*The entire injection molding process is automated to increase the production speed and capacity while maintaining accuracy and precision.

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Plastic injection molding enhances your manufacturing capabilities with the ability to mass-produce intricate plastic components and complex products. It offers greater flexibility while ensuring efficiency in meeting market demand. By utilizing plastic injection molding, businesses like yours can reduce production costs, increase productivity, and ultimately thrive in today’s competitive market.

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Injection molding, a process developed in the 1930s, allows mass production with high precision and consistency. LEGO integrated this technology into their manufacturing processes in the late 1940s, resulting in bricks that featured consistent dimensions, improved structural integrity, and enhanced clutch power. Through this technology, they were able to release the first interlocking brick, the aptly named Automatic Binding Brick, in 1949.

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The story of LEGO® began in 1932 when carpenter Ole Kirk Christiansen started a small workshop in Denmark to produce wooden toys. Through his incredible tenacity and passion for toy-making, Christiansen built a successful company after suffering numerous setbacks. He soon renamed his company LEGO after the Danish phrase leg godt, which means “play well.”

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Implementation of a high speed drill motor with solid carbide drill bits, along with careful attention to all details of the process, has resulted in an extraordinary increase in drill bit life, as well as improvements in cycle time and hole quality. During the implementation of a new wing panel riveting machine for use on the 737NG and 757 models a major goal was to significantly improve the drilling process. The phase out of Freon™ as a coolant/lubricant on existing machines forced changes to the drilling process, which resulted in a significant reduction in drill life, from an average of approximately 1,500 holes per drill to 305 holes. The new process on the new machine has increased the average drill life 11,375% to over 35,000 holes, decreased the drill cycle time by 80%, and improved hole quality.

One key factor contributing to the LEGO® brand’s success is its reputation for quality and durability. LEGO® bricks are renowned for their sturdiness, capable of supporting the weight of 375,000 other bricks before failing – a testament to their incredible design.

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The final step involves assembling all the necessary pieces to create complete LEGO sets. Since LEGO toy sets contain hundreds of components, the packaging process must be fast and accurate.

What plastic are LEGOs made of, and how are they made? This blog will explore how LEGO® is made and how precision molding produces these injection-molded toys.

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What types of plastic are LEGOs manufactured with? LEGO® uses a variety of materials to manufacture different products. But their classic blocks are made from a specific type of plastic called acrylonitrile butadiene styrene (ABS), a polymer known for its durability and versatility. The general manufacturing process for these products involves the following steps:

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After World War II, LEGO transitioned from wood products to plastic due to material shortages. Despite bans on plastic products due to these shortages, Christiansen bought Denmark’s first plastic injection molding machine.

At the core of LEGO®’s success lies precision molding, which plays a crucial role in maintaining the highest standards that ensure the quality and fit of each brick. This commitment to excellence has solidified LEGO®’s position as a leader in the industry.

Today, LEGO continues to invest in advanced molding machines, precise tooling, and research new materials to maintain the highest standards of quality and playability. From its humble beginnings to becoming a global toy empire, LEGO’s journey is intertwined with the advancement of injection molding technology, enabling builders of all ages to unleash their creativity and build extraordinary worlds.

As LEGO expanded its product range, injection molding played a vital role in creating intricate elements like minifigures, wheels, hinges, and gears, adding realism and imaginative possibilities to LEGO sets.

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All-Plastics offers plastic injection molding solutions that help you reach your production goals. Whether you’re developing toys or plastic products with complex configurations, we deliver everything you need to optimize your manufacturing processes and achieve outstanding results. Please complete our online contact form to request a quote or more information about our services.

LEGO® is one of the most easily recognizable and highly esteemed brands globally. Its distinctive design of interlocking plastic bricks has captivated children and adults as it helps unlock their inner creativity while offering endless possibilities.