subjects interesting and engaging, and it's a must-see for anyone who has ever wondered how products are made.