Historical Background

• Quest for perfect artificial tree since late 19th century
• Evolution: feather trees → animal bristle trees → 1960s synthetics breakthrough
• Modern faux trees: several stories tall, suitable for town squares
• Come pre-decorated to reduce setup effort

Steel Framework Construction

• Steel skeleton foundation using bent steel tubing
• Rollers bend tubing into arcs for base framework
• Workers weld vertical supports to arcs
• Structure built in sections
• Polyester powder spray coating (tougher than paint)
• Parts baked to set coating
• Assembly with U-bolts and ratchet after cooling

PVC Needle Manufacturing

• Green PVC plastic rolls fed to roller with circular cutters
• Sliced into 4-inch wide strips
• Secondary roller with more blades shreds strips into needle-like configuration
• Solid spine left at center to hold simulated needles
• Automated spool winds fringed green PVC
• Multiple colors available for variety

Branch Assembly Process

• Streams of fringed green + brown PVC strip travel over tension guides
• Steel wire unwinds and merges with PVC materials
• Machine twists materials together
• Brown strip creates stem illusion among needles
• Giant scissors cut to correct lengths
• Continuous supply of artificial greenery produced

Snow-Tipped Branch Creation

• Special machine twists and frosts PVC needles
• White latex paint spray creates snow effect
• Ring fastener crimps artificial foliage together branch by branch
• Creates tightly knit massive greenery for framework coverage

Tree Assembly

• Single garlands applied to key grid parts first using pneumatic fastener
• Assembled branches fill sections between garlands
• More efficient than individual branch attachment
• Lights strung and tested (easier pre-installation than post-erection)
• Ornaments wired to branches (reduces customer work)
• Example tree: 1.5 stories tall

Final Installation

• Cone of wired greenery bolted to lower framework
• Panels of artificial greenery hooked onto remaining structure
• Complete assembly: 1 day
• Comparison: real tree this size would take decades to grow