Ep 16. Paintbrushes and Flashlights

In the season 4 episode 16 of How It's Made, viewers get an in-depth look at the production process of everyday objects - paintbrushes and flashlights.

The episode starts out with a segment on how paintbrushes are made. The process begins with the manufacturing of the brush fibers, which typically consist of either animal hair or synthetic materials. The fibers are then inserted into metal ferrules and clamped to hold them in place. The brush handles themselves are typically made of wood, and the production process for these varies depending on the type of handle being produced.

Viewers get to witness the process of brush handles being produced through the molding of a plastic material. The hot plastic is shaped into a handle using a mold that is pre-designed to the desired shape. When the handle is complete, it is trimmed and sanded down to fit the brush head correctly. Once the head and handle are combined, the brushes go through a final inspection stage to ensure that they meet the required quality standards.

The second segment of the episode shifts the focus to the production of flashlights. Viewers get to see the inner workings of a flashlight on the factory floor, starting with the battery compartment. The batteries are inserted and locked into place, and in some cases, the flashlight circuitry is waterproofed to ensure that the flashlight can be used in wet conditions. The circuitry of the flashlight is then added to the top of the battery compartment along with the LED light source.

The LED light source itself is a small, complex piece of technology featuring multiple different elements. The lens of the LED is made up of multiple layers of materials that work together to focus and distribute light evenly. The LED also contains a tiny microchip that controls the amount of energy that is fed into the LED, allowing it to function efficiently and effectively.

Finally, the show explores the production of the flashlight casing itself. Different types of casings are used depending on the intended use of the flashlight, with more durable, shock-resistant materials being used for heavy-duty applications. The casings are mold injected, meaning that they are melted and poured into a specific mold to ensure absolute precision in the final product.

Throughout the episode, viewers get a behind-the-scenes look at these production processes, showing just how much work goes into creating everyday objects that many people take for granted. From the materials that go into brush fibers to the complex electronics within a flashlight, viewers get to witness how these objects come together from start to finish.

Overall, the episode is an engaging and informative look at the intricate processes involved in creating two very different but essential objects in modern society. Whether you're an avid painter or a fan of the outdoors, watching How It's Made Paintbrushes and Flashlights is sure to provide you with a newfound appreciation for the effort that goes into creating everyday objects.