Lego is a line of plastic construction toys manufactured by the Lego Group, a privately held company based in Billund, Denmark. Lego consists of variously colored interlocking plastic bricks made of acrylonitrile butadiene styrene that accompany an array of gears, figurines called minifigures, and various other parts. Its pieces can be assembled and connected in many ways to construct objects, including vehicles, buildings, and working robots. Anything constructed can be taken apart again, and the pieces reused to make new things.
The Lego Group began manufacturing the interlocking toy bricks in 1949. Moulding is done in Denmark, Hungary, Mexico, and China. Brick decorations and packaging are done at plants in the former three countries and in the Czech Republic. Annual production of the bricks averages approximately 36 billion, or about 1140 elements per second.
Films, games competitions, and eight Legoland amusement parks have been developed under the brand. One of Europe's biggest companies, Lego is the largest toy manufacturer in the world by sales. As of July 2015, 600 billion Lego parts had been produced.
History
The Lego Group began in the workshop of Ole Kirk Christiansen (1891–1958), a carpenter from Billund, Denmark, who began making wooden toys in 1932. In 1934, his company came to be called "Lego", derived from the Danish phrase leg godt which means "play well". In 1947, Lego expanded to begin producing plastic toys. In 1949 the business began producing, among other new products, an early version of the now familiar interlocking bricks, calling them "Automatic Binding Bricks". These bricks were based on the Kiddicraft Self-Locking Bricks, invented by Hilary Page in 1939 and patented in the United Kingdom in 1940 before being displayed at the 1947 Earl's Court Toy Fair. Lego had received a sample of the Kiddicraft bricks from the supplier of an injection-molding machine that it purchased. The bricks, originally manufactured from cellulose acetate, were a development of the traditional stackable wooden blocks of the time.
The Lego Group's motto, "only the best is good enough" (Danish: det bedste er ikke for godt, literally "the best isn't excessively good") was created in 1936. Christiansen created the motto, still used today, to encourage his employees never to skimp on quality, a value he believed in strongly. By 1951, plastic toys accounted for half of the company's output, even though the Danish trade magazine Legetøjs-Tidende ("Toy Times"), visiting the Lego factory in Billund in the early 1950s, wrote that plastic would never be able to replace traditional wooden toys. Although a common sentiment, Lego toys seem to have become a significant exception to the dislike of plastic in children's toys, due in part to the high standards set by Ole Kirk.
By 1954, Christiansen's son, Godtfred, had become the junior managing director of the Lego Group. It was his conversation with an overseas buyer that led to the idea of a toy system. Godtfred saw the immense potential in Lego bricks to become a system for creative play, but the bricks still had some problems from a technical standpoint: Their locking ability was still limited, and they were not yet versatile. In 1958, the modern brick design was developed; it took five years to find the right material for it, ABS (acrylonitrile butadiene styrene) polymer. A patent application for the modern Lego brick design was filed in Denmark on 28 January 1958 and in various other countries in the subsequent few years.
The Lego Group's Duplo product line was introduced in 1969 and is a range of blocks whose lengths measure twice the width, height, and depth of standard Lego blocks and are aimed towards younger children. In 1978, Lego produced the first minifigures, which have since become a staple in most sets.
In May 2011, Space Shuttle Endeavour mission STS-134 brought 13 Lego kits to the International Space Station, where astronauts built models to see how they would react in microgravity, as a part of the Lego Bricks in Space program. In May 2013, the largest model ever created, made of over 5 million bricks, was displayed in New York City; a one-to-one scale model of a Star Wars X-wing fighter. Other record breakers include a 34-metre (112 ft) tower and a 4 km (2.5 mi) railway.
In February 2015, marketing consulting company Brand Finance ranked Lego as the "world's most powerful brand", overtaking Ferrari.
Lego bricks have acquired a reputation for causing extreme pain when stepped on.
Design
Lego pieces of all varieties constitute a universal system. Despite variations in the design and the purposes of individual pieces over the years, each remains compatible in some way with existing pieces. Lego bricks from 1958 still interlock with those made presently, and Lego sets for young children are compatible with those made for teenagers. Six bricks of 2 × 4 studs can be combined in 915,103,765 ways.
Each piece must be manufactured to an exacting degree of precision. When two pieces are engaged, they must fit firmly, yet be easily disassembled. The machines that manufacture Lego bricks have tolerances as small as 10 micrometres.
