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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[@mattthelegomaniac]

heyy spitbrix, your vids are awesome!

[@erikpersson3893]

I thought extra peices where to make sure you would not lose one

[@ctrlkerdel]

bros just reinvented nfts and went about their day

[@MurrmorMeerkat]

@@ctrlkerdel except they were here before nfts and just as scummy

[@omikronweapon]

classy ad. "inflation is causing everybody to have less money to spend, so why not risk what you have left, by buying ART". nothing against investing, and certainly not against art, but why couple it with inflation? Seems weird

[@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.

[@alexc5557]

same lol

[@ZWallAbuser]

This is the real reason and was definitely misrepresented in the video

[@trumpsmicropenis12]

@@ZWallAbuser source: trust me bro

[@Mimic_Gaming]

Every extra piece is a missing piece in another kid’s set

[@sed6]

They are.

[@flashkraft]

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

[@leftfinned]

Literally a dream come true!!!

[@Dragon-Slay3r]

Yeah it's even bought in the vertical rectangle Yahoo! Really enjoyed last night guys thanks really appreciate it

[@michaelchavez4673]

Imagine being a full time geek 💀

[@THEAMYGDALA]

AI will blow them away 😢

[@zine-nightcore1023]

@@michaelchavez4673 ik would be amazing

[@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?

[@kyleharner3437]

This guy legos!

[@kentslocum]

@HLaci That would probably explain why sets sell out or go on backorder for a while, then come back in stock.

[@matthewedmondson2713]

@@CalebBerman go away

[@awesomepants184]

​@@matthewedmondson2713 no u

[@harasen_haras5]

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

[@MesaperProductions]

When I heard him say the "finished product", I couldn't stop myself from joking (with myself) "They're not Finnish, they're Danish!" (I crack myself up, I do.)

[@harasen_haras5]

@@MesaperProductions lol What a classic 😆

[@JohnVanderbeck]

@@MesaperProductions I mean, if YOU can't laugh at your jokes then who will, right?

[@tehpurplepills]

the production doesnt take place in dane, it takes place in Denmark lol, lern geology.

[@harasen_haras5]

@@tehpurplepills Yes, it doesn't take place inside the body of a Dane. "Dane" is the word for a person from Denmark.

[@YT0091]

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.

[@AK.__]

I had one or two sets, where the colour of piece was either incorrect in the manual or incorrect in the set: dark gray instead of black. Otherwise all was perfect for years.

[@bennebolle6054]

LEgos Qualtiy is getting worse and worse every year, only the prieces goes high

[@YT0091]

@@bennebolle6054 Care to back up that statement with any proof? Because this is exactly the opposite of what I said.

[@wingw25]

I am usually impressive with the quality. However, between my husband and my daughter, we got 8 new Lego sets the last few months. Two sets had a missing piece and another set had a piece that was crack/smashed at the corner. The set with the problem are pretty large sets. Lego does have excellent customer service. We got the replacement piece in a week.

[@creepii5816]

@@YT0091 I recently got the lego Benatar set and had a piece missing. I've gotten a ton of lego sets over the years that were all perfect, so it came as a surprise having a piece missing. Especially on a fairly big set

[@tyfunk8614]

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!

[@EzBricks_]

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

[@bananacomma]

Fr

[@H3ROBOYz]

Yes

[@knifetech101]

You love google? 😢

[@EzBricks_]

@@knifetech101 no duck duck go is better

[@battletapesrecording]

This is the only result for LEGO on google

[@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!

[@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.

[@kailahmann1823]

I guess, having spares for the customer is a positive side effect. And no, there is nothing really random about them - in fact these pieces are very predictable, as every mold either comes always as a spare or never. Also there are a few rather light pieces that don't go as a spare (like the infamous blue technic pin) for some reason and in large sets, you may find repeat spares in later bags. And if you don't have one spare left for a mold where you'd expect it, that's one of those rare packaging errors they are buffering.

[@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.

[@Immortalcheese]

i notice this sometimes that some sets seem to have artificially increased their piece count. like a step involving placing two 2x2 brings side by side instead of one 2x4 brick, which increases the piece count and justifies a higher price.

[@thrillhouse4151]

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.

[@scoutgaming737]

I love how they invite kids to play with the sets

[@tha_dealler4811]

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

[@Blobbyboi986]

They are currently changing them to a recyclable plastic

[@Michael-dj6pd]

The infamous brittle brown pieces

[@massimookissed1023]

Lego's own website says most bricks are made of ABS. ABS is almost infinitely recyclable. The main change was clear pieces used to be polycarbonate, but are now a type of transparent ABS, which doesn't require different molds (unlike polycarbonate) but does scratch more easily.

