Lego's 0.002mm specification and its implications for manufacturing (2025) (thewave.engineer)
304 points by scrlk 7 hours ago
scatbot 6 hours ago
Lego is one of those companies that is simultaneously amazing and kind of sucks. On one hand the core product is incredible. The tolerances on the bricks are micrometer-level precision and the fact that pieces from the 70s snap perfectly into ones made today is mind blowing.
On the other hand, a lot what the company does today just sucks. Set prices are outrageous. Printed bricks get replaced with stickers and many sets feel like display models than something you can play with. The Mindstorms/NXT line had huge potential but then just sort of fizzled out. And the push towards smartphone-dependent toys feels weird. Who actually wants their kids staring at a phone to play Lego?
It's so sad, because the core product is basically perfect.
mmustapic 5 hours ago
Lego was always expensive, you can compare prices adjusted for inflation. For example, the 1979 Galaxy Explorer <https://brickset.com/sets/497-1> was around $32, that's $144 today. The reimagined set from 2023 <https://brickset.com/sets/10497-1> was sold at $99, $106 today. Not only it is cheaper, but much larger and with many more pieces.
potatototoo99 4 hours ago
Yes, they have kept up with inflation, and that is the problem. Manufactured goods like Lego bricks should fall in price through innovation in processes, scale, etc. What does raise higher than the average inflation should be be labor-intensive products/services. In other words, it feels much stranger today how expensive Legos are compared to 47 years ago.
atomicnumber3 4 hours ago
sixo 2 hours ago
mytailorisrich 3 hours ago
dclowd9901 5 hours ago
I have the re-release secondhand unopened and I think I paid about that much, so even in a collector's market, not terrible at all. An expensive toy to be sure but a deeply satisfying experience if you like that kind of thing.
Xerox9213 4 hours ago
onlypassingthru 5 hours ago
Wow, childhood memory unlocked. I had set 497. And, yes, it was a very expensive toy in its day.
serallak 3 hours ago
Spooky23 2 hours ago
Yes! We were never bougie enough to get Lego, I played with Sears bricks growing up.
sbcorvus 2 hours ago
Thanks for this reminder about the cost variable.
detourdog 4 hours ago
I remember the Lego 404 set being $40 in 1980. I actually can’t believe my Mom bought it for me.
brazzy 5 hours ago
It has almost 4 times the number of pieces, but is only about 50% longer and wider - there's just way more smaller pieces. Price per piece is very misleading when comparing older and newer sets. The newer ones have more details, look slicker, but have a lot less "meat". Which is not that great for creative play.
StilesCrisis 5 hours ago
jdwithit 4 hours ago
etrvic 5 hours ago
bombcar 4 hours ago
mmustapic 5 hours ago
seqastian 5 hours ago
There are so many better alternatives these days it’s mostly fanboys and people who don’t care who are still buying original Lego.
radpanda 4 hours ago
mmustapic 5 hours ago
esafak 5 hours ago
utopiah 6 hours ago
Nostalgia... Lego was amazing decades ago so we want it to remain so. It's not anymore though. The whole raison d'etre, namely infinitely recomposable bricks to be creative, was lost the moment they realized they were a LOT more money in custom sets. Sets become collectible, perishable, trends can form, secondary markets exists, etc. It's simply about the baseline, not the principle. Sorry.
Aurornis 4 hours ago
The existence of specialty sets doesn’t subtract from creating building.
My kids get some of the specialty sets, build them, then hours later they’re either taken apart or heavily modified.
The specialty sets can provide some interesting unique pieces too. My kids have a photographic memory of each of those special pieces and which set they came from. They’ll remember them and search until they find that exact piece.
> Sets become collectible, perishable, trends can form, secondary markets exists, etc. It's simply about the baseline, not the principle. Sorry.
I don’t know what this is supposed to mean, but you can completely ignore secondary markets and collector sets if you want.
There are more sets and pieces than ever. You don’t have to collect anything.
FarmerPotato an hour ago
johnisgood 3 hours ago
arkh 4 hours ago
You can still buy basic brick sets. With lot of nice color nowadays. Like the CLassics or Creator lines: https://www.lego.com/en-us/themes/classic
And for $100 you get a lot of bricks to play with and let your imagination go wild. Just don't buy sets aimed at adults and IP fansumers.
roelschroeven 3 hours ago
mmustapic 6 hours ago
Lego sets aimed at children are still good! They work as standalone toys, and can also be reassembled, modified and combined. Very few toys are like this.
