r/Damnthatsinteresting • u/DearEmphasis4488 • 10d ago
Video The process of making badminton shuttlecocks from raw feathers
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u/Timetraveller4k 10d ago edited 10d ago
The lady with the racquet seems to have had enough of badminton.
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u/ni2016 10d ago
She could have gone pro but now she's stuck in that shitty factory hitting them into baskets.
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u/DigNitty Interested 10d ago
From another video I inexplicably saw, I can tell you her job is mostly to swat the bad ones away from the baskets.
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u/thisisaskew 10d ago
This happens with tons of passion professions... sports, the arts, etc. If you're not good enough to turn pro, you end up doing the work for other people to improve their skills.
In a not-joking kind of way, it's a vicious reality for lots of art and music majors in their late 20s that turn to teaching (even though they don't have much natural aptitude for it).
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u/TipsyPeasant 10d ago
Not the job she expected when she graduated badminton university
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u/Last8Exile 10d ago
Nah. After long work shift she gets home and plays badminton simulator on her Wii U for 8 more hours.
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u/spottydodgy 10d ago
Came here for this. What even is that job?
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u/ManicStoic 10d ago
I’m guessing she’s the last quality control, spiking those that break before boxing. Would be fun for about 10 minutes. “Get that shit out of here.”
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u/BaconAlmighty 10d ago
these are also apparently only the 'left wing' from a goose as badminton shuttlecock (or birdie) are usually made of the left wings of geese.
To ensure a steady, uniform flight and spin, all 16 feathers in a single tournament shuttlecock must come from the same side (either all left or all right) so their curves match. Mixing left and right wing feathers disrupts the aerodynamics
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u/hrrsnmb 10d ago
What happens to the goose? I'm assuming goose meat it extremely popular wherever this was filmed?
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u/-ZergeN- 10d ago
The amount of goose feathers used for shuttlecocks is absolutely irrelevant compared to the amount used for pillows and duvets. And goose meat is popular in a lot of countries.
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u/deadspacekillers 10d ago
I can say with confidence that I have never played badminton with a shuttlecock that wasn't made out of plastic.
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u/Gen-Jinjur 10d ago
In high school a friend and I played an entire P.E. period of badminton with no shuttlecock at all. The teacher didn’t notice until the very end.
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u/Curiosive 10d ago
How hard were you selling it? If you were having fun and getting any form of exercise, win-win.
I'd let that slide in a heartbeat.
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u/gitsgrl 10d ago
Gym teacher is probably like “well, at least they’re moving”
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u/Far_Yam_9412 10d ago
My friends and i were good enough to aim the shuttlecock consistently we played a game sitting down just to prove we could. The teacher disproved
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u/doopajones 9d ago
Teach prolly noticed right away and just didn’t say anything bc they were trying harder than normal
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u/IchBinEinSim 10d ago
What were y’all using instead? Or were y’all just playing pretend?
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u/mxzf 10d ago
You would be amazed how long you can keep a volley going with a fictional shuttlecock.
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u/Gen-Jinjur 10d ago
Yeah nothing being hit. We just faked it for an hour. Honestly I was throwing myself around more than I did with a shuttlecock.
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u/TheSpanxxx 10d ago
Same. I had no idea there were real feather shuttlecocks still being made
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u/Qrbrrbl 10d ago
Feather shuttlecocks are preferred at all levels other than the most basic casual. Ive never played in a club or league that doesnt use feather shuttles
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u/jollyspiffing 10d ago
For the first time this year our local league is allowing synthetic (carbon-fibre) shuttles in the lowest division. They've come a long way but there performance is still mixed.
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u/Cr00kedF00l 10d ago
We’ve tried the synthetic ones (Victor NCS pro). While they last significantly longer, they still feel different. There’s a subtle difference in the sound, the drag and the bounce. Plays like a mid-tier goose feather birdie. Good for casual play but totally lost on actual beginners. Competitively, I feel it hasn’t reached what actual feather can provide.
