Each of the 16 feathers on a shuttlecock must be precisely the same length. The assembling process is started by the punching machine. 16 holes are first punched around the edge of the shuttlecock tip. The angle of each feather is altered by a worker using flat-nosed pliers.
After that, she tests the balance of the shuttlecocks in a wind tunnel. To achieve the best balance, some shuttlecocks may have slightly varied angles for each feather. The feathers are transferred to a machine that puts a bead of glue around the shuttlecock tip after the angle of the feathers has been adjusted. The feathers are held in place by this.
The shuttlecock is put in a specialised sewing machine where two rows of thread are securely sewn together to further stabilise the feathers. Each feather is attached to the next by the threads. The shuttlecocks become stronger as a result of this process, enabling them to keep their strength even when they are being smashed back and forth over a net. A worker ties off the thread to prevent it from unravelling after the machine has stitched the shuttlecock and trims the excess.
She finally straightens the thread rows. The shuttlecocks need to be tuned after the threads are in place. The feathers are once more adjusted by a worker to guarantee perfect balance. The shuttlecocks threads are glued to one another, keeping them in place and providing the necessary stiffness. The thread is designed to absorb adhesive quickly.
Testing for quality assurance is now necessary. The shuttlecocks are fired to a worker waiting by a machine with an arm like a badminton racket. The speed of a shuttlecock can reach 300 feet per second. After passing the quality control test, a worker places 12 shuttlecocks at a time into lengthy cardboard tubes that resemble tennis ball holders. It makes sense that the shuttlecock is also referred to as a birdie because it has 16 feathers. These top-notch shuttlecocks are prepared for play.