Adults collect them, true, but there are whole lines dedicated to them.
dclowd9901 5 hours ago
jonhohle 5 hours ago
bombcar 4 hours ago
wincy 4 hours ago
bpev 6 hours ago
It was kinda funny to see the Lego Movie, which puts a bunch of emphasis on breaking the rules and mixing and matching everything, and then seeing them release the sets for the movie. I mean, it makes perfect sense. But it was still kinda lowkey humorous. But imo they're still a great toy; very fun to go to conventions and the like, where people just have giant piles of loose pieces you can buy by weight.
bigstrat2003 6 hours ago
They still sell the sets of generic bricks. At that point it is up to the individual customer to buy them if he prefers that. I could see your point if they stopped selling the more free form product, but they haven't.
qingcharles 5 hours ago
These collectible (read: branded) sets are what saved them from bankruptcy, though.
Keyframe 31 minutes ago
FarmerPotato an hour ago
WillAdams 6 hours ago
Look at it from the corporation's viewpoint:
- they have a finite production capacity
- they have a finite warehousing capacity
- there is a certain number of sets which will be bought
- crates of bricks without an established design have a limited appeal and while a consistent SKU, don't have the baked in demand a new set will have
mrgoldenbrown 3 hours ago
There's nothing stopping you from buying the basic sets and only the basic sets. They didn't stop making basic sets, unless you're objecting to the new colors that go beyond blue red yellow and black?
thinkingtoilet 6 hours ago
Lego is still amazing and you don't have to buy expensive sets for your kids to enjoy them. My son loves Legos and if he gets a set for his birthday it doesn't last long before he takes it apart and starts building other stuff with it.
This is one of those instances where it feels like people are terminally online. Or like the meme of the guy standing in the corner while everyone else is having fun at the party. You can find Legos being given away in a local buy-nothing group. It's still just as magical for kids as it ever was. These complaints are only from an adult who doesn't play with Legos. Who cares if sets become collectibles? Get other sets and have fun with Legos. These are toys that are meant to be played with. Play with them.
Latitude7973 5 hours ago
bazoom42 5 hours ago
You can still buy “generic” lego sets if you want. Look for “Lego Classic” sets.
bluescrn 4 hours ago
maxglute 4 hours ago
You can also only get so creative with lego. At the end of the day roblox/minecraft and video games trains kids to build more "relevant" things. Apart from tactility, I don't see what technic/mindstorm offers over digital.
kjkjadksj 3 hours ago
Diederich 18 minutes ago
I believe the inflation adjusted price per piece has remained fairly consistent? https://flowingdata.com/wp-content/uploads/2013/02/priceperp...
Perhaps sets of a given physical size have more pieces now compared to before? Not sure.
bdunks 5 hours ago
Agree. They seem to have a “price per piece” equation. Perhaps as a result, the 5+ sets are made of hundreds of small pieces.
Older sets had larger foundational and platform pieces which gave a good starting place for new creative builds.
Today, airplanes fuselages, wings, and car chassis are instead built up piece by piece.
It’s hard for my 6 year old to start creative builds that are stable when he hardly has any pieces larger than 2x6 across dozens of sets.
My wife found a huge mixed bin from the 80s and 90s at an estate sale. It really helped.
ryukoposting 5 hours ago
Several years ago I wrote this reddit post analyzing LEGO piece pricing: https://www.reddit.com/r/lego/comments/1328f52/detailed_lego...
It's a little out of date, but the conclusions are still relevant.
Main things of note: Brickheads are pretty economical as a "parts pack." No significant correlation between per-piece pricing and IP licensing (except for Star Wars). Star Wars and City sets are overpriced.
eru 5 hours ago
> Today, airplanes fuselages, wings, and car chassis are instead built up piece by piece.
Well, people did complain about the whole 'special pieces' trend that you praise.
alexjplant 5 hours ago
Aurornis 4 hours ago
mmustapic 5 hours ago
5yo sets have smaller pieces but also use big foundational pieces. Also the builds are simpler and better explained. Sets for 8yo are more complex.
SlinkyOnStairs 5 hours ago
> Older sets had larger foundational and platform pieces which gave a good starting place for new creative builds.
They stopped doing the many unique parts because it was bankrupting them.
awkward 6 hours ago
The decline of technic sets is such a shame. There's so little support for anything but representative models of specific cars, despite the platform being able to support a ton of mechanical creativity.
georgefrowny 4 hours ago
The disappearance of real metal Meccano is really crazy. I know metal is expensive, but also bulk processing of it has never been cheaper or faster.