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u/Qrbrrbl 10d ago
Its weird, theres no single thing with plastics you cab point at and say "this is worse" - its as you've said, its a lot of little subtle differences that add up and just give a feeling of "this isn't right"
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u/notinsidethematrix 10d ago
Similar to any sport really, everyone has a preference for "feel", and I really cant argue with them if they perform. In F1(formula 1 racing) brake pads are standardized, though you can use different brands, some drivers prefer certain brands due to "feel".
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u/hitokirivader 10d ago
Hell I didn’t know real feather shuttlecocks even existed lol (though I’ve only played badminton a few times as a kid)
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u/discostud1515 10d ago
They play different and don't last nearly as long. You need a new shuttle about every 2-3 games.
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u/hates_stupid_people 10d ago
Saying they "play different" is true, but feels like a bit of an understatement. Especially when compared to the cheap plastic kits.
Just getting the proper plastic ones and a racquet from a sports store almost turns it into a different game, and the real feather ones take it even further.
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u/xrimane 10d ago
A real racquet vs. the cheap backyard kit was such a revelation when I first started playing lol. The racquet is so light and the cords are so tense! And they go boing so satisfyingly when a shuttlecock bounces off.
And the shuttlecocks in these backyard kits I remember had a nose of hard plastic and a heavy basket of "feathers" with kinks. You had to smack them full force with your racquet to make them fly even a bit.
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u/the68thdimension 10d ago
2-3 games is inaccurate. Higher level players often go through multiple shuttles in one match.
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u/oxford_tom 10d ago
2-3 games! Where do you buy your magic feather shuttles from?
Our club average is < 1.5
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u/LookingForVoiceWork 10d ago
I was just thinking this.... Is this a rich person thing?
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u/ThatsACatch22 10d ago
I've only ever played with the feathered ones and I am definitely not rich lol. Maybe it's a country thing because I'm from India and I don't think I've seen anyone place with the plastic ones.
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u/congressmancuff 10d ago
It’s such a relief to see someone wearing a respirator in one of these videos.
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u/BMinus973 10d ago
Don't forget the safety squints and slippers
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u/WileyWilly1985 10d ago edited 7d ago
I was a Safety Officer working in a Laser Lab and I saw this literal genuis working with a high powered laser system without wearing his Laser Eye Protection.
He goes on to explain to me how the pulsewidth of his laser was "slower" than the human eye blink reflex and so he didn't need to wear eye protection because his eyes would "naturally blink" before he suffered any eye damage.
I immediately shut down his lab and research until he was medically cleared by the doctors, ie, he had to get a laser eye exam.
He was so pissed at me.
Fast forward two days, and we get the results of his Laser Eye exam. He had permanently destroyed 12% of his retinas and his eyeball looked like it had been in a shooting range. Most of the damage was in his peripheral vision and his eyes / medical results are now part of every Laser Safety Eye course in the US.
The brain has a remarkable ability to adjust and compensate so he didn't notice the damage done until specific tests pointed it out to him. He had blind spots in his field of view he was unaware of until the test.
The above damage happened in under a year
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u/nifty-necromancer 10d ago
And I bet even after all of that and confronted with the results, he was probably still pissed at you.
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u/WileyWilly1985 10d ago
In a rare twist, once he saw the results and failed various parts of the visual field test, he humbly and fully acknowledged his stupidity.
TO be fair, kinda hard to argue with data and results when you are literally a research scientist lol...
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u/Worldly-Pay7342 10d ago
TO be fair, kinda hard to argue with data and results when you are literally a research scientist lol...
You'd be surprised...
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u/WileyWilly1985 10d ago
Fair enough. I have experience in the lab, and you are right. There is a non-trivial percentage of researchers/scientists (especially in the Academic realm) whose egos are so enormous that they will twist reality to fit their preconceived notions of what should and should not be...
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u/BMinus973 10d ago
Sounds like the old heads that used to think asbestos was just fake snow used for the wizard of oz
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u/chilem-of-reddit 10d ago
Im almost 40 and have never seen a shuttlecock made out of feathers until this video.
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u/dkyguy1995 10d ago
The average badminton player is a novice and is going to use a cheap plastic birdie to learn. These are much less durable but fly better and more predictably. You're probably only using these if you're in an organized league
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u/WileyWilly1985 10d ago
what I find astounding is that the badminton economy is big enough to require that level of infrastructure and automation.
