How It's Made — Season 11

Sept 200821m

Precision lenses and prisms are aligned inside binoculars, metal wire is coated with pyrotechnic material to make sparklers, liquid rubber is molded and vulcanized into waterproof boots, and hardened steel is cut and sharpened into circular saw blades.

Sept 200821m

Detailed molds and painted components are used to create anatomical teaching models, mechanical and electronic systems are assembled into jukeboxes, corn dough is formed and fried into tortilla chips, and ceramic insulators and metal electrodes are combined into spark plugs.

Sept 200821m

Graphite cores are enclosed in shaped wooden slats to make pencils, discarded ferrous and non-ferrous metals are sorted and processed for reuse, and coffee beans are roasted, blended and packaged.

Oct 200821m

Lightweight materials are shaped and balanced into competition javelins, carved wooden cases and mechanical movements are assembled into cuckoo clocks, cultivated palm stems are harvested and processed into hearts of palm, and rubber blades and articulated frames are combined into windshield wipers.

Oct 200821m

Specialized glass formulations are heated and molded into durable technical components, drums, pumps and electronic controls are assembled into washing machines, printed sheets are coated and cut into playing cards, and limbs, stocks and trigger mechanisms are fitted together to make crossbows.

Oct 200821m

Precision film-transport and optical components are assembled into motion-picture cameras, heated glass is blown, silvered and decorated into Christmas ornaments, and layers of reinforced rubber are built and cured into enormous tires for mining and construction vehicles.

Oct 200821m

Sound-sensitive elements and electronic components are enclosed in microphones, heated acrylic shells and plumbing systems are assembled into hot tubs, synthetic fibers are tufted into artificial turf, and molded ceramic bodies are decorated and fitted with pewter lids to make beer steins.

Oct 200821m

Classic vehicles are rebuilt with customized bodies and high-performance components to create hot rods, emptied eggshells are intricately decorated, machined valves and controls are assembled into fire-hose nozzles, and layers of yarn, rubber and leather are formed into regulation baseballs.

Nov 200821m

Reeds, keyboards, buttons and bellows are assembled into accordions, pineapples are cultivated, tested for ripeness and harvested, and metal and plastic components are manufactured into artificial joints used in replacement surgery.

Nov 200821m

Massive cast and machined components are assembled into industrial flow-control valves, sardines are cleaned and sealed in cans, pressure-sensitive capsules and recording mechanisms are combined into barographs, and absorbent pulp and polymer layers are formed into disposable diapers.

Nov 200821m

Heating elements and electronic controls are incorporated into skate-blade assemblies, lightweight composite sections are molded into gliders, molten metal is cast and tuned into hand bells, and woven polyester jackets receive flexible inner linings to become fire hoses.

Nov 200821m

Electromagnetic coils and electronic controls are installed beneath glass induction cooktops, heavy platforms and load cells are assembled into truck scales, layered packaging material is printed and folded into Tetra Pak containers, and reeds and combs are fitted inside harmonicas.

Dec 200821m

Selected leather is cut, stitched and shaped into baseball gloves, conductive materials and adhesive backings are assembled into disposable medical electrodes, and felt is steamed, formed and finished into traditional Stetson hats.