The Harley-Davidson V-Rod is the first Harley-Davidson motorcycle to go from 0 to 96 kilometres per hour in just 3.52 seconds nearly twice as fast as any other Harley-Davidson bike. With its thrilling speed, liquid-cooled engine and exterior frame, the V-Rod represents a number of important firsts for Harley-Davidson. At the Harley-Davidson factory in Kansas City, U.S., it is up to the engineers, designers and factory workers to ensure the V-Rods creative look can handle the high speeds for which it was designed while maintaining the signature Harley-Davidson style that consumers expect. Robots engage in a carefully choreographed dance to create...
The John Deere factory houses more than 2,000 employees, 49 robotic welders and eight laser cutters, all of which help make the John Deere STS Combine – a harvesting mega-machine.
At the Peterbilt factory in Texas, workers are busy building Model 387 trucks titans of the road, made to pull vehicles weighing up to 36 tonnes. To produce this aerodynamic marvel, the Peterbilt design team partnered with its engineers to create the ideal full-scale model. However, with more than 20,000 parts per vehicle, turning this truck from life-size model into a full-fledged vehicle made of aluminium and steel is a formidable task. Making things more difficult, each truck is individually made to fit exact customer specifications so no two trucks are built exactly alike. In this Mega Factories episode, viewers will see the ultimate test...
The Apache is perhaps the most lethal attack helicopter in the world. ULTIMATE FACTORIES takes you to the Boeing plant in Mesa, Arizona, to see how this battle tank of the air is built and how it has evolved from the days of the Huey in Vietnam into a Cold War tank destroyer and now a 21st century digital fighter, the eyes in the sky for the troops on the ground. Aerial cavalry. PARAGRAPH The Apache is perhaps the most lethal attack helicopter in the world. ULTIMATE FACTORIES takes you to the Boeing plant in Mesa, Arizona, to see how this battle tank of the air is built. How it is engineered to be a stealth fighter, flying low over the battlefield,...
PARAGRAPH It is the worlds most famous sports car Ferrari. ULTIMATE FACTORIES takes you inside Ferraris top-secret factory in Maranello, Italy. Witness the creation of the newest and most powerful Ferrari ever from molten metal to two-hundred miles an hour sports car. Incredible robots and spectacular processes at every point along the production line are filmed with special close-up lenses and illustrated with advanced 3D computer graphics. Learn the design secrets of Ferraris newest car, and take the final test drive on Ferraris private race track, where failure could be catastrophic. TV GUIDE Witness the birth of a Ferrari from molten metal...
The Abrams tank is one of the most powerful land weapons systems in the world. It is also rebuilt from the ground up, rather than built new. ULTIMATE FACTORIES brings you to two factories responsible for the Herculean effort of overhauling the 70 ton Abrams, to the proving grounds of Fort Bliss, Texas where the reborn tanks flex their better-than-new muscles and to the dangerous battle zones of Iraq where the tank is seeing action daily. PARAGRAPH The Abrams tank is one of the most powerful land weapons systems in the world. It is also rebuilt from the ground up, rather than built new. ULTIMATE FACTORIES brings you to two of the factories that...
Our cameras go inside the Audi R8 factory in Neckarsulm, Germany and follow the crafting of a road car modeled after a champion racecar. With the introduction of the R8, Audi breaks out of its elegant sedan image to create a sportscar that rivals the likes of Porsche and Lamborghini. Modeled after the R8 racecar that dominated at LeMans, the Audi R8 road car is a mid-engine two-seater with explosive power and a smooth ride. Audi has combined all of its engineering innovations over the last few decades into this one sportscarall wheel drive, an ultra-light aluminum spaceframe and high-tech fuel injection. Since its launch in 2007, the super sleek...
In 36 countries, in 296 stores IKEA represents a distinct design and an affordable price. Each year nearly 600 million customers choose IKEA. From teaspoons to living rooms, the entire contents of a home are designed, manufactured and supplied in a huge variety of styles, colors and models... almost 10,000 items. To get the job done, suppliers in 54 countries carry out IKEAs vision. In Zbaszynek, Poland, IKEAs largest wood production plant in the world, creates 2 million tables, chairs, sofas and recliners each year. Nearby, in Nowe Skalmmierzyce, IKEAs the companys textile supplier builds over 500 pieces of upholstered furniture daily. In southern...
