Learning More About The Bricks
July 15th, 2010
Photo Via Geekologie.com
Have you ever wondered how Lego bricks work? Or how they are made? How can some poeple make 30-meter towers out of Lego? How can one snap two Lego pieces together, and they don’t slide off from each other? It has been over 50 years since the bricks were introduced, and a lot has changed be it in addition of another piece, or a minifigure, but one thing has not changed about Lego -it is still is utterly fun to play with. Despite its age, the mechanism behind the Lego bricks have remained the same.

Photo Via Aleptu.com
How Lego Works
With a look at a Lego block’s structure, you will notice studs on the top, and tubes on the underside of the block. Apart from being an iconic feature to the toy, it serves a very important purpose. Studs are a bit larger than the tubes at the bottom of a piece. When you put together two blocks, the slightly larger studs fit tightly between the tubes pushing it’s way in. However, since the tubes are very resilient, it pushes back on the studs. Since both parts are pushing against each other, this allows the two pieces to hang on to one another. This is called an interference fit. It is a firm, friction-based connection which allows two pieces to stick without a separate fastener.

Photo Via Cartype.com
All Lego pieces work on this principle , no matter the size, shape, or color -be it bricks, plates, roof bricks, even base plates.
How Lego Pieces are Made
All Lego pieces begin their lives as plastic granules and require much heat and huge machines before they become the recognizable Lego pieces that people know. The plastic granules are composed of acrylonitrile butadiene styrene or ABS.

ABS Granules Used For Lego Bricks (Photo Via BusinessWeek.com)
Lego pieces are formed when the ABS get to Lego’s manufacturing plants, and vacuumed into storage silos within the facility for storage. A Lego manufacturing plant has about 14 silos that can hold a total of thirty three tons of ABS granules.
Production begins when the granules are funneled through tubes and into super accurate molding machines. These machines are so accurate, that only 18 out of a million pieces are considered defective. The ABS is melted in the machines at temperatures of up to 450 degrees and injected into molds with twenty five to a hundred and fifty tons of pressure. The actual injection takes about 7 seconds,before a new Lego piece is formed.
The new Lego piece then falls into a conveyor, and transported into bins. When the bins are filled, eight robots transport them into an assembly hall where machine stamps put designs on them. These robots carry about 600 bins of new Lego bits and pieces every hour. This is also where Lego bits that have multiple pieces come together to be assembled (i.e. minifigures).

Photo Via Lego
After assembly and stamping, pieces then go to packaging where more and more robots are automatically putting these elements together and packing them. These then gets sorted out where which particular bunch goes into which packaging, whether for assorted buckets or a themed play set.










