From Layout Notion to Goods: How LEGO Sets Are Created

LEGO is the biggest toy organization globally, with an illustrious background that no other enterprise can match. The extensive history of this business has aided it to convey joy to youngsters and even young adults for decades. A number of families appreciate their design kits throughout the world, and there is barely any dwelling that doesn’t have one particular.

You are in all probability curious about how LEGO achieves its set layouts. We ended up, far too, so we did some deep digging to deliver you this information. Examine on and discover as we briefly adhere to their product kit manufacturing from principle to output. Let’s get straight to it!

What is LEGO All About?

As you may well currently know, LEGO is a Danish corporation. The title comes from the abbreviation of two Dane words and phrases which are “leg” and “godt.” These words and phrases translate to English to mean “play effectively.” The good thing is, they seen that the Latin (legō) translation of the time period suggests “put with each other.” 

LEGO has its major factory in Billund, Denmark, with 3 very important sections. They are:

  • The 4 towering silos – In this article is the place LEGO stocks its raw components (unprocessed plastic pellets).
  • 12 generation strains – This is exactly where LEGO bricks are created at an once-a-year output of up to 21 billion blocks. 
  • A 23-meter-higher warehouse – The developing blocks are packed here, divided into categories, and transported absent. 

The Producing Method for LEGO Kits?

This part of the post will abide by the LEGO kits sequence enhancement from the design and style phase to packaging. 


Designing LEGO Sets

Each individual constructing block follows a lengthy style and design method. In this scenario, designers re-examine the entire world in children’s eyes. For occasion, designers may perhaps have to enter the precise police station, journey in police autos and use handcuffs to layout “police constructing blocks.”

This group of detailed controls experiments the brick by brick of the police station. The designers then make a design centered on the scene noticed with their eyes. For illustration, when measuring their top, they reproduce the area environment, up to the crowbar observed under the cell’s bed. 

Designers very first provide hand-drawn types of new components. Right after this, the models are made on CAD or 3D programs. Designers can decide on distinct hues, textures, and finishes at this stage. They experiment with the layout details until eventually they get the best match selection for their supposed package. 

Once designers are content with the simple design and style, the future move is to create a prototype mildew for the developing blocks. 

Building the Prototype Mould

LEGO considers the mold as the soul of its bricks, and rightly so. All developing blocks appear from mould. The precision specifications of mildew creating in this company are now excessive for the reason that they want all blocks to be a part of jointly usually. The precision tolerance for these molds can be as very low as .002 mm.

Designers initially review the buildings of the intended toy and run them by way of 3D scanning to make prototype injection molding. They can make slight variations to the molds, removing all sharp edges that may perhaps injure the players. Robots help LEGO to polish the molds with brass. On completion, designers manually examine the molds before sending the ideal types to the workshop.

Forming the Mixture

All fundamental LEGO sets start off as plastic pellets, mostly acrylonitrile butadiene styrene (Abdominal muscles) supplies. The plastic injection molding procedure turns these pellets into bricks, demanding significant machines and really large temperatures. Hence, devices normally manage most Lego brick creations.

The plastic pellets are vacuumed into the storage silos obtainable at the manufacturing services. Each silo at LEGO can keep up to 33 tons of Stomach muscles pellets. Upon the get started of generation, the granules move as a result of tubes into the injection molding device. This device melts the pellets at up to 540 degrees Fahrenheit. 

Then, it injects the melted plastic into previously formed molds although implementing amongst 25 to 120 tons of pressure. The new elements are authorized to cool before they fall into the cargo box. The blocks are randomly sampled for high quality screening. The exams contain the sizing, peak of the particles of the making blocks, and the grip of these blocks. 

If fabricators explore any faulty components, they remove them from the team. Other blocks will enter the sorting box alongside with the conveyor belt. The moment the box fills, there are robots prepared to decide it up and transfer it to the assembly hall. 

Automation and the Use of Robots

LEGO’s molding devices create up to two million parts for each house. Sorting and assembling this will call for greater human labor. This phone calls for the automation of procedures and the use of robots. 

Robots are accountable for using away prepared cargo containers via mechanical forks. The central mainframes notify them to harvest the building blocks and send the created Lego into the conveyor belt that qualified prospects to the warehouses. The warehouses are categorized, and only robots are there. 

4 cranebots constantly shift to prepare the huge bins of Lego sets into various groups prior to they enter the final levels of growth.

Finishing the Production

The ultimate levels are the coloring, decoration, and packaging. Extremely specific machines support paint and decorate LEGO bricks at a continual rhythm ahead of sending them to the packing strains. The equipment separates the Lego bricks at the packaging strains and uses optical sensors to depend them. This classification robot is pretty exact.

The moment counting is full, it filters the blocks according to the number and pours them into the sorting box to finish the packaging. The conveyor belt then takes advantage of the weight to figure out if the box is correctly packaged. The machine drops the contents of a total box into the wrapping device to end the binning operation. Entirely packaged sections are transported to distinctive locations worldwide.


Each individual LEGO established you see out there is a final result of the concerted endeavours of many persons, ranging from designers to professionals. The advancement approach of LEGO making blocks correctly represents a blend of industrial technology and human ingenuity in plastic injection molding.

This is also the circumstance for every prototype injection molding and other prototyping processes. Developing a new merchandise from the style and design phase to closing output is in no way quick, involving a good quantity of time and meticulous setting up.

Also, the style to merchandise process is not usually easy. Take injection molding for case in point this procedure involves large temperature and stress inputs which may well lead to the injection molding pieces to fall short.

Hence, it is vital to do the job with specialist professionals and expert associates. This will make your design to merchandise method far more successful with superior-quality conclusion-consequence.

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