One of the first irons to be manufactured, an illustration of which is shown herewith, did not offer the pleasing appearance nor give the service of its youngest sister, the illustration of which is also shown. One of the first problems was to control the heat at the iron, and to do this a separable switch plug was developed, enabling the operator to connect or disconnect the current supply at the iron.

The real problem, the one of most vital importance from the point of efficiency, was that of the heating element that would do more than heat the center of the sole plate. One of the pioneer manufacturers, after numerous experiments, concluded that, since the point or nose of an iron comes first in contact with the damp goods, naturally it should have first and most heat applied to it. The result was a double heating element in the form of a V, the resistance wire used being symmetrically wound on a flat, thin mica core. This V-shaped element, the point of the V coming up into the nose of the iron, insured a hot point, as well as hot sides, center, back and heel, where the terminals were connected with the switch plug receptacle. Another development which followed was that of an attached stand, eliminating the necessity

Original Electric Iron.

Electric Irons, 1916.

Fig. 1. - Pouring Molten Metal into Molds for Casting Iron Sole Plates.

Fig. 2. - Workman Polishing Sole Plates.

of lifting the iron on and off a stand many times during the ironing. At first the iron was heavy and clumsy, being built of cast iron, but modern manufacture has made it possible to build the sole plate of cast iron and the top of pressed steel.

The illustrations show some of the steps necessary before the iron reaches the shipping room. Fig. 1 shows the workman pouring an earthen ladle of molten metal into the molds in which the sole plates are cast. Fig. 2 shows the sole plate in the hands of the workman, held against a rapidly revolving polishing wheel, after it has been run through a milling machine and ground to a perfect size. Fig. 3 shows a huge punch press which cuts the blank of steel that is afterwards drawn to the shape of the iron top. The workman is seen holding in his hand the blank cut from a sheet of steel (Fig. 4). The blanks of flat steel of such irregular shape are next passed to a mammoth draw press which draws blanks into the perfect shape to be fitted over the top of the pressure plate which holds the heating element firmly against the sole plate. At the operator's left hand is a stack of blanks and in his left hand he holds one ready to be placed in the draw press. In his right hand is a top just pulled from the press, and at the extreme right a large truck full of finished tops ready for the polishing wheels.

Mica, which so many people know as isinglass, is one of the most important materials in the manufacture of the standard electric iron. The highest grade mica comes from India and the open box in the picture shows thin, transparent pieces just tumbled out (Fig. 5). At the edge of the table is a stack of mica strips known as cores. Hanging over the top of the board are several cores on which the resistance wire has been wound, showing the V-shaped heating element.

One of the most important and yet seemingly simple parts of an electric iron is the switch plug which connects the electric light socket with the iron. The operator in Fig. 6 is shown assembling switch plugs and is in the act of driving home a screw which holds in place the fiber bar over which the cord bends.

Fig. 3. - Blanking the Steel Tops.

Fig. 4. - Drawing the Blanks into the Perfectly Shaped Tops.

Fig. 5. - Showing a Box of Imported.

Mica

Above on the table, a stack of "cores" and several elements ready for insertion in the iron. Notice the V shape.

Fig. 6. - Operator Assembling Switch Plugs.

Operator Holding Element Before Strong Light to Detect Defects in the Mica.

Inspector with Carefully Trained, Sensitive Fingers Inspecting Finished Irons Before they are Encased in the Carton.

Fig. 7. - Electric Boudoir Set Three-pound Iron.

Stand for converting the iron into small stove, curling tongs heater, felt bag.

A standard six-pound iron consists of seventy-nine parts and represents two hundred and ten distinct factory operations. Every part is carefully inspected before being routed to the assembling department, and after being fully assembled the irons are placed on a traveling table where each is examined in its turn by an inspector with carefully trained fingers, sensitive as those of a miller who tells the quality of flour by pinching it between his thumb and forefinger. This inspector can quickly detect in the handsome finish a defect that is unnoticeable to the average person.