Ep 35. Carbon-Fibre Masts, Fortune Cookies, IMAX Projectors, Roller Chains

In season 4 episode 35 of How It's Made, viewers get an inside look at the production processes of carbon-fibre masts, fortune cookies, IMAX projectors, and roller chains. Each segment delves into the specialized techniques and machinery required to manufacture these complex items.

First up is the carbon-fibre mast segment, which explores how these strong and lightweight structures are created for sailboats. The process begins with the cutting of carbon fibres, which are then woven into a tube using specialized equipment. Next, an epoxy resin is applied to the fibres to create a strong bond, followed by the insertion of a foam core for added stability. The mast is then cured in an oven, sanded, and finished with a protective coating.

The fortune cookie segment takes viewers through the fascinating process of creating these beloved treats. The segment begins with the mixing of ingredients – flour, sugar, egg whites, and water – to create the batter. The batter is then poured onto a specially designed machine that drops exact amounts of batter onto a conveyor belt. The conveyor belt moves through an oven where the cookies are flattened and baked. As the conveyor belt cools, the cookies are shaped into their iconic curved form before they are packaged and sent to stores.

The third segment of the episode showcases the intricate process of building IMAX projectors, which are known for their incredible size and stunning picture quality. The production begins with the creation of a steel skeleton, which is then coated in a black, anti-reflective paint. Lenses are fitted onto the projector before it is wired and tested to ensure it meets strict IMAX standards. The finished product is then packaged and shipped to theaters around the world.

Finally, the roller chain segment delves into the complicated process of creating these essential components of machinery. The production process begins with the creation of steel bars that are cut to length and heated in a furnace to soften them. The bars are then molded into the chain form using specialized machines that stamp, stretch, and bend the raw materials. After the chains are assembled, they are coated in a lubricating oil and tested for durability.

Overall, the fourth season, thirty-fifth episode of How It's Made offers viewers a fascinating glimpse into the specialized craftsmanship and techniques required to produce a diverse range of items. From fortune cookies to IMAX projectors, viewers will be impressed by the complex and precise processes required to bring these products to market.