How It's Made

1Classic Car Gauges, Chocolate Marble Cake, Ghillie Kettles, Condoms

21 minAug 22, 2016

Ceramic forms are repeatedly dipped in liquid latex before the finished condoms are cured, removed, tested and packaged. Precision mechanisms, numbered faces and pointers are assembled and calibrated into gauges for classic cars; contrasting cake batters are swirled, baked and decorated to create chocolate marble truffle cakes; and formed metal sections are joined into chimney-style ghillie kettles that rapidly boil water over a small fire. NOTE: The US version contains a late regional editorial decision to use the S21 E01 segment on Rubber Gloves in place of the Canadian original segment on Condoms due to "content sensitivity."

2Pasta Dies, Blueberries, Composting Toilets, Surge Arresters

21 minAug 29, 2016

Metal blanks are precision-machined with shaped openings and inserts to create dies that extrude pasta into different forms. Blueberries are cultivated, harvested, graded and prepared for distribution; waste chambers, ventilation systems and supporting components are assembled into composting toilets; and voltage-sensitive elements are enclosed in insulated housings to produce surge arresters that protect electrical equipment.

3Angle Grinders, Berry Baskets, Omnidirectional Speakers

21 minSep 5, 2016

Electric motors, gearboxes, spindles and protective guards are assembled into high-speed angle grinders. Thin wooden components are cut, shaped and fastened into lightweight berry baskets, while multiple speaker drivers and specially designed enclosures are arranged to distribute sound evenly in every direction.

4Cartridge Blades, Chocolate Banana Loaves, Vending Machines, Dive Computers

21 minSep 12, 2016

Fine strips of steel are hardened, sharpened, coated and mounted in plastic cartridges to create replacement razor blades. Banana-flavoured batter and chocolate are mixed, portioned and baked into loaves; payment systems, product dispensers and electronic controls are installed in vending machines; and pressure sensors, processors and displays are sealed inside waterproof dive computers.

5Ultra-Thin Glass, Pallet Dismantling Machines, Cupcakes, Seamless Stainless Steel Tubing

21 minSep 19, 2016

Molten glass is drawn into extremely thin, uniform sheets suitable for sensitive electronic and technical applications. Heavy frames, conveyors and cutting mechanisms are assembled into machines that recover boards from used pallets; batter is deposited, baked and decorated as cupcakes; and solid stainless-steel billets are pierced, rolled and drawn into seamless tubing.

6Potash, Leather Bracelets, Wild Rice, Hex Key L Wrenches

21 minOct 6, 2016

Potassium-rich ore is brought to the surface, crushed and separated to produce potash for agricultural and industrial use. Leather strips are cut, decorated and fitted with clasps to create bracelets; harvested wild rice is dried, parched and hulled; and steel rods are formed into hexagonal profiles, bent into an L shape and heat-treated to make hex keys.

7Metal Nail Files, Birch Bark Canoes, Cruiser Boat Hardtops, High-Voltage Circuit Breakers

21 minOct 13, 2016

Steel blanks are cut, textured, hardened and finished to produce durable metal nail files. Sheets of birch bark are fitted around a wooden framework and reinforced with ribs to create traditional canoes; composite materials are moulded and finished into hardtops for cruiser boats; and insulated contacts and interruption mechanisms are assembled into high-voltage circuit breakers.

8Macarons, Pine Needle Baskets, Micrometers

21 minOct 20, 2016

Almond-based meringue batter is piped, rested and baked into smooth macaron shells before pairs are joined with flavoured fillings. Bundles of long pine needles are coiled and stitched into decorative baskets, while precision-machined frames, spindles and calibrated screw mechanisms are assembled into micrometers capable of measuring extremely small dimensions.

9Endoscopes, Megaphones, Uranium

21 minOct 27, 2016

Miniature optical fibres, cameras, lights and control cables are installed inside flexible tubing to create medical endoscopes. Moulded horns, microphones, amplifiers and speakers become portable megaphones, while uranium-bearing ore is mined, crushed and processed into a concentrated material that can undergo further preparation for use as nuclear fuel.

10Hollow Disk Pumps, Palm Sugar, Yachts

21 minNov 3, 2016

Closely spaced rotating disks are machined and installed inside pump housings to move liquids containing delicate or suspended material. Sap collected from palm trees is filtered and slowly reduced into concentrated palm sugar, while moulded hulls receive engines, navigation systems, plumbing, electrical equipment and fitted interiors to become luxury yachts.

11Abalone Collagen, Digital-to-Analog Converters, Embosssed Wood Mouldings, Plier Staplers

21 minNov 10, 2016

Material from farmed abalone is cleaned and processed to extract collagen for cosmetic and other specialized products. Electronic components are mounted and tested in digital-to-analog converters; wooden strips are shaped and pressed with repeating decorative patterns to produce embossed mouldings; and stamped metal levers, magazines and springs are assembled into plier staplers.

12Thai Barbecues, Diving Masks and Fins, Bassoons

21 minNov 17, 2016

Metal sheets are cut, shaped and joined into domed tabletop grills used for Thai-style barbecuing. Tempered lenses, flexible skirts and straps are assembled into watertight diving masks, moulded rubber or plastic components become swimming fins, and carefully seasoned wood is bored, shaped and fitted with an intricate system of metal keys to create bassoons.

13Wooden Utensils, Transport Refrigeration Units, Moccasins, Electronic Impact Drills

21 minNov 24, 2016

Selected wood is cut, carved, sanded and treated to produce spoons and other kitchen utensils. Compressors, condensers, fans and electronic controls are assembled into refrigeration units for trucks and trailers; leather pieces are cut and hand-sewn into traditional moccasins; and motors, gear systems and impact mechanisms are installed inside electronic impact drills.