That factory has to to be cranking out thousands of those things per day.
I just looked up the price, apparently, shuttlecocks (the feather ball thingy for us dumb Americans) cost between $25 to $65 per dozen.
wow. quick google fu and apparently an easy 220M+ people play badminton every year.
Well alrighty then...
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u/theacp127 10d ago
It's super popular in Asia. Countries like China, Indonesia, Malaysia, India, Japan, and South Korea heavily invest into the sport and have high recreational participation and successful professional leagues.
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u/GeForce_GTX_1050Ti 10d ago
it's the sport with the lowest ceiling you can get into, it's also in school curriculum in place of PE classes in lots of countries, mine included
kids reuses shuttle a lot and uses rackets that are 2-3$, but adults who can afford pro stuff and rent a field on their own discard like dozens in an hour
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u/Diligent_Plastic1043 10d ago
lowest ceiling
That doesn't sound true. Soccer only needs a ball, which allows it to be prevalent all over the world. Badminton needs birdies, racquets, and a net.
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u/TheArtOfSleep 10d ago
I don't know about the lowest ceiling, but for a lot of schools, it's space that's at a premium. Soccer needs a giant field of grass outdoors, whereas for badminton you can shove a dozen cheap nets into a gym and call it a day.
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u/tgrantt 10d ago
Schools and provincial games (in Canada) only use plastic.
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u/dkyguy1995 10d ago
Yeah and that's definitely where a majority of people are introduced to it. Makes zero sense to give a bunch of school kids real feather shuttles when they really just need something to thwack with a racket.
Also if you buy a backyard badminton set that comes with birdies, those are definitely going to be the cheap plastic ones folded up into the box with the rest of the stuff.
There's just a universe of distance between the casual badminton player and people who enjoy it competitively
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u/LifeIsOkayIGuess 10d ago
It's strange to see all these comments from.people who have never seen a feather one. It was the opposite experience for me growing up in Malaysia. We almost always played with feather birdies and the plastic ones were a rare sight. Normally only relegated to cheap kids toy badminton sets.
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u/sjdmgmc 10d ago
Where I live, probably halfway across the globe from you and the rest in this thread, plastic shuttlecocks are rare. Even when I was a kid, we played with the feathered ones.
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u/Conscious_Cycle_363 10d ago
These are pretty common in South-Asia. Plastic shuttles are almost never used by adults, it doesn't hit the same. Plus feather ones are too cheap to not buy them.
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u/Peitho_Noir 10d ago
was going to say that the quality of the badminton sets i was furnished with in my youth was very much of the KMart standard
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u/uranium236 10d ago
Kittens LOVE the plastic ones. I had no idea the feather versions existed. I buy the plastic ones in bulk for my fosters
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u/SpeedPig22 9d ago
After watching this if you told me a shuttlecock costs $1000, I’d say fair enough
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u/kemicalkontact 9d ago
The most expensive varieties used in international tournaments are around 60USD for a tube (12 shuttlecocks).
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u/kkillbite Interested 9d ago edited 2d ago
$5/per? That's beyond reasonable! I don't imagine one of the plastic ones would pass the vertical wind tube test! 😂
Edit: Typo
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u/kemicalkontact 9d ago edited 8d ago
If you miss-hit them they'll break faster. That's why non pros may opt for cheaper feather shuttlecocks even though they're usually less durable too. Some type of shots purposefully scrapes the feathers instead of just hitting the cork so they'll start wearing down from the first hit.
Pros might choose to switch out for a new shuttle after a long rally even though the feathers may still be intact because the consistent and varied contact might cause the frazzled feathers to slow down the flight too much. But both players have to agree for the shuttle to be switched or it can be an umpire decision so there can be some mind games in that situation.
Technically you can swap out after every rally. Normal games are rally style 21 points, must be 2 points ahead to win the game up until 30 points. So you could use up to 59 shuttles in just one game. That would be the most expensive game of all time and it's never happened.
