Ep 22. Dress Forms, Boat Propellers, Duvets, Faucets

How It's Made, season 5 episode 22, takes viewers behind the scenes of the manufacturing process of four different products: dress forms, boat propellers, duvets, and faucets. Each segment starts with the raw materials and follows the intricate steps required to create the final product.

The first segment focuses on dress forms - those life-size figures used by tailors and clothing designers to help create garments that fit properly. The process begins with a basic molded foam body, over which a layer of fiberglass is applied. The fiberglass is then sanded and polished, and a layer of foam padding is added to create a smooth, sturdy surface that can withstand repeated measurements. Finally, a cover made from jersey or spandex is pulled over the form, allowing designers to easily pin and drape fabric for their creations.

The second segment dives into the world of boat propellers. These essential components are responsible for transferring power from the engine to the water, and must be carefully crafted to ensure a smooth, efficient ride. The propeller-making process begins with a thick, blank piece of aluminum, which is heated to soften and shape into the desired blade angle. Each blade is then finely tuned using precise machinery to achieve the ideal weight, balance, and pitch.

In segment three, viewers get a glimpse into how duvets - fluffy, down-filled comforters - are made. The manufacturing process starts with the careful sorting of high-quality goose feathers, which are washed, sterilized, and dried to remove any impurities. The feathers are then sewn into pockets of a luxurious cotton shell, creating a fluffy, insulating layer. Finally, the duvet is sealed and finished with piping and an elegant cover, ready to keep sleepers cozy all winter long.

The final segment focuses on faucets - those essential fixtures found in every bathroom and kitchen. The production process starts with a solid block of brass, which is carefully molded and shaped to create the various parts of the faucet. Each piece is then polished and coated to create a durable, attractive finish that will withstand years of use. Finally, the various components are assembled and tested to ensure a tight, leak-free seal.

Through in-depth interviews with the manufacturers and footage of each step of the process, viewers gain a firsthand understanding of the care and precision required to create these everyday products. How It's Made season 5 episode 22 offers a fascinating look into the manufacturing processes of dress forms, boat propellers, duvets, and faucets, and will leave viewers with a newfound appreciation for the products we often take for granted.