What does it take to build a car that can go from zero to 62 mph in 3.4 seconds and hit a top speed of 211 mph? NGC heads to the small farming community in Italy that is home to the main factory for the Lamborghini Murcielago SV to find out. See how a workforce of 130 people makes the Murcielago's lightweight carbon fiber frame and a 640-horsepower V-12 engine. Much of the work is done by hand, and despite the massive workforce the factory outputs a mere 2.7 Murcielagos a day.
Rolling of the assembly line and taking the world by storm in 1964, the Porsche 911 is now one of the worlds iconic sports cars. Still produced on the same grounds that gave birth to the first 911, this car has grown to 14 variations. From the "modest" 911 Carrera with a top track speed of 185 mph to the 911 GT3, a street legal racecar that tops out at 194 mph; this Ultimate Factory, in Stuttgart, Germany, can offer a color, style, and speed for even the most fastidious driver.
Taking an average of 450 hours to build, with contributions from artisans, engineers and painters, find out how the Rolls-Royce Phantom is made.
Join us as we follow the creation of the car that moves millions. The R-160 Subway car is the newest member of the New York City Transit fleet -- bringing 21st Century safety and technological innovations to a mass transit system over 100 years old. These innovations include LCD screen maps, a passenger emergency intercom system, soundproofing and a braking system that actually generates electricity and returns power to the third rail. It starts as sheets of metal in Sao Paulo, Brazil where human skill, fire, and steel come together to build the body shell. After a month-long voyage, the body arrives in Hornell, NY for final assembly, motor installation,...
After nearly a decade off the production line, visit the 10-million-square-foot factory rolling out the astounding 2010 Camaro SS.
Exclusive behind-the-scenes footage from GM's Pre Production Operations factory reveals the secrets behind the electric Chevy Volt.
Bugatti Super Car+
This episode falls under the series Mega Factories This is simply an internal repackaging of an existing asset. This is a repackage of Bugatti Super Car. Other than the "Mega Factories" title graphic, they are the exact same show. Mega Factories: Bugatti Super Car was repackaged as a Mega Factories show in order to be run as part of the Mega Factories series.
From the hallmark matrix grille to the classic wooden interior, theres not much that changes in a Bentley from generation to generation. After all, its not often one messes with excellence. But this fall Bentley is remaking their flagship car. Named in honor of the fastest stretch of Frances famed 24 Hours of Le Mans race a race Bentley has won six times the new Mulsanne takes Bentley back to its roots, underlining its passion for power and speed. With a higher level of customization than any of its competitors over 90% of Mulsannes are custom ordered traditional assembly lines are thrown out the window. Here, power meets luxury in Bentleys meticulously...
Going into labs with chemist/"beverage engineers" to see how they design new drinks *The world's largest bottle recycling plant in North Carolina just opened where we can see how any old bottles are transformed into the signature Coke bottle *The strange ingredients you'd never expect--like vanilla and nutmeg--that go into making Coke--millions of tons of them (they're the world's largest consumer of both) *Lots of HD stock available to show off bottlers/brands/assembly lines around the globe--plus any ads we want, old and new--that they'll provide to us *Concentrated Coke is produced in just 30 places around the globe and shipped out to 900 factories...
The Dodge Challenger; an All-American legend reborn. Loud, curvy and packed with power, the modern version of the 70s classic stays true to its roots, and adds technology and 21st century engineering into the mix. The Challenger comes to life at two factories. A vast, highly-automated production line in Canada, transforms sheet metal into speed machine in 20 hours or less. And a state-of-the-art plant in Mexico, which crafts the iconic Hemi engines that power most Challengers. Two Ultimate Factories that pack just as many thrills as the car they create.
The Dodge Viper is a muscle car, a super car and an American icon all rolled into one. A $93,000 sports car with a 600 horsepower V-10 engine and an attitude to match. The Viper is raw, it's mean and it's nasty… And it's built inside the Dodge Viper Ultimate Factory in Detroit, Michigan! A factory that is unique for Detroit: the Viper is completely hand built. A special team of fewer than 100 craftspeople take two and a half days to build each car. They are men and women who live to build the Viper!
Follow the cycle of the famous bourbon from cornfield to bottling plant, all taking place in the tiny town of Lynchburg, Tennessee.