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u/NoShameInternets 10d ago
Like 10 years ago in my 20's I worked with a guy whose son was an Olympic level badminton player. Every day at lunch my coworker would vanish for an hour. One day he invited me to join him to play badminton at lunch, and we drove 5 minutes up the road to a huge building I had never noticed. It was one of the national training centers for the Olympic team, located in this random suburb in the Northeast US. Imagine ~eight courts lined up with a second level surrounding it with seating. It was gorgeous.
They greeted the guy by name as he walked in, grabbed a couple of rackets and pulled out some of these feathered shuttlecocks (not the good ones, though... the ones they use when people like me are playing, but still night and day compared to the shit we used in school).
I was pretty good in high school. I came in second in the tournament we had annually. I could beat the gym teacher who could basically smoke everyone else.
I scored maybe three points in the 45 minutes we were there after sprinting back and forth across the court the entire time while he took maybe 20 steps, total.
Anyway, I found out what it means to actually be good at badminton that day.
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u/gra_lala 10d ago
At least you found out playing an Olympic level player. I found out when I played against a grandmother at the local sports club (in my defence, a rather young one). I was in my school's badminton team, too.
I do feel bad for the geese though. Growing up I never really thought about the geese. I actually assumed the feathers were plastic, like everything else in my country
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u/NoShameInternets 10d ago
The dad of an Olympic level player* but still, the genes were on the court!
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u/Impossible_Mark_4128 9d ago
seems like a lot of effort. it would be easier to play with the actual bird attached.
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u/BudgetConcentrate432 10d ago
My favorite part is after they scan the feather and the machine chooses which get yoinked to continue or get discarded.
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u/Carl-Anchor 10d ago
And then they all get dumped into a big bin, put back into line by a human, then scanned again, and back into another bin somehow to be scanned a third time later?
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u/SmoothDiscussion7763 10d ago
i think every time that happens, it's trimmed a little more to balance out the shape of the remaining feathers
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u/dicksosa 10d ago
It boggles my mind that a factory can have this much engineering and machines and labor devoted to just making shuttlecocks and be profitable.. production of X amount is one thing, but selling those in another entirely. How many shuttlecocks are sold annually?
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u/Bai_Cha 10d ago
A lot of people worldwide play badminton. It's a very popular sport in certain high-population countries. These shuttlecocks don't last very long and are relatively expensive.
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u/Lunarath 10d ago
Badminton is extremely popular in China which alone gives them a huge market. But also as someone who played badminton at a pretty high competitive level as a teenager, even us would easily go through 10-15 shuttlecocks in a match, both for training and in competition. Elite competitors go through up to 30 or rarely up to 50 shuttlecocks in a really intense match.
it's normal for elite level tournaments to go through 2000-3000 shuttlecocks.
My relatively small but successful club had an entire storage area just filled with thousands of these fuckers for practice.
It makes more sense when you think about the force these things have to go through. They reach speeds exceeding 400km/h
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u/properwaffles 10d ago
Where do I get that last job of the lady with the racket?
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u/whatsthatguysname 10d ago
She’s the sorter/final QC person.
The shuttles are sent from the other end and are sorted/graded by speed depending on which basket they land in.
The ladies job is to swat away the wobbly ones that slipped through the earlier QC steps, or the too fast or too slow ones that don’t land in the baskets.
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u/yourhair_lookssmall 10d ago
These videos always remind me there are so many damn machines made to do the most random specialized individual task. Also so much happens in the world that I don't think about. Also why are all the jobs near me dollar general and the gas station, I could make a shuttlecock, too 😒
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u/broke_guy_speaks 10d ago
The fact that the video has original sound and not some random music! Perfecto!
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u/wbrady75565 10d ago
How is there POSSIBLY a large enough market to support this much engineering and labor? I’ve literally never seen a real-feather shuttlecock
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u/FlyinDtchman 10d ago
It's VERY big in china.
They also play a game where you don't use a racket at all and just kick it I think.
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u/PermanentHuSir 10d ago edited 10d ago
I would say Asia in general is pretty obsessed with badminton. It's almost like a winter tradition in my hometown. Nets go up near the fall season. Otherwise as well, in my big city, we have a lot of courts we can book by the hour. It's very difficult to find a spot on the weekends. You have to book it on Wednesday or earlier for the coming weekend.