It's also a shame because it's really good for mechanical rapid prototyping and you can bend and cut it in a pinch and it stays put. But buying vintage Meccano to abuse like that is expensive and feels like a war crime.
amelius 4 hours ago
^ This
rkangel 5 hours ago
> the push towards smartphone-dependent toys feels weird
I haven't seen this push? The new Lego Smart stuff is explicitly "screen free play". There is an app but it's just for firmware update and configuration and you can't even connect it unless the brick is on the charger.
bombcar 3 hours ago
Lego has been testing modern sets without instructions and instead tell you to download an app for your phone.
The ones I know of are the Mario ones, but they apparently need a phone anyway to setup the little characters.
ryukoposting 5 hours ago
Call me names, but I'll go to bat for stickers.
Even when I was a kid, I wasn't keen on graphic designs on the pieces. I liked the uniformity of consistently-colored pieces. Most graphics only make sense in the context of the set they were packaged in. Stickers give the customer flexibility. Use them when you build the set, and remove them later if you take the set apart and don't want them anymore.
Killing Mindstorms was a head-scratcher to me. Hell, there was an entire international tournament built around Mindstorms. I know FLL still exists, but why kill that darling specifically?
NXT still kicks ass by the way. I have a backup of the NXT programming environment somewhere, it can be coaxed into running on Windows 11.
FinnKuhn 5 hours ago
You can argue this for their sets targeting children and I don't think anyone minds stickers on those.
On display sets for multiple hundred Euros however it just looks cheap due to different surfaces and colors - especially as no one is ever going to disassemble these sets.
ryukoposting an hour ago
bigstrat2003 4 hours ago
closewith 5 hours ago
But you can only remove them once, and then never recreate the original set. Not great.
hibikir 4 hours ago
If you want advancements in engineering and plastics for much better prices, see the wonders that Bandai has made with modern Gundam models. A Gundam Aerial HG is under $20, and you end up with a large multicolor model that assembles easily, has minimal mold lines, and needs no glue. And that's one of the intro models
ibizaman 4 hours ago
You weren’t kidding. I just took a look and the models are gorgeous!
foobarian 5 hours ago
Oddly enough I found the Duplo line much more fun to play with as our kid went through the blocks years. You could build something substantial with fewer block clicks, there were fewer different types of blocks, they were less fiddly and prone to vanishing into rugs/carpets, etc. Also the proper Legos tended to be sets which makes it very stressful to mix them into a misc bag.
bntr 2 hours ago
Duplo is also compatible with regular Lego. We used Duplo for the big structure and Lego on top for details. Great way to build huge stuff quickly.
https://upload.wikimedia.org/wikipedia/commons/0/04/LEGO-kom...
tracker1 4 hours ago
I feel the same... I remember as a kid, being able to get kits of hundreds of just random blocks and variations and just being able to build/play... all the sets today are all custom blocks that just constrain you and often aren't significantly reusable while I'm not sure that I've even seen basic block kits anywhere in decades now.
edit: I know you can get thousands piece brick sets from third parties or random bulk set sales on Amazon... the issue is the random bits are from the current sets mostly with little reuse value, and the bricks sets are from third parties of questionable tolerance compared to real lego. I just want to be able to get a classic 1000-3000 piece set of classic bricks/pieces from Lego proper, even if it's $100-200 total, still way more than 3rd party but maybe not the same margins for Lego as the bespoke sets.
edit2: there are some "Lego Classic" sets that are closer to what I would like to see, this is probably the closest.
https://www.amazon.com/dp/B0B5FMF8BF/
But even then, maybe need that many more bricks that are just bricks... again, there are third party sets that are all block variants that are much bigger/cheaper... would just be nice to be able to get more of those without paying an arm and a leg.
jacquesm 6 hours ago
They suck because instead of buying the rights to the bricks they outright stole the design, the packaging and the marketing materials from the original inventor.
And then they sued the pants of everybody that tried to do the same thing to them.
throw310822 6 hours ago
> the fact that pieces from the 70s snap perfectly into ones made today is mind blowing
Is it? It's not like it's hard to keep producing the pieces to the same original specifications. If they snapped then they snap now.
flatline 5 hours ago
I think it's more the consistency of product design than the manufacturing process. Everything around me, especially in the software world, seems to change for no good reason on a frequent basis. Companies change products all the time for reasons other than utility/functionality. A consistent specification over 50+ years is an outlier.