[@nils920]

Meanwhile in a LEGO City family home: "Dad, where do babyfigures come from?" "Son, it's time you finally learn..." *shows this video*

[@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.

[@jorggamingcr409]

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...

[@ACSF007]

This is exactly what I want to do later in life. It’s a dream job for me, and I’m chasing that down and will find a way in some how. I feel like I would never not be happy in this place of work. I hope I get there one day.

[@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

[@aquestforthetruth1653]

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

[@JOlivo94]

I always thought the extra pieces were in case we lost one. I always wondered how they decided which ones were most likely to be lost. 😂

[@beelzemobabbity]

I think its an added bonus, since small pieces are the most likely to be missing and go missing

[@brianrooker8527]

I’ve always been curious how they did all this. Thank you

[@jeffreycoyle12]

Great video. Thank you!

[@amancalledkev]

LEGO is probably the greatest toy ever developed, playing a part in the childhood of many a person out there. An extremely creative toy that encourages thought and experimentation in the developing mind. Having actually worked for this company some years ago, much as I found it interesting to be part of the LEGO world it was also an eye-opener ..... The Danish company are heavily into psychology and the their angle is that everyone within it should be a big happy family... Nice in theory (if not a little creepy and 'Stepford') but sadly didn't actually work in the UK. Another little known fact about this company is that they NEVER fire anyone..... They just make your life so difficult that you just resign (no HR to speak of back then). Having been part of the original UK LEGO team, it became apparent that their magic formula didn't translate particularly well over here, mainly because their selected management were completely unsuitable and made some staggeringly bad decisions with regard to staff employment - Narcissist's and bully's do not make great co-workers! It was so bad that I left the company on my own terms. It great shame really, as it soured something that I had a great fondness for. LEGO have now sunk to deeper depths by heavily relying on income from licensed Disney models at ridiculous prices....

[@Songal18]

This was an astounding video, thank you so much ^^

[@wai0937]

Fantastic video. I learned a lot!

[@fkeevs]

Very interesting. Nice video!

[@kylehc15]

its crazy that some people will make something that isnt a set from pieces they either ordered from their site or found at a garage sale like the fly scotsman steam locomotive and others ive even seen one where someone makes a working car which was cool

[@SlingbladeJim]

Now THAT was astounding..................................

[@brucemartini2288]

😏😆how many times my bedrooom floor looked just like that🤣, 4am rootin thru my LEGOS, while parents were sleeping😂

[@rocketgames951]

I love extra parts cause I can use them for Mocs but they are rarely ever good extra bricks

[@thewhitewolf58]

I always wondering if lego sets were designed physically or in a custom cad program. Thankyou for answering that. I guess when it comes to things with alot of small cheap universal parts physical is best. Though i do like the idea that lego is one of those toys that you dont really have to grow out of if your creative. True action figures have an age limit because they are usually based on a tv show made for kids but lego sets are 3d pixel versions of model sets thats only limit is your wallet and creativity.

[@Dragon-Slay3r]

I literally ment mating not Matt 😂

[@TheExileFox]

They did offer "Lego Digital Designer" to give you an option for digital lego modelling but it's no longer supported. I don't know what they use internally but I think it might be a different version of the same software

[@theseriesofheroesrise2149]

This is so interesting! I love Lego! I also wrote a book called Heroes Rise: Kingdoms Restored and if it, one day, becomes a movie, Lego would probably (I don't know) make my book, (and/ if one day, movie) characters into Lego and that would be fun to see the Heroes Rise characters in person! Great job on the video, too!

[@elixsdelrey]

being a lego designer is my dream job

[@Madcat0]

I wonder what are the requirements for a new piece to be approved for production. I mean, a new piece requires a new mold and storage and it's going to be used in just one set until the designers use it again in the future so i guess someone has to approve it or tell the designer to use a different solution.

[@thewhitewolf58]

Probably like the lego ideas set where they thing it has to be stable and popular enough to justify the cost. Though i feel that it would just have its own temporary machine to make 10,000 to 50,000 sets.

[@massimookissed1023]

I suspect there are many deciding factors. Can they make many in one mold, or is it a large piece that can only fit one per mold ? Is the new set predicted to sell enough that the new piece will cover its cost with just this set ? Or ... Does the proposed new piece have other possible uses ?

