How It's Made — Season 28

Aug 201621m

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."

Aug 201621m

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.

Sept 201621m

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.

Sept 201621m

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.

Sept 201621m

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.

Oct 201621m

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.

Oct 201621m

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.

Oct 201621m

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.

Oct 201621m

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.

Nov 201621m

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.

Nov 201621m

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.

Nov 201621m

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.

Nov 201621m

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.