Key insights

• 🧱 🧱 LEGO bricks have a rich history of over 80 years, establishing themselves as a beloved toy worldwide.
• 🖊️ 🖊️ The design phase begins with brainstorming and sketching ideas, allowing for creativity to flow.
• 🔧 🔧 Designers leverage advanced software to refine prototypes, ensuring every piece fits seamlessly with existing bricks.
• 🛠️ 🛠️ Creating the mold involves state-of-the-art techniques like Electric Discharge Machining (EDM) for precision.
• 💡 💡 The injection molding process uses high pressure to form molten plastic into beautifully shaped bricks.
• 🌟 🌟 Advanced machinery guarantees that LEGO bricks maintain consistent high quality across various designs.
• 🔍 🔍 The finishing touches involve meticulous sprue removal and comprehensive safety testing before distribution.
• 🌍 🌍 LEGO's efficient global distribution system ensures these iconic bricks reach children around the world.

Q&A

• How does LEGO incorporate creativity in the design process? 💡

  LEGO encourages creativity in the design process by employing over 200 designers from diverse backgrounds. The initial stages involve brainstorming and sketching ideas freely, which fosters innovation. This creativity, combined with technical skills and design software, enables them to come up with exciting new brick designs that cater to various themes and building concepts.

• How long has LEGO been in production? ⏳

  LEGO has been a household name for over 80 years! Since its inception, it has continuously evolved, focusing on creativity, innovation, and quality in its products, which have made it a staple in the toy industry worldwide.

• How does LEGO ensure the quality of its bricks? 🔍

  LEGO ensures the quality of its bricks through meticulous design and production processes. Each new design goes through rigorous testing, and during the mold making and injection molding phases, each batch of bricks undergoes inspections for defects. Additionally, the finished bricks are repeatedly tested for safety, guaranteeing they meet strict standards for playability.

• What happens during the finishing process of LEGO bricks? 🏁

  The finishing process of LEGO bricks entails several critical steps. After injection molding, excess plastic, known as sprue, is removed through cutting and sanding. The bricks are then sorted by color and size using automated systems to ensure uniformity. Rigorous safety tests are conducted to confirm that the bricks are child-friendly and meet high standards before they are distributed globally.

• Why is injection molding important for LEGO? 🌟

  Injection molding is vital for creating precise and uniform LEGO bricks. This process utilizes automated machines to ensure consistent quality, precise temperatures, pressures, and speeds during production. It also allows for complex designs, including multi-colored pieces and specialized parts like wheels or minifigure components, which may require more intricate molds and additional finishing steps.

• How is the injection molding process conducted for LEGO? ⚙️

  The injection molding process is integral to producing uniform LEGO bricks. It begins with heating plastic pellets, which are then injected at high pressure into precise molds, which dictate the shape and size of the bricks. After cooling, the bricks solidify, are ejected, inspected for defects, and sorted by color and size before distribution.

• What steps are involved in creating molds for LEGO bricks? 🛠️

  Creating molds for LEGO bricks starts with a 3D computer model of the brick design. A Master model is then crafted from metal using milling and hand finishing techniques. Subsequently, a mold insert is produced from high-quality steel alloy through Electric Discharge Machining (EDM). This insert is mounted in an aluminum mold base and rigorously tested to ensure it meets quality standards before it’s used in production.

• How is a LEGO brick designed? 🎨

  The design process for a LEGO brick involves several steps: it begins with sketching ideas on paper, then building physical prototypes with existing LEGO pieces. Designers use advanced computer software to refine these designs, ensuring that new pieces are compatible with current bricks. This process culminates in an approval stage where executives review the designs before they move on to the mold creation phase.

• 00:00 Discover the fascinating process of how Lego bricks are made, from design to production, showcasing the precision and creativity behind each piece. 🧱
• 01:27 The process of designing new LEGO bricks involves sketching ideas, creating prototypes, refining designs with software, and going through an approval process with executives before moving on to precise mold creation. This meticulous approach ensures high-quality, compatible bricks. 🧱
• 03:00 The mold making process for Lego bricks involves creating a precise 3D model, crafting a Master model from metal, and producing a high-quality mold insert using specialized machining techniques. This mold is then tested rigorously to ensure quality before being used for production. 🧩
• 04:29 🔧 The injection molding process is crucial for producing uniform Lego bricks, where heated plastic pellets are shaped in precise molds before being ejected, inspected, and packed for distribution.
• 05:54 Injection molding is essential for creating precise and uniform Lego bricks, involving automated machines for consistent quality and intricate designs. 🌟
• 07:27 🔍 The finishing process of Lego bricks includes sprue removal, adding designs, sorting by color and size, and rigorous safety testing before global distribution.