Primary concept and development work for the toy takes place at the Billund headquarters, where the company employs approximately 120 designers. The company also has smaller design offices in the UK, Spain, Germany, and Japan which are tasked with developing products aimed specifically at their respective national markets. The average development period for a new product is around twelve months, split into three stages. The first is to identify market trends and developments, including contact by the designers directly with the market; some are stationed in toy shops close to holidays, while others interview children. The second stage is the design and development of the product based on the results of the first stage. As of September 2008 the design teams use 3D modelling software to generate CAD drawings from initial design sketches. The designs are then prototyped using an in-house stereolithography machine. These prototypes are presented to the entire project team for comment and testing by parents and children during the "validation" process. Designs may then be altered in accordance with the results from the focus groups. Virtual models of completed Lego products are built concurrently with the writing of the user instructions. Completed CAD models are also used in the wider organisation for marketing and packaging.
Lego Digital Designer is an official piece of Lego software for Mac OS X and Windows which allows users to create their own digital Lego designs. The program once allowed customers to order custom designs with a service to ship physical models from Digital Designer to consumers; the service ended in 2012.
Manufacturing
Since 1963, Lego pieces have been manufactured from acrylonitrile butadiene styrene (ABS). As of September 2008, Lego engineers use the NX CAD/CAM/CAE PLM software suite to model the elements. The software allows the parts to be optimised by way of mould flow and stress analysis. Prototype moulds are sometimes built before the design is committed to mass production. The ABS plastic is heated to 232 °C (450 °F) until it reaches a dough-like consistency. It is then injected into the moulds using forces of between 25 and 150 tonnes and takes approximately 15 seconds to cool. The moulds are permitted a tolerance of up to twenty micrometres to ensure the bricks remain connected. Human inspectors check the output of the moulds to eliminate significant variations in colour or thickness. According to the Lego Group, about eighteen bricks out of every million fail to meet the standard required.
Lego factories recycle all but about 1 percent of their plastic waste from the manufacturing process. If the plastic cannot be re-used in Lego bricks, it is processed and sold on to industries that can make use of it. Lego, in 2018, set a self-imposed 2030 deadline to find a more eco-friendly alternative to the ABS plastic.
Manufacturing of Lego bricks occurs at several locations around the world. Moulding is done in Billund, Denmark; Nyíregyháza, Hungary; Monterrey, Mexico; and most recently in Jiaxing, China. Brick decorations and packaging are done at plants in the former three countries and in Kladno in the Czech Republic. The Lego Group estimates that in five decades it has produced 400 billion Lego blocks. Annual production of the bricks averages approximately 36 billion, or about 1140 elements per second. According to an article in BusinessWeek in 2006, Lego could also be considered the world's number-one tyre manufacturer; the factory produces about 306 million small rubber tyres a year. The claim was reiterated in 2012.
In December 2012, the BBC's More or Less radio program asked the Open University's engineering department to determine "how many Lego bricks, stacked one on top of the other, it would take for the weight to destroy the bottom brick?" Using a hydraulic testing machine, members of the department determined the average maximum force a 2×2 Lego brick can stand is 4,240 newtons. Since an average 2×2 Lego brick has a mass of 1.152 grams (0.0406 oz), according to their calculations it would take a stack of 375,000 bricks to cause the bottom brick to collapse, which represents a stack 3,591 metres (11,781 ft) in height.
Private tests have shown several thousand assembly-disassembly cycles before the bricks begin to wear out, although Lego tests show fewer cycles.
In 2018, Lego announced that it will be using bio-derived polyethylene to make its botanical elements (parts such as leaves, bushes and trees). The New York Times reported the company's footprint that year was "about a million tons of carbon dioxide each year" and that it was investing about 1 billion kroner and hiring 100 people to work on changes. The paper reported that Lego's researchers "have already experimented with around 200 alternatives." In 2020, Lego announced that it would cease packaging its products in single-use plastic bags and would instead be using recyclable paper bags. In 2021, the company said it would aim to produce its bricks without using crude oil, by using recycled polyethylene terephthalate bottles, but in 2023 it reversed this decision, having found that this did not reduce its carbon dioxide emissions.
Set themes
Since the 1950s, the Lego Group has released thousands of sets with a variety of themes, including space, pirates, trains, (European) castle, dinosaurs, undersea exploration, and wild west, as well as wholly original themes like Bionicle and Hero Factory. Some of the classic themes that continue to the present day include Lego City (a line of sets depicting city life introduced in 1973) and Lego Technic (a line aimed at emulating complex machinery, introduced in 1977).
Over the years, the company has licensed themes from numerous cartoon and film franchises and some from video games. These include Batman, Indiana Jones, Pirates of the Caribbean, Harry Potter, Star Wars, Marvel, and Minecraft. Although some of these themes, Lego Star Wars and Lego Indiana Jones, had highly successful sales, the company expressed in 2015 a desire to rely more upon their own characters and classic themes and less upon such licensed themes. Some sets include references to other themes such as a Bionicle mask in one of the Harry Potter sets. Discontinued sets may become a collectable and command value on the black market.
