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The Surprising Science, Design, and Engineering of LEGO

2022.08.15
  • Owen KOZLOWSKI **Photo courtesy of Alena Darmel @Pexels.com**
  • Hobbies_LeisureActivities
  • Intermediate
  • 2022

You know LEGO. We all know LEGO. These plastic brick toys have been world famous for over 70 years. There are toys, models, robots, animated movies, visual art, and more. For most people they are a childhood toy; something fun and creative to play with on a rainy day. But LEGO are not just simple blocks. Behind the popular toy is a deep history of cutting-edge technology, manufacturing, research, design, and engineering. 


Materials

The LEGO company originally made toy blocks from wood. Eventually they shifted to plastic in 1947. Different types of plastic were tried, but eventually LEGO chose ABS plastic (acrylonitrile butadiene styrene) as its main material. ABS has been LEGO’s only plastic for over 50 years, but recently they are changing this. Since 2018 they started using a bio-based plastic made from sugarcane. The company is planning to completely change to an eco-friendly plastic by 2030 and is already ahead of schedule.


Finding a good material for LEGO is difficult. The LEGO quality standards for materials are some of the highest in the world. LEGO pieces must be precise, strong, and last for a long time. LEGO manufactures over 36,000,000,000 parts in a year (1,140 bricks/second) with a success rate of 99.999982%. Each piece is so strong one brick can support 375,000 bricks. To break the bottom brick, you would have to build a LEGO tower 3,591 meters high. Independent testing and in-house company testing shows that the life of a LEGO piece is between 2,000 to 3,000 uses (maybe more, depending on the piece). 


Design and Engineering

LEGO pieces are not only strong, they are well-designed. For each piece the maximum size variation is 0.004mm (that is less than the width of a human hair). In 1958 LEGO designers and engineers created, and still use, a special “universal system” for piece design. This means EVERY piece from EVERY set since 1958 will fit together with ANY other piece from ANYWHERE in the world.


To create the pieces and sets LEGO designers create and customize special 3D imaging software, modified versions of CAD, and even virtual reality models. Recently LEGO has also been training AI to design pieces, sets, and to package the toys. 


The People

LEGO Designers have backgrounds in engineering, CG modelling, design, fashion, art, architecture, and more. The application process is very difficult, very competitive, and candidates must be highly qualified. LEGO often scouts and recruits people from PhD programs and high-tier universities worldwide to become designers and LEGO creators. 


Q1: How many bricks are needed to break one LEGO brick?

A. 2,000-3,000

B. 375,000

C. 3,591


Q2: What were the first LEGO blocks made from?

A. Sugarcane 

B. Plastic

C. Wood

D. ABS 


Q3: What is special about LEGO’s “universal system”?

A. Every piece is almost perfect in size and shape.

B. Every possible piece fits together.

C. Every piece is made from eco-friendly plastic.


--- Scroll down for answers ---























A1. B

A2. C

A3. B





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