Ep 9. carbon fibre masts, fortune cookies, IMAX projectors, and roller chains

In season 4 episode 9 of How It's Made, viewers are taken on a journey through the intricate processes behind the manufacturing of carbon fibre masts, fortune cookies, IMAX projectors, and roller chains. This episode is a unique blend of solid engineering and creativity that is sure to captivate fans of the show.

The episode begins with a detailed look at the process behind the manufacturing of carbon fibre masts, which are widely used in the construction of sailboats. To create these lightweight and durable masts, carbon fibre must be woven into a specific pattern and layered onto a mandrel. The mandrel is then wrapped with a release film before being placed into an autoclave where it is exposed to high temperatures and pressure. Once the process is complete, the mandrel is removed and the carbon fibre mast is left to cool, ready to be shipped off to a sailboat manufacturer.

Next up are fortune cookies, the quintessential treat enjoyed at many Chinese restaurants around the world. Viewers learn that the process of making fortune cookies is far more complex than one might expect. The dough is mixed and then squirted onto a hot rotating plate where it cooks and takes on its characteristic shape. Once the cookie has been removed and cooled, a fortune is inserted by hand and the cookie is folded into its iconic shape.

The third segment takes viewers behind the scenes at a manufacturing plant for IMAX projectors. This is where the magic of the beloved giant screen format happens. A range of different parts are manufactured, including lenses, light bulbs, and projectors. Watching the process of creating the lenses is particularly interesting; they require incredible precision and are crafted from raw glass that is carefully ground and polished to create the perfect final product.

Last but certainly not least, viewers are treated to an in-depth look at how roller chains are made. These power transmission chains are used in a wide range of machinery, including motorcycles, bicycles, and conveyor belts. To create a roller chain, a metal wire is first drawn into the required shape before being cut to the appropriate length. The chain is then heat-treated to give it extra strength and durability, before being assembled by hand into the final product.

Overall, season 4 episode 9 of How It's Made is a fascinating exploration of four vastly different manufacturing processes. From the intricate weaving of carbon fibre masts to the careful insertion of fortunes into fortune cookies, the attention to detail and precision of each process is truly impressive. Fans of the show are sure to find this episode both educational and entertaining.