How is Lego done?
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The history of world famous designers Lego began in the last century, back in 1949, when in Denmark in the small town of Billund the first details of this wonderful toy were born. Small plastic blocks were designed in such a way that they could easily be interconnected due to the presence of special elements. The basis of all further variety of components of the designer are small bricks of several sizes, equipped with spikes and grooves, which connected the parts together.
Gradually, the assortment of parts expanded, first wheels began to be included in the sets, then figures of people and animals were added, and then, as technological progress developed, even miniature electric motors and various sensors. Therefore, now from Lego parts you can assemble not only houses, as originally intended, but also space ships, airplanes, pirate frigates, cars and even moving robots. Real fans of this wonderful designer are interested in literally everything about him.For them, we will tell you how Lego is made.
LEGO plants are located in three countries - Denmark, Mexico and the Czech Republic. Every day, about 60 tons of multi-colored thermoplastic are transformed into several million cubes on these giant factories. The technological process of the production of parts is quite simple, there are no special secrets in it.
What and how Lego is made: the manufacturing process
1. The birth of a new set of Lego begins with an idea. The developers of the company decide which new set should be put into production based on market conditions - a pirate ship, a robot or a fire station.
2. When the project is finally approved, design engineers are taken to work. They create models of the necessary parts, and on their basis special metal matrixes are made — molds, into which thermoplastic will be poured. Every time there is no need to make the matrix of all the details, because most of the blocks are standard. They are used in all sets since the sixties of the last century. Therefore, it is necessary to re-create only the forms for exclusive details, peculiar only to the new set.It is worth noting that the Lego forms are very expensive. We are talking about amounts in the tens or even hundreds of thousands of dollars. Therefore, all the matrices, even those that are no longer used at the present time, are carefully stored in the factory warehouse, because who knows, maybe they will also be needed.
3. The finished matrix is transferred to the plant, and the next designer starts in production. Its basis - modern injection molding machines, which are large; pressure and at temperatures above 200 degrees are molded parts from molten multi-colored plastic.
4. High-quality acrylonitrile-based plastic enters the plant in the form of granules - transparent or red. Granules are stored in a special bunker, from where they are fed into molding machines. There, the plastic melts, mixes with the necessary dyes and, under high pressure, is literally injected into the matrix forms.
5. After water cooling, the molds open, and the finished bricks fall onto the conveyor belt.
6. The process of creating parts is almost completely automated and does not require human presence. The robot collects Lego fragments from the conveyor, packs it in packages and weighs it.The robot even fastens the figures of the head and hands and draws them facial features and details of the costume.
7. After that, the finished parts of the designer are sent to the packaging department. Boxes for sets are developed by high quality designers. They depict colorful drawings corresponding to the theme of the set, and the Lego logo. A special machine takes a typographical blank, bends it in predetermined directions and glues the box. Then the robot places in it a set of parts sealed in a package. The next machine closes the lid and seals it.
8. Now it remains only to pack bright elegant boxes with designers of six pieces in large cardboard boxes, to cover them with plastic wrap, and fresh Lego will be ready for shipment.
Now that you know how Lego is done, it's time to open a new set, pour bright parts onto the table and immerse yourself in an exciting game!