[@klockibymichael4825]

Great video man :)

[@lego_minifig]

3:00 I have a similar setup at a much smaller scale. I have my entire collection sorted by piece in around 30 tackle boxes and a few bins for larger or more common pieces. I have custom labels printed on each box and have them numbered with a master document showcasing all the pieces. Its a nightmare to disassemble sets/creations. I hated it when I was younger as it stifled play. Now that I am older I appreciate it as it makes it easier to reassemble nostalgic sets in my collection and far simpler to find specific pieces when building a stop motion set.

[@oidbrando4740]

great video keep it up :D

[@BrickHQ]

Ninjago sets come with extra weapon pieces, which I really like

[@dpcicchetti]

Awesome video!

[@lewisgilbertson7506]

Working at an amazon fulfillment center its crazy to see the small similarities through the process because they are both using so much robot automation

[@tfoxsw7652]

One of my last sets I got came with a extra 2x5

[@DylansDIYWorkshop]

been loving watching these videos. really well put together

[@SpitBrix]

Thank you! I'm glad that you enjoy them.

[@lutherevans968]

I didn't know about the hidden side line. It looks cool.

[@fruitlooponthefloor3528]

its pretty mid the sets are cool but the app is pretty boring and buggy

[@lutherevans968]

@@fruitlooponthefloor3528 Oh, it's one of those. Yeah, I'm not into the app aspect of it, but I like the spooky theme.

[@Earth-Ninja]

I actually like the app, but I being taken down in 2023…

[@rustyshobbies8430]

sometimes the extra pieces are something that isnt used in the set at all. This always perplexes me. :)

[@ashhplayz9489]

personally, if i just got to work in the back-end part of the jobs (like molding, packaging etc.) i would be very happy cuz its lego!

[@mattraviler8500]

Fun fact the building that where they do there brainstorming has a maximum security protocol. "If a visitor is spotted with eyesight. All of the windows closed that are made of steel. All the doors are locked and blacked out" after some time the building will unlock....

[@Muradwalis92]

Those designers have an amazing job

[@penguinbob22]

This makes me want to work for lego

[@chaoticfloralarrangement8741]

I remember watching some of these clips in orientation. Crazy but fun

[@the_tsuken685]

man sounds like working at lego seems fun

[@dirediredude]

Thanks for the video that was awesome 😊 Honestly though at the end watching I was wondering why the final packaging step wasn't automated as well. Seems like all the steps along the way were much more complex and were handled with automation as well just fine.

[@drewmeeker6013]

I’d say Lego is the most famous toy on the planet❤

[@letsauditinheels]

Love my sets I collect Lego friends sets I’ve around 80 so far just building the new art school and purchased the tiny house today also. Absolutely love the Harry Potter series also but I love the small accessories with the friends sets even as an adult

[@charlesyost418]

Pretty cool video. I like seeing how they are made. I do have one odd question. What kind to drawers on wheels are shown in the video when talking about lego designers? I have been trying to find the right thing to organize my Lego pieces, and those would work great! Thanks for answering. If you do know.

[@dougadams9419]

What a change from the beginning as shown on "The Toys That Built America", Season 2 Episode 4.

[@MesaperProductions]

Every LEGO enthusiast's dream: ENDLESS LEGOS!

[@Lego_plane_disasters]

I'm just a kid but when I grow up im going to inspire people with my creations!

[@violetcupcake]

Wow this is seriously mind blowing!! Honestly the first video I watched to actually explain properly how lego is made!! 👍

[@kailahmann1823]

For precision of the machinery it's often stated Lego is an even more demanding customer than medical or military.

[@thewhitewolf58]

Which military. I know in the usa military buys from the lowest bidder so military grade means barely functional.

[@massimookissed1023]

The size tolerances must be very demanding. Too tight and they won't fit, too loose and they'll fall apart. I recently heard that polycarbonate shrinks more than ABS, so clear pieces needed their own special molds for standard parts to allow for extra shrinkage. One reason why Lego switched polycarbonate for transparent ABS.

[@hoodbaxter]

I once got a Lego off road crane (42082) and it was missing a little bag because they gave he an extra rim

[@adriang3492]

I always thought that extra small pieces are added on purpose, as those are the most likely to get lost due to size. But it looks like it's due to the machine's accuracy. Interesting. :)

[@Ingram091]

For me as now adult who loved legos as a child, it’s all about unique parts. If a set does not have unique parts in most cases it’s not worth buying cause it can be made just looking at a picture of it. But sets with unique parts are always high demand. Especially unique canopy or colored glass wall pieces. The biggest disappointment has been not being able to get certain parts in quantity outside of certain sets for unique building opportunities.