Famed for matching affordability with sleek designs, find out how Maserati engineers maintain standards despite their low costs.
Renowned as a classic since its creation over 50 years ago, witness the extraordinary new take on the Mercedes Benz 1954 300SL Gullwing.
Step behind the scenes at Europe's largest brewery, the one million square meter home of Heineken, in Zoeterwoude, the Netherlands. There, the world's most international beer company, produces over half of its annual output, which came to 11 million hectoliters in 2009. Of that quantity, they ship 80% to the United States and the rest within the Netherlands. Zoeterwoude is also becoming the greenest megabrewery in the world, with a biogas-producing powerplant and a new shipping hub that saves 100,000 truck trips per year. We meet the beer experts and enthusiasts who make the 150 year-old recipe and ship it out fresh every day.
LEGO It's one of the most popular construction toy in the world. In the age of unprecedented competition for their attention - from videogames to TVs to countless activities - children still spend over 5 billion hours a year playing with LEGO bricks.
A closer look at the step-by-step process behind the making of the AGV – Alstom's high-tech, high-speed train of the future.
Armored Troop Carrier+
A look inside the world-famous Italian Ducati motorbike factory to see how top designers and engineers build the Multistrada 1200.
The latest 'super choppers' are built to fly to places helicopters could never go before, even to the reaches of inner space. Using live action, archival footage and CGI, we marvel at the creation of today's 'super choppers'.
Eurofighter Typhoon is the world's best multi role fighter jet. It's capable of reaching speeds of 2000 kilometers per hour, pulls up to 0 Gs, and it's built to kill. But constructing it piece by piece in 3 different factories across 3 different countries is a mega challenge that only the world's best engineers can overcome. We'll explore how this army of engineers constructs the Typhoon.
Enter the Jaguar mega factory in Castle Bromwich, England as we uncover the design secrets that gave life to the new XJ.
Swedish Super Car+
Adored by many and owned by few, Koenigsegg has definitely hit the streets to quickly become one of the greatest hyper cars in the world. Each car is lovingly hand built in the Swedish factory that looks more like an art studio than a car production plant. Enter the Koenigsegg mega-factory and discover what it takes to create one of the most powerful cars in the world.
Each new version of the Actros is custom made by Mercedes-Benz, a supreme test of efficiency for a factory that builds a truck every two minutes.
Take a behind-the-scenes tour and gain insight into BMW's high-tech and innovative manufacturing plants as they create the sleek and stylish Z4 Roadster.
In a distillery in San Juan, Puerto Rico, family tradition and technology meet to create one of the world's most popular premium rums: Bacardi.
A look inside Ford's most modern production facilities – the Dearborn Truck Plant in Michigan, where the Ford F150 is built.
Frito Lay goes through a million pounds of potatoes a day to make its variety of chips in preparation for the Fourth of July. Working with potatoes from farms scattered across North America, and using some of the most innovative processes in potato chip production, Frito Lay is a serious competitor in the chip market. Ultimate Factories takes a trip to Perry, Georgia to visit this almost million square foot facility as it works 24 hours a day, 7 days a week to prepare for one of its busiest times of year.
When the Mack brothers began building trucks they had a vision, to produce the most durable heavy-duty trucks and engines in the world. Now, over one hundred years later the Mack Titan extends that tradition and sets the new standard for large, heavy-duty hauling. It's over ten tons of chrome and steel packing 605 horsepower and a 200-ton towing capacity making it one of the most powerful trucks on the road today.
Explore the state-of-the-art $200million factory where the controversial four-door Panamera that divided sports car fans worldwide is made.
Follow every step in the creation of the Aston Martin One-77, a million-pound production car created at the height of the global economic crisis.
Join charismatic CEO Dany Bahar in Norfolk, unlikely home of the Lotus megafactory, as he unveils plans for their latest super car: the Evora.
Megafactories is granted unprecedented access to elite Formula One team Williams F1. Back from their latest race in Europe, the team have a week to get the car in shape at their English HQ before they leave for months away on the other side of the globe. They must improve the aerodynamics and completely repair and rebuild the car at their state-of-the-art facility before they fly away. Cutting edge design and incredible technology need to come together as team race for success.
EA Sports: FIFA 12+
Enter the EA factory in Burnaby, Canada, to learn how video game creators took football off the field and turned it into a virtual masterpiece.
