The Incredible Process For Making Zippo Lighters And IEDs Is REVEALED! | Battle Factory

Learn all about how manufacturers create the Special Operations Delta helmet, the iconic Zippo, a military-grade fuel bladder, and a simulated IED used for training soldiers in handling deadly threats without risking their lives.

Battle Factory - Season 1 Episode 5 "A Pistol, a Firetruck, a Ghillie Suit, and an Armored Fighting Vehicle" – Battle Factory takes viewers into the hidden world of military and frontline gear factories all over the world — where raw materials become finished products. Battle Factory has unprecedented access and reveals how these items are manufactured right before the viewers' eyes.

HELMET:
When a series of delicate snowflake shaped sheets of Aramid are pressed together, they’ll form a piece of headgear that’s comfortable enough to wear to war, and tough enough to take a bullet. Up until the mid-90’s, helmets hadn’t evolved that far from the steel doughboy helmets of World War 1. A helmet had to be developed that offered the same comfort as a hockey helmet, with the ballistic protection and utility of combat gear. The Special Operations Delta helmet has answered that call.

The ZIPPO:
These ribbons of solid brass will get pressed into service as an icon that’s known by its look, its sound, and its name. The Zippo. From World War 2 through Vietnam, Zippos have played their part in the war effort. To light fuses, hammer nails, and heat rations in a helmet. There’s even a legend that a Zippo sitting in a shirt pocket saved a GI’s life by stopping a Vietcong bullet.

FUEL BLADDER:
In war, fuel becomes a target. How that fuel gets to the frontline can make the difference between winning a battle and losing lives. Now there’s a portable filling station that can gas up a tank in minutes and take a bullet without spilling a drop. When it’s cut and welded, military-grade nylon will make one tough plastic bag, able to carry 125,000 liters of gasoline.

The SIMULATED IED:
Landmines and IEDs, or Improvised Explosive Devices, are as lethal as they are terrifying. They’ve killed more than 3,000 troops and wounded 3,000 more since coalition forces landed in Iraq and Afghanistan in 2003. These surprise attacks cause panic and confusion. In the past, it’s been impossible to mentally prepare for these deadly threats without putting the soldier’s life in danger. Now, a Military Simulation Special Effects company has created the ultimate training tool from an aluminum bar. When detonated, they unleash a sensory assault without causing injury. A soldier learns to handle the sounds and smoke of an IED blast while keeping his cool and carrying on with his mission.
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