[@jacobvriesema6633]

As an automation design engineer, I would absolutely love to tour their manufacturing facility!

[@MRdeLaat]

i miss the early lego technics pneumatic sets, i used to have a truck with a crane on the back that you could operate with pneumatics. if i ever have the chance to buy the same set i buyt it

[@Idontusethischannelanymore.]

Good video

[@Hujtir9]

When I was a kid I got lego a lot, as you do, however there was a string of 4 sets I got over a year and each one had missing parts. Thank god you can just tell them and they will send replacements for free. One of the times it was 2 whole bionicle feet

[@brucemartini2288]

AHH the SOUND of all those pieces☺🤣

[@vilIagernerd]

once on bricklink a piece was being sold and it was rare because it was a transparent glitter purple instead of pink

[@fornello123]

What do they do with the jumble of bricks that are leftover after designing?

[@joseluisvargas8234]

I love the medieval ones!

[@babyTOY-YODA777]

This is my heaven.

[@doctoronishispsychosislab1474]

what a job that must be

[@penngwinn]

LEGO is so awesome. I always wondered how the sets get put together. The organization of everything is insane.

[@massimookissed1023]

7:45 That's the machine that adds the scratches to all the windshield pieces.

[@asgads]

I think they just added a few feelgood stories into the doc;) nonetheless, good vid

[@JoeEnderman]

I saw the original Death Star droid being made. That means that video was from around 2008-2011.

[@thomasdoubting]

Sounds like a jobb Ii'd LOVE❗️❤️ ...for about a week...

[@seanward]

What a great video. I really enjoyed this look inside the Lego process

[@pikasnipe1]

A shark with a freakin' laser beam!

[@RokkeMC]

EYYY!! COOL to see Ancotrans presented in this video! I Drive for that Company and have delivered severel loads og pellets to Lego Billund :D SO NICE THAT IS ACTUALLY COOl

[@pwcorgi2000]

Lego needs to get back to creativity or "Make it Your Own. The manuals are just detailed guides." "Use these manuals to help create your own masterpieces."

[@lester44444]

That segue to the ad 😂😂😂😂

[@imacgra1]

Watch as he waves his hand through the Lego. That’s how I find my Lego pieces. 2:13

[@davidaIano]

1:49 so stunning.

[@stargazeronesixseven]

Always wanted to know how our beloved LEGO sets are made! 🙏 Thank You So Much SpitBrix for the short tutorial! 🌷🌿🌏💜🕊🇩🇰

[@sparrowhawk3422]

first few years working there all you do is put the pieces back in the correct places in the drawers.

[@leonvanderlinde5580]

I actually have a set that is missing two pieces of one kind to build the specific project. However there are four extra pieces that has nothing to do what the set is all about. I thing sometimes their QA computer makes mistakes. I don't mind, since I only build it once and then like to build my own ideas.

[@YouGoneMad]

You forgot to mention that those ABS Plastic Granules also come in transparent as well

[@massimookissed1023]

MABS methyl-methacrylate-acrylonitrile-butadiene-styrene as opposed to ABS acrylonitrile-butadiene-styrene.

[@Everyweapon]

I woulda assumed the Innovation House would have been a bit more colorful lol

[@duvitan_chelly]

2:15 St. American Petersburg...

[@AK.__]

Thank you very much. Very interesting. Can Lego employees in the factory take some sets to home for free or take home some pieces for their sets?

[@zabooka]

Awesome!

[@LandondelGamer]

the ocean clean up should help lego with all the plastic pellets they are making

[@pradeepkumar-mb1li]

Wow

[@pixart_king]

It's good to know that with all the hatred in the world, That we can still rely on Lego to brighten up our day.

[@MrWnw]

8:20 how is this printing technology called? I need to print on curved objects

[@360dom360]

So all the pieces from a given set will come from the same factory? That would mean needing to make sure the right factories have the right molds before having it build a set with pieces that factory hasn't had before

[@massimookissed1023]

They could just get a consignment of pre-made parts, ready to go in the picking/counting machines.

[@bucktheducktv201]

I always thought the extra pieces were in case you lost them since they're so small

[@genew2278]

Especially if they come in their own bag... 🤔