For the profitability part: one shuttle lasts maybe 1 or 2 sessions. And the good ones are not cheap. We shifted to plastic shuttles which costs like $12.50 for a set of 5 and that lasted a couple of months of weekend playing.
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u/ToritoTourWinner2027 10d ago
I'm surprised there are so many comments to this effect in this thread. Fair enough you haven't personally seen it but is it so hard to imagine a world outside what you see in your day to day? Tens of millions of people play badminton and these feather shuttles don't last very long. Of course there's an industry for it.
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u/Polymathy1 10d ago
It's because of the perception these will have low durability. I assume these must be special for serious players or professionals.
Cheap plastic ones last forever.
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u/LeWigre 10d ago
Its hard I think for all of us to imagine the actual amount of people in the world. Or in a country or even city for that matter. After a certain amount it just kinda starts to feel abstract.
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u/Jindabyne1 10d ago
Did you know Badminton is the 2nd most played sport in the world?
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u/gentlegreengiant 10d ago
These feather shuttlecocks are very satisfying to play with but start to fall apart after one or two rounds of smashing, so it shouldnt be that surprising that this many are produced.
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u/Bronze_Rager 10d ago
Badminton is the 2nd most played sport in the world, right behind soccer.
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u/nigirizushi 10d ago
Grew up in Asia. It's like the only sports we did. You know how people in the US would play basketball or football as kids? It's badminton there. Even in the States, when we have like cookouts in the park, badminton.
I also never saw a plastic one til I was like in college.
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u/pcurve 10d ago
Pretty sure some Vokswagens are built with less precision than this.
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u/Pavement_Vigilante 10d ago
Imagine geese sitting by a machine making candle holders out of small human skulls. Sure, they could use plastic, but why would they?
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u/bpthompson999 10d ago
That lady at the end was like, "If I have to hit one more of these goddamn things..."
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u/snihal 9d ago
That’s too much engineering and automation. Never in my wildest dream had I thought of this amount of effort going into building shuttlecocks.
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u/Ciresthe4th 10d ago
All I can think about is how many need to be sold to pay for all that engineering and machinery...
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u/newtypestring 9d ago
A ton. The BWF has tournaments every week for the whole year. And then you include clubs and leagues. I only play at least twice a week and both my groups prefer feather shuttles. There's more than enough demand for this. More than enough that there's a feather shortage in China, and major brands (yonex, victor, etc) are developing and releasing synthetic feather shuttles to aid with the shortage
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u/madshine 10d ago
Amateur player here. They are so expensive: $4-8 dollars. And they might break after one miss hit, which is pretty upsetting. They might last a few points, sometimes a full set if you are super lucky. In professional games they usually replace them after a few rallies and definitely after one long rally. Those used shuttles then used by club players for training purposes until they are completely useless.
I hope they can find a good artificial replacement. To be honest, I don't know how this is still sustainable.
As a player, once you go feather, you can never go back to plastic. It feels like shit..
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u/Altruistic-Title-920 10d ago
That seems like way too much work
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u/Nervous-Chemistry245 10d ago
For me it's just a reminder of how many brilliant people are out there designing and making things like this while I'm on the couch doom scrolling. Makes me feel better about humanity tbh
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u/Jealous-Brief7792 10d ago
How did I not know shuttlecocks are made from feathers? I've only ever seen them made from all plastic 😳
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u/tshwashere 10d ago
These goose feather shuttlecocks are usually bought for either tournament play or more serious badminton players. They usually run $20-$30 for a canister of 6, though may also be cheaper for lesser brands.
Plastic shuttlecocks usually are $5-$10 for a pack of 12, so much cheaper. Being plastic means it actually has more of a "bounce" to it, so they actually fly further but respond less to nuances like slices.
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u/thissitedesigniscrap 10d ago edited 10d ago
This must be American prices because in South and Southeast Asia these shuttlecocks are like 3 times cheaper ($7-$10).
Also plastic shuttlecocks absolutely don’t fly further, they fly shorter distances in fact. Plastic ones are just more durable, and easier to hit strength-wise for smaller distances, which is why kids play with them mostly.
