Lego
Lego is a brand of plastic construction toys manufactured by the Lego Group, a privately held company based in Billund, Denmark. Lego consists of variously coloured 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. Assembled Lego models can be taken apart, and their pieces can be reused to create new constructions.
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. One of Europe's biggest companies, Lego is the largest toy manufacturer in the world by sales., 600 billion Lego parts had been produced.
Lego maintains a large fan community based around building competitions and custom creations, and a range of films, games, and ten Legoland amusement parks have been developed under the brand.
History
The Lego Group began in the workshop of Ole Kirk Christiansen, 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.File:Billund Lego House 01.jpg|thumb|left|The Lego House, headquarters of the Lego Group in Billund, Denmark
The Lego Group's motto, "only the best is good enough" 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, 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; ABS subsequently replaced cellulose acetate as the manufacturing material five years later. 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 became 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 1997, more than five million Lego pieces were swept into the sea when a wave hit a cargo ship off the coast of Cornwall, England. Pieces have washed up over the ensuing decades, attracting attention from news outlets and social media.
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 tower and a railway.
In February 2015, marketing consulting company Brand Finance ranked Lego as the "world's most powerful brand", overtaking Ferrari.
While Lego has generally been considered a children's toy, there have also been adult fans of the toys. In 2020, Lego introduced sets aged 18+, generally some of their more expensive and difficult-to-assemble sets based on real world or fictional objects, such as the Concorde or Rivendell. The timing of these sets favorably aligned with the COVID-19 pandemic, with many adults purchasing these sets to work on during various lockdown periods. Popularity within adults was further pushed by the release of The Lego Movie and the reality series Lego Masters. By 2024, nearly 15% of the sets released in the U.S. were aimed at adult builders.
In May 2025 Lego announced that it was planning to move its London headquarters from Farringdon to 76 South Bank, in 2027.
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. 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 was an official piece of Lego software for Mac OS X and Windows which allowed 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. Lego's website now recommends BrickLink Studio.
Manufacturing
Since 1963, Lego pieces have been manufactured from ABS plastic., 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 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 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 April 2023, Lego broke ground on its first manufacturing facility in the United States. The new carbon-neutral factory will be located near Richmond, Virginia. It will amount to over $1 billion in investment once completed in 2025. The 340-acre site will have rooftop and ground solar panels and an on-site 35-40 MW solar plant, generating the equivalent of the energy of powering 10,000 American homes. In April 2025, Lego opened its sixth factory worldwide, located in Vietnam, with Lego saying the location is its most environmentally sustainable factory to date.
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, according to their calculations it would take a stack of 375,000 bricks to cause the bottom brick to collapse, which represents a stack 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. 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.