Swiss Army Knife+
The Swiss Army Knife may be the most ingenious multipurpose tool ever invented - and the most recognized. It's used by everyone from Boy Scouts to presidents. Who knows how many lives it's saved. And how it's made is as ingenious as the tool itself. At the Victorinox factory in Switzerland, parts start out as raw steel and emerge many stages later as gleaming tools. Everything here goes like clockwork - Swiss clockwork. Then came 9/11. The fallout of that day would reach all the way to this quiet valley and threaten the survival of a company that makes one of the world's most iconic products.
The 48-acre St. James Gate Brewery is situated smack bang in the middle of Ireland's capital city, Dublin. Guinness is the most popular dark beer on the planet. Globally, the megabrewer sells over a billion pints a year in 150 countries. In this hour, we ride along for the busiest two months in Irish beer, from the massive spring barley harvest all the way through roasting, brewing, bottling, kegging, marketing, and distribution.
In 2007 the mammoth Airbus A380 took the Boeing 747's crown for size and capacity - a record Boeing held for decades. Boeing wants its crown back, but it needs to get a new plane in the air, and fast. The upgrading of Boeing's 747 is already two years overdue.
Sir Ratan Tata is a man on a mission: to make India's roads safer by getting people off motorbikes and into the world's cheapest car - the Tata Nano. In India it's common to see a family of four ride together on a motorbike. On bad roads in Monsoon rain that's a lethal way to commute. Tata envisages the Nano as a 'people's car' - India's answer to the Model T. But to bring his car to the people he must overcome some formidable challenges. Design issues and skyrocketing costs threaten to blow out the car's $2200 price tag, and violent protests force him to dismantle and shift his 3 billion dollar Megafactory 2100km across India.
Our story will take you inside the factories and R & D facilities for one of the largest tire companies in the world: Michelin. The company designs and manufactures everything from car and motorcycle tires to the tires on Jumbo Jets and even the Space Shuttle.
MV Agusta is a legendary Italian motorcycle manufacturer. Purchased by a father and son team, the company is now betting its future on a brand new motorcycle design. Our story is about the MV Factory in Varese, Italy, and we will be there as the new motorcycle goes into production. It's design and manufacturing is key to whether the MV brand can return to glory.
This 60 metres high thrill ride is only the 5th ever to be constructed. Its adrenaline fuelled tracks speed riders to 100 kph over loops, drops and banks, pushing them to g force limits usually reserved for fighter pilots. Building this mighty machine takes an army of engineers, designers and master technicians. Find out how one of the world's greatest roller coaster factories creates the world's scariest rides.
Australia's Howard and Sons have been making fireworks for almost 100 years, now the reigns have been handed down to a new generation and they are breaking with tradition. Andrew and Christian Howard along with show designer Stuart Bensley are competing in the 2011 International Festival des Feux in Montreal with a new pyro musical, but will this break with convention see them leave Montreal with a crown or a frown?
For 50 years, Learjet has been synonymous with high-flying luxury and the celebrity jet-set. This is the construction story behind Learjet's top of the range 60XR - one of the world's most iconic private aircraft.
Learn how the Italian company use cutting-edge technology to produce 37,500kg of coffee a day, and export to 140 countries worldwide.
Super Cars: Corvette ZR1+
A rare look inside the Corvette Mega Factory which produces the ZR1-a genuine American supercar. It is the fastest, most powerful, and most expensive Corvette ever built and it can compete against the best that Europe has to offer.
Super Cars: Ferrari FF+
A rare look inside the Ferrari factory where they are building the new FF, the first four-wheel drive Ferrari with four full-sized seats. The FF's 12-cylinder engine is one of the most powerful engines ever built at the factory in Maranello, at 651 Horsepower. The engine block is actually cast there and must go through multiple quality checks before it's ready to join the final assembly line.
Super Cars: Ford Mustang+
Take a rare look inside Ford's impressive Mustang factory, where four different models are made, including the super-powerful 650HP V8.
Super Cars: Lamborghini Aventador+
In 2011, almost a decade since the release of its last flagship model, the Murcielago, Lamborghini launched its latest creation - the Aventador. With a top-speed of 350 kmh and improved handling, it's a symbol of a new era for Lamborghini. Megafactories visits its factory in northern Italy, to follow the story of its creation from conception to launch and to witness an incredible production process, from the brand-new 5,400 square ft facility, devoted entirely to the creation of the Aventador's revolutionary full carbon-fibre monocoque, to the assembly line, where highly skilled mechanics work alongside state-of-the-art equipment to produce four...