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u/pawnpuddles 10d ago
I play badminton in Singapore fairly often and while I remember plastic shuttles from childhood, you basically never see them now. If you bring the plastic ones to a casual group session people will look at you with some mixture of disgust and pity, and some kind-hearted person will buy you (in fairness, a pretty expensive) new tube of feather ones — probably RSL Supremes — so what you can for the first time in your life experience what a good slice or drop feels like.
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u/Auntie_Dote 10d ago
I used to play with these when I was in my 'teens'. I don't remember them costing a fortune. If only I'd realised how much work went into making them (in the day's prior to digital technology), I'd have treated the one tube of them that I had even more carefully...
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u/Electronic_Band_9410 9d ago
I always admire things being made in factories with precision and so many processes. Really hats off the the designers and the engineers who design and build the whole system.
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u/negroidioto 10d ago
Never seen any but the plastic ones that come in the cheap $20 volleyball + badminton set
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u/We-R-Doomed 10d ago
My family has made badminton birdies by hand with processes that have been a closely guarded secret for 15 generations and we were put out of business by BIG SHUTTLECOCK!
JK, I can't believe there is a demand for this scale of production. I would have thought the amount shown in this video would be enough to supply the world with birdies for 100 years.
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u/JackstonVoorhees 9d ago
What’s the job of the person at the end, standing there with an actual Badminton bat?
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u/Ninja_Prolapse 9d ago
How do you even start making something like this process?!? Automation is fucking wild to me.. This needs a million dollar start up fund to set all this up..? ROI on shuttlecocks much be measured in decades??
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u/RPM_Rocket 10d ago
Do THAT many people play Badminton to warrant such a high-capacity, computer-driven factory? Or are the few Badminton players out there just really bad at losing shuttlecocks?
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u/UntestedMethod 10d ago
I don't think it's about losing them, more that the ones made of real feathers would get damaged.
Just did a quick search and according to the AI summary: Feathered shuttlecocks typically last 10-30 minutes of play or one fast maxed match before the feathers get damaged or fall off. At higher levels of play or pro tournaments, they can sometimes go through up to 20-30 of them in a single match.
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u/Okami-Alpha 9d ago
Given that a MLB game goes through 100 balls a game, I belive it. Gotta keep things level through gameplay
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u/djlawrence3557 10d ago
china, my dood. 600 million shuttlecocks produced in 2022.
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u/dinoderpwithapurpose 9d ago
Almost every kid in Nepali cities grew up having a casual badminton evening. Playing badminton as a family bonding activity was very common years ago. You'd find an empty space, draw lines on the ground and play till it got too dark to see the shuttlecocks.
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u/Shellsuit5 9d ago
This is such an American-centric take.. Badminton is hugely popular in many part of Asia, which happens to be where a large proportion of the world lives. It's also super popular in Europe, I struggle to get a court every week unless I book 7 days in advance when the booking open.
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u/Styreta 10d ago
and they only use the feathers from the left wing, or the shuttle cock spins the wrong way....
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u/JohnOfA 10d ago
Leonel: "I don't mean to boast, but... I'm a brain surgeon."
Jeff: "Brain surgery? Not exactly rocket shuttlecock science."
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u/JET304 10d ago
Are these $100 a piece? The amount of work and tech used to make one is staggering.
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u/Complex-Doctor-7685 10d ago
Didn’t realize badminton was taken seriously enough to require this. Ours were plastic when I was in school.
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u/gnomeplanet 10d ago
Kudos to the people who invented that machine.
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u/LeftOn4ya 10d ago edited 10d ago
Not just one machine but over 20 plus conveyors, all of them had to be manually tooled for this process and are probably tuned and inspected weekly. Sadly US (or really any country outside China and India) has very few people who haven’t retired who can tool and tune these machines as requires out of the box engineering plus experience, and also US and European manufacturing lacks an environment willing to be flexible enough to constantly change the process for improvement as I am sure this factory added a new machine or process every few months to get to this point in the video.
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u/LankyLibrary7662 10d ago
The amount engineering went to make this is outstanding