This slide will show you on how Lego bricks are made. This will tell you from what composition its contain and how it is manufacture also how its packing for selling. I hope this will answers some of your curiosity regarding this topic.

1. HOW LEGO’S BRICK ARE
MADE

2. The Innovators
2
Nur Izati Bt Abustarim
Sia Zhen You
Muhammad Akmal Naim Bin Saleh
Muhamad Arif Kamal Bin Mohd Jalani
Department of Mechanical & Manufacturing Engineering
Faculty of Engineering & Built Environment
Universiti Kebangsaan Malaysia

3. 3
LEGO’S BRICK HISTORY
1934
Bild-O-Brik
1935
MiniBrix
1939
American Brick
(compressed wood)
1939
Kiddicraft
1946
American Bricks
(plastic)
1947
Kiddicraft
1949
LEGO
1958
LEGO

4. 4
Material : Acrylonitrile Butadiene
Styrene (ABS) granulates
Manufacturing Process :
Plastic-Injection Molding
Comes in various colour
and shapes.
International Company
LEGO’S BRICK

5. 5
LEGO’S BRICK MATERIAL
● The material of lego’s brick that we use which is Acrylonitrile
butadiene styrene
● Acrylonitrile butadiene styrene known as ABS is a common
thermoplastic.
● It can be re-melted and re-molded numerous times.

6. a. Physical and Material Properties
6
● High impact resistance.
● High toughness.
● High durability.
● Good abrasion.
● Low melting point ( 105°C).
● High tensile strength (46 MPa).
● Resistance toward chemical.

7. b. Chemical Composition
● Acrylonitrile butadiene styrene (ABS) is made by 3 monomers , they linked
and mix together to form copolymer.
● It is consists 15-35% of acrylonitrile , 5-30% of butadiene and 40-60% of
styrene.
Acrylonitrile Butadiene Sytrene
Molecular Structure of ABS

8.  Acrylotrile (C8H8 ) – This component is able chemical resistance and heat
stability to ABS.
 Butadiene (C4H6) – This component give the toughness and impact
strength to ABS
 Styrene (C3H3N) – It provide rigidity and process ability.
● The ABS its typical milky and readily color with pigment.
● ABS is generally low hazard material and a few risk to health for human.

9. LEGO’S BRICK MANUFACTURING PROCESS
(Method: Injection molding)
● Its been decade since LEGO bricks has been made, but until now they still use
the same method as before.
● Although the method is the same, but the technologies gaps between it is
quite large.
● Nowadays method is more modernize than before and the workload mostly
has be given to robotic system which can made the product more precise and
without any fatigue feeling.
● Thus, the productivity is consistent and meet the criteria needed.
● So after this is the steps or things that need to be done to make a LEGO bricks.

10. a. Raw Material
● Acrylonitrile butadiene styrene (ABS) is made by 3 monomers , they linked
and mix together to form copolymer.
● The ‘Granulate’ was delivered by a trucks, then it will be suck and dump into
those silos. Estimated volume for each silo is about 33 tons of granulates and
there is about 14 of them.
● There is many types of plastic granulates depends on the functionality of
each LEGO elements.

11. 11
b. Molding Processes
● There is many types of plastic granulates depends on the functionality of each
LEGO elements.
● Granulates are transferred into the factory heart which is the molding area.
● Its is transferred by a pipeline that will direct the granulates to the dye area.
The plastics will be mix with dye colors which over 50 colors.
● Dyed granulates then lead into the molding machines while its will be melted
into a molten granulates plastics that being heated under between 230 ºc
and 310 ºc.
● In the mold, great pressure must be applied and controlled during the
molding process. It even can reach up to 29 thousand PSI. Its is to get a
precise brick that can be attach to each other without failure.

12. 12
● Then the brick will be cooled inside the mold just in matter of time.
● The brick that had been cooled will be injected out of the mold.
● As for the plastic wastes, right after the products has been ejected out the
wastes will be taken to ground and recycle right away.
● In act of safety and precision of product, automated system has been
introduce in the factory to do almost all of the work.

13. c. Packaging Process
● AGV – Automatic Guided Vehicle was introduced into the production as
early as 1987. Because of these intelligent, the work has been more easier
than it is before.
● After the box has been filled with the mold bricks, these intelligent will
automatically replace the box with a new empty box .
● The filled box then will be taken to the conveyer system by the AGV.
● Then the bricks will undergo a step that make it more appealing which is
decorating some of the bricks with the specific design that has its own
criteria.
● The details are made with a precision as the complex pieces that been
snapped together more likely to attach tightly.
● After that, all the pieces will be put together by a complete set. That
means it has a variety of pieces that been molded beforehand.

14. ● The sets will be put into a single box with a instruction manual and will be
label using bar code according to the filling inside.
● After the box has been filled with the mold bricks, these intelligent will
automatically replace the box with a new empty box .
● After being identified, the boxes will be transferred into a warehouse
which is a stop before the boxes go out of the factory to the retailer for
selling.

15. YEAR : 2012 – PRESENT
● All in stock: 100% brand new and high quality.
● Malaysian seller offers local shipping and customer support.
● 12 in 1 animals block set collection.
● Building bocks is Simple, Engaging, Educational and
Entertaining.
● Non-toxic, BPA-Free and Lead-free material.
LOCAL COMPANY
15
Price : REASONABLE !
For this 12 in 1 animals block set
collection,
Its ONLY RM 21.90 !!

16. LEGO’S BRICK FUTURE
DEVELOPEMENT
● Using a complex shapes to make it more harder and challenging. (marketing
target : family)
● Adding certain materials that can change color at certain temperature.
● Researching on other type of eco- friendly materials.
● To produce different shape of lego such as curve shape ,cone , tetrahedron
and pyramid , not only limit on cuboid or cube shape.
● Researching on other type of eco-friendly materials.
● Make LEGO bricks from a new substances which more squashy or high
viscosity liquid so that it will bring no harm to people when step on it and
even for children.

17. Thanks!
Does anyone have any questions?
Leave comments down below.

18. WORK DISTRIBUTION
Introduction, local company – Izati
Material – Sia Zhen You
Manufacturing – Akmal Naim, Arif Kamal
Future Development – Arif Kamal
Slide Compile – Arif Kamal
Video Editing – Arif Kamal

19. REFERENCES
● Noe, Rain. (23 February 2016). The History of Interlocking Toy Bricks – Core77.
Retrived from https://www.core77.com/posts/47438/The-History-of-
Interlocking-Toy-Bricks
● Prado. Retrived from https://www.prado.com.my/Toys/prado-malaysia-12-in-
1-animals-blocks-collection-brick-toys-set-educational-building-blocks-early-
learning-kids
● Reed, Stanley. (31 August 2018). Lego Wants to Completely Remake Its Toy
Bricks (Without Anyone Noticing). Retrieved from
https://www.nytimes.com/2018/08/31/business/energy-environment/lego-
plastic-denmark-environment-toys.html
● LEGO. Retrieved from https://www.lego.com/en-us/service/help/bricks-
building/brick-facts/how-lego-bricks-are-made-408100000007834