STAGE ONE: (DESIGN)

Creation begins with the requirement for the model being given to the LEGO model design team.   The design team develops a concept for the model that is then submitted for approval.  When a concept has been approved, a LEGO Model Designer begins work on the model.

Many times a LEGO Model Designer will begin with a sketch of what she envisions the model will look like when finished.  For simpler models, she may just start building.  For more complex models, she may start by building a scale model.  Then the work begins on the prototype model.  Model Designers are less worried about the actual building techniques to arrive at the finished model as they are in it's aesthetic qualities.

Once a LEGO Model Designer has finished work on a prototype, she calls all of the other designers in for a "Model Check".  The model is then critiqued by her peers.  Once these changes are decided upon, they are made to the prototype and the "Model Check" is called again.  Once the changes are minor enough that the LEGO Model Designers feel the model is finished, then it is considered complete and wheeled next door to the LEGO Model Builders.

STAGE TWO: (CONSTRUCTION)

Once a Prototype moves into Production, the Model Designer, Model Builder, and Model Animator have a meeting to discuss the last changes that will need to be made to the model and any requirements for extra strength in the model or extra spots to leave hollow for animation.  Then construction begins.

The LEGO Model Builder builds an exact copy of the prototype's outside structure and color, but with an eye towards building a model that is stronger and can accommodate the animation changes needed.  Each brick is glued with a MEK/ABS glue solution.  (Methyl Ethyl Ketone is the glue, ABS is the material they make bricks out of.)   It is important to remember that even though the models are glued, they are originally built without glue.  Every LEGO model you have ever seen displayed can be build with elements that you can buy.  They are very strict about making certain that there are no special tricks, elements, or techniques.  It also makes a good selling point. <grin>

(There are two exceptions to this rule;  There are some models that are built for display in LEGO parks that are built with colors not available to the consumer.  This is purely an aesthetic consideration.  While I was in Enfield, it was impossible for us to do this because we were not allowed to order those colors for the model shop, although I think that policy may have changed.  The second exception is that we were allowed to use a piece in a standard size that was not available, but could be constructed from smaller pieces.  A example is green.  There are very few green elements on the product line, but we were allowed to use green 2x4 bricks as they could be easily assembled from green 2x4 plates that were available on the product line.  I have seen similar concessions to pink and brown.)

Once the model is finished be built, it is sent to Animation.  This is where the lights and pneumatics are added to enable a model to move and light up.  Electric motors are not used very often due to the heat generated by the motor.

STAGE THREE: (RETIREMENT)

Ever wonder what happens to the older LEGO models?  When I was in Enfield, I was in charge of recycling them.  LEGO as a rule, never sells the older models (they very very rarely give them away, but don't hold your breath.)  Instead, when a model has outlived it's usefulness in the field, it is brought back home to Enfield, where I would use a 8lb. sledge hammer on it.  Each model needs to be reduced to smaller pieces that can be ground up and recycled.  Models are picked through to separate the ABS elements (which can be easily recycled) from the non ABS elements (which cannot.)  Although this may sound horrible to some of you to see some of these works of arts reduced to rubble, nothing felt better after spending eight hours building a pink ice cream cone out of 1x2,1x3 and 1x6 plates then smashing a model into itty bitty pieces.

The prototype models are taken apart piece by piece and reused by the model designers after they have been constructed by the Model Builders.  They are spared the hammer.

STUFF I GET ASKED A LOT:

"Do you get to use special tools to make there things?"
LEGO does not allow you to use any tools not available to the average ten year old.

"Are they hollow?"
As a model builder, you are mostly judged on (a) How fast can you build a model?  (b) How light is the model?  (c) Are your models made to the highest quality standard?  So the answer is "Yes."  I got paid more at review time if my models weighted less (cost less to ship and for elements)

"Do you get directions?"
No directions.  The model designer builds out of her imagination, and the model builder only gets to look at the prototype.  By coping each level of bricks exactly, the models are reproduced.

"Did you ever design anything?"
As a general rule, Model builders do not do design.  However, they did throw us a bone once in a while and let us design the play themes.  (The models with all of the mini-figures.)  This was also how they could see who might be moved to Model Designer if a spot opened up.

"What is your favorite model?"
My favorite model was a play theme I built for toys 'R' us stores.  It was in about 20 stores and featured the dragon master sets.  Long since recycled.