For the 2012 Summer Olympics in London, Lego released a special Team GB Minifigures series exclusively in the United Kingdom to mark the opening of the games. For the 2016 Summer Olympics and 2016 Summer Paralympics in Rio de Janeiro, Lego released a kit with the Olympic and Paralympic mascots Vinicius and Tom.
One of the largest commercially produced Lego sets was a minifig-scaled edition of the Star Wars Millennium Falcon. Designed by Jens Kronvold Fredericksen, it was released in 2007 and contained 5,195 pieces. It was surpassed by a 5,922-piece Taj Mahal. A redesigned Millennium Falcon retook the top spot in 2017 with 7,541 pieces. Since then, the Millennium Falcon has been superseded by the Lego Art World Map at 11,695 pieces, the Lego Titanic at 9,090 pieces, and the Lego Architect Colosseum at 9,036 pieces.
In 2022, Lego introduced its Eiffel Tower. The set consists of 10,000 parts and reaches a height of 149 cm, which makes it the tallest set and tower but the second in number of parts after the World Map.
Robotics themes
Main articles: Lego Mindstorms, Lego Mindstorms NXT, Lego Mindstorms NXT 2.0, and Lego Mindstorms EV3
The company also initiated a robotics line of toys called 'Mindstorms' in 1999, and has continued to expand and update this range ever since. The roots of the product originate from a programmable brick developed at the MIT Media Lab, and the name is taken from a paper by Seymour Papert, a computer scientist and educator who developed the educational theory of constructionism, and whose research was at times funded by the Lego Group.
The programmable Lego brick which is at the heart of these robotics sets has undergone several updates and redesigns, with the latest being called the 'EV3' brick, being sold under the name of Lego Mindstorms EV3. The set includes sensors that detect touch, light, sound and ultrasonic waves, with several others being sold separately, including an RFID reader.
The intelligent brick can be programmed using official software available for Windows and Mac computers, and is downloaded onto the brick via Bluetooth or a USB cable. There are also several unofficial programs and compatible programming languages that have been made to work with the brick, and many books have been written to support this community.
There are several robotics competitions which use the Lego robotics sets. The earliest is Botball, a national U.S. middle- and high-school competition stemming from the MIT 6.270 Lego robotics tournament. Other Lego robotics competitions include FIRST LEGO League Discover for children ages 4–6, FIRST LEGO League Explore for students ages 6–9 and FIRST Lego League Challenge for students ages 9–16 (age 9–14 in the United States, Canada, and Mexico). These programs offer real-world engineering challenges to participants. FIRST LEGO League Challenge uses LEGO-based robots to complete tasks, FIRST LEGO League Explore participants build models out of Lego elements, and FIRST LEGO League Discover participants use Duplo. In its 2019–2020 season, there were 38,609 FIRST LEGO League Challenge teams and 21,703 FIRST LEGO League Explore teams around the world. The international RoboCup Junior football competition involves extensive use of Lego Mindstorms equipment which is often pushed to its extreme limits.
The capabilities of the Mindstorms range have now been harnessed for use in Iko Creative Prosthetic System, a prosthetic limbs system designed for children. Designs for these Lego prosthetics allow everything from mechanical diggers to laser-firing spaceships to be screwed on to the end of a child's limb. Iko is the work of the Chicago-based Colombian designer Carlos Arturo Torres, and is a modular system that allows children to customise their own prosthetics with the ease of clicking together plastic bricks. Designed with Lego's Future Lab, the Danish toy company's experimental research department, and Cirec, a Colombian foundation for physical rehabilitation, the modular prosthetic incorporates myoelectric sensors that register the activity of the muscle in the stump and send a signal to control movement in the attachment. A processing unit in the body of the prosthetic contains an engine compatible with Lego Mindstorms, the company's robotics line, which lets the wearer build an extensive range of customised, programmable limbs.
In popular culture
Lego's popularity is demonstrated by its wide representation and usage in many cultural works, including books, films, and art. It has even been used in the classroom as a teaching tool. In the US, Lego Education North America is a joint venture between Pitsco, Inc. and the educational division of the Lego Group.
In 1998, Lego bricks were one of the original inductees into the National Toy Hall of Fame at The Strong in Rochester, New York.
"Lego" is commonly used as a mass noun ("some Lego") or, in American English, as a countable noun with plural "Legos", to refer to the bricks themselves, but as is common for trademarks, Lego group insists on the name being used as an adjective when referring to a product (as in "LEGO bricks").