Follow the Mini Coupe – the Oxford plant's first ever two-seater sports vehicle – as it makes its way through the state-of-the-art Mini factory.
Super Cars: Gumpert Apollo+
The Gumpert Apollo Enraged - a $1 million street-legal racing car for the road. It's one of the fastest cars on Earth and one of the most exclusive. It's hand built in Germany, using some of the finest racing components Europe has to offer. Roland Gumpert, the firm's founder, is counting on selling it to keep his company afloat.
Super Cars: Lexus LFA+
For 20 years, Lexus has been synonymous with quiet, efficient, luxury. Now they have launched their first supercar - the Lexus LFA. Going from 0 to 100kph in under four seconds, it's anything but understated. This is the construction story behind the Japanese supercar. Hand built at the LFA Works in Toyota City, Japan, this car's body is 65% carbon fibre and powered by one of the highest revving production engine on the road. At $375,000 it's also one of the most luxuriously priced Japanese road cars ever.
Super Cars: Nissan GTR+
Visit Nissan's megafactory, where cutting-edge aerodynamics, hi-tech engineering and a handcrafted V6 engine create a mass-produced supercar.
Super Cars: Tesla Model S+
Mankind has long relied on the internal combustion engine for transportation. Now, with fossil fuels becoming increasingly sparse one company is trying to change the way we commute; this is the story behind the world's first fully electric premium sedan - the Tesla Model S. Tesla's electrical experts in Fremont, CA are gearing up for mass production in a groundbreaking new Mega Factory - but will the Model S take the world by storm?
This isn't just a megafactory, it's a village. The Technogym HQ in Cesena, Italy, boasts a convention hall, library, spa and restaurant and of course a world class fitness centre.
Since it's start in 1977, Almarai has grown into the largest dairy producer in the Middle East. Keeping cows in the desert of Saudi Arabia is no easy task. Using new technology, a secret recipe for cow feed, and a stringent testing process, viewers follow milk from cow to bottle to store shelf.
Explore the mega-brewery in Mexico and discover how the factory operates 24 hours a day to meet the phenomenal demand for its beer.
The fire truck is taken to the next level of engineering, making it a feat of technological genius. This is the ultimate firefighting vehicle.
A 400 square-foot movable mansion that can travel at 75mph. Hit the open road in a Winnebago, America's finest home from home.
High Speed Delivery+
Step inside the largest and most efficient automated delivery system on the planet. More than a courier, UPS is an epic transport network.
Super Cars: Pagani+
What makes a car worth a million Euros? The answer for Horacio Pagani is a super car that perfectly blends art and engineering, that has unsurpassed power, performance and luxury, the finest possible raw materials and in which every single one of its 4700 components will be recognised as a work of art. This film tells the story of Pagani's successor to his world famous Zonda. It follows the creation of the Pagani Huayra from the start of its secret design and development eight years ago through a testing programme that has exceeded one million kilometres… to its launch in Geneva in 2011 and to the production of the very first customer cars. We'll...
Super Cars: Porsche 911+
A closer look at the redesigning of the seventh-generation Porsche 911, which is virtually brand new in terms of size, design and performance.
It’s the SUV with the spirit of a sports car! Explore why BMW moved production of the iconic X3 from Europe to South Carolina.
Go behind the scenes at Corvette, where they create the ZO6 supercar. It has a unique, hand-built, powerful engine that can propel it to speeds of 200mph.
With more horsepower than 30 Ferraris, CAT make the biggest mining trucks in the world, with 12ft wheels and engines bigger than a car.
World's Greatest Concert Hall+
On top of an old warehouse in Hamburg, the architects of Beijings Birds Nest Stadium are building a dramatic new concert hall. Its hoped the stunning design will make Hamburg famous throughout the world. But to attract the worlds best musicians, the concert hall must sound perfect, and getting the acoustics right is notoriously difficult. To add to the pressure, the building is years behind schedule, and millions of Euros over budget.
The challenge of redesigning the Porsche 911, an automotive icon. This is the 7th generation of the car and while it clearly looks like a 911 it is virtually brand new in terms of size, design, and performance.