How It's Made: LEGO Sets

LEGO's design process is very complex!
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In this video, we look at how LEGO creates their sets - from ideation to production! In many cases, the design process of a new LEGO set may take 1-2 years. Watch the entire video to see exactly how LEGO does it - Enjoy!

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[SpitBrix]

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[gaijininja]

I always thought the extra pieces were there because they were the ones most likely to be lost on the builder's floor, or broken in the case of the laser bolt projectiles.

[kentslocum]

The packaging process is the one that I find most fascinating, because each set has so many different components. We never get to see where or how the instruction booklets are printed; are they printed off-site or on-site? Do they ever run out of instruction books and have to delay the entire production line? This is also the step where machines are currently being swapped out for recyclable paper bags, replacing the single-use plastic bags. I would love to see where the paper bags are made. I also wonder how many different sets a LEGO packaging facility manufactures at one time, and if all the factories make all the sets, or some facilities specialize in certain sets. Do they spend an entire day (or week, or month) just packaging a few set until there is a huge inventory to ship out, then switch to different sets, do they have one assembly line for each set, or do they vary how many assembly lines are dedicated to each set based on demand? What do they do with canceled sets that were already in production, like the Technic V-22 Osprey or Overwatch 2 Null Sector Titan?

[flashkraft]

Imagine being a LEGO designer. Could there be more of a dream job.

[YT]

Great video! I'm not a hardcore Lego guy but I've played with them my entire life. I'm always amazed how I've never bought a single set that was missing a piece. Not once. The level of quality control in Lego is second to none.

[harasen_haras]

As a Dane, I find it really cool that despite LEGO being so international, the main production still takes place in my home country.

[tyfunk]

One of my favorite sets (and the most recent one I got) is the LEGO Moulding Machine (40502) which is only found in LEGO House in Denmark. I was a lucky duck and got it fairly cheap from Bricklink!

[nzoomed]

Pretty amazing how the automation works in this factory, its essentially possible with a few mouse clicks to create a new set and the robots grab all the various parts from the inventory and bring them all together!

[nils]

Meanwhile in a LEGO City family home:

"Dad, where do babyfigures come from?"

"Son, it's time you finally learn..." *shows this video*

[EzBricks_]

I love this channel because it’s like a Lego version of google

[DeadlyPlatypus]

Huh.
I always just assumed they gave you "extras" of the smallest, most commonly LOST pieces just in case you lost one. But this explanation makes way more sense given the seeming randomness of the pieces and their numbers.

[thrillhouse]

The only time I had pieces missing from a set there were two pieces included that were nowhere in the set at all, one was a small window which was kinda cool. Thankfully LEGO will send you replacements if you’re honest about it. I really like the bag the replacement pieces come in, it’s labeled like a set.

[kentslocum]

Setting the price before designing the set makes sense for smaller sets and themes, but it results in big problems for larger sets like the Tabletop Football set and the UCS Hulkbuster, where the sets are unnecessarily padded to meet the price point.

[PlutoniumBoss]

What I'm really interested in is a closer look at the double-molding process some LEGO elements have these days. I've never seen anything else quite like it.

[jorggamingcr]

Im currently building the Discovery space shuttle set and I was amazed by how do this sorting process works, the correct pieces on the exact bags. Even as an engineer myself it is crazy for me to think the proces is automated...

[scoutgaming]

I love how they invite kids to play with the sets

[tha_dealler]

5:59 old ones were made in ABS but in 2015-ish they swapped to PVC which is still good but less prone to break like old Bionicle parts which were made in ABS

[aquestforthetruth]

1:40 that image is beautiful the haunted house and imperial flagship casually sitting next to each other!

[ntmetroid]

I work in Injection molding for the auto industry and love seeing closer looks at how the tech is used in other industries

[interstateruler]

It's amazing and I really love legos. In my closet, I have a half of wall filled with legos with drawers and I divided my bricks. For example, arches goes in the arch drawer