StilesCrisis 5 hours ago
How many plastic things from the 70s still work perfectly with no cracking or warping?
throw310822 4 hours ago
Aurornis 4 hours ago
> It's not like it's hard to keep producing the pieces to the same original specifications.
It’s extremely hard to build consistent products to the spec.
There are a lot of knock-off LEGO on the market now. We get them as gifts. Some of them stack okay, some are too tight, some are too loose.
It’s hard to manufacture at scale at these tolerances and keep it that way for decades.
Paratoner 4 hours ago
Did you even read the article? No, even just the Title? Nothing is ever impressive I guess. Certainly not a 60 years running manufacturing process where your childhood pieces can be passed down and combined seamlessly with a set you just bought for your kid. So trivial and easy to do guys.
georgefrowny 4 hours ago
In terms of creativity of model options, the Chinese compatibles are stomping them.
You can even get a model of post-explosion Chernobyl. Not to mention all the sci-fi tie in from Star Trek to Warhammer that real Lego hasn't signed contracts for. But if you want an 60cm Gloriana class, there it is.
Plus Technics-ish sets and bulk boxes that aren't 75% special body panels that only fit that specific model, since Technics itself mostly seems to have been downgraded to the automotive brands advertising department.
detourdog 4 hours ago
I got my first Lego set in the early 70’s through a Velveeta cheese mail in promotion. The company almost went out of business in the early 90’s before they discovered movie tie-ins. I believe the quality of play was lost in this transition because the sets became more literal and less open ended. My first big set was a fire station which certainly literal but somehow seems more open ended then the movie tie/in sets.
bombcar 3 hours ago
The fire stations et al still exist, its just that they don't sell nearly as well as the tie-ins do, at least based on shelf space allocations.
This year's isn't huge: https://www.lego.com/en-us/product/fire-station-with-fire-tr...
But the police station is pretty big: https://www.lego.com/en-us/product/police-station-60316
(To me this looks more fun, but I'm a pirate guy: https://www.lego.com/en-us/product/police-prison-island-6041... )
detourdog 40 minutes ago
0x457 3 hours ago
Lego was always expensive.
> many sets feel like display models than something you can play with.
That's because they are. There probably never been this many adults building lego than today.
> The Mindstorms/NXT line had huge potential but then just sort of fizzled out.
That's a small niche in today's world, a child is too young for arduino/feather/cyberbrick/whatever.
MaKey an hour ago
Other manufacturers give LEGO a run for their money nowadays. Look at the CaDA Mercedes-AMG One for example.
bityard 4 hours ago
I'm not a Lego nerd, but I recently saw a really sweet Lego DeLorean in Walmart priced at almost $200. Now that I have disposable income, I would have impulse-purchased that thing so hard if it would have been closer to $100. But I can't quite bring myself to part with a pair of benji's for a plastic toy, no matter how thoroughly it triggers my nostalgia.
bluGill 5 hours ago
I heard your same rant in the 1980s - only small details have changed (not mindstorms then ...) But kids who want to build have always been able to, and most sets mix and match for those kids.
wongarsu 5 hours ago
> I heard your same rant in the 1980s
The two options would be that either the perception is unsubstantiated but persists, or there has been a continuous decline for the last 40 years. I'm strongly leaning towards the latter. I also having the same issues in the 00s looking at old sets from the 80s, and looking back now the 00s look much better than what we have today. Obviously not in every way, and not all recent sets were bad. But overall I have the feeling that there's been a steady trend that the bricks got better but the sets got worse
bluGill 5 hours ago
iso1631 5 hours ago
abtinf 3 hours ago
Quality is expensive.
Lego’s net profit margin is only about 19%.
They couldn’t lower prices much even if they wanted to.
Aurornis 5 hours ago
> many sets feel like display models than something you can play with
That’s what I thought when comparing to my childhood sets, but it doesn’t stop my kids from loving them and playing with them.
My kids are learning a lot of cool building tricks from the advanced sets that I never thought of as a kid. Lots of angle pieces, hinges, and creative building.
bombcar 3 hours ago
That's probably the biggest change in the last few decades, they went from never doing anything out of the ordinary to SNOT (studs not on top) for "adult model" sets only (first in the trains I believe), to now where advanced techniques are used even it children's toys that aren't models.
dec0dedab0de 5 hours ago
The expensive sets ARE display models. They still have the older style generic sets for significantly cheaper.
hypercube33 4 hours ago
Not just NX but technics basically was a build things that do stuff mechanically and now isn't that seemingly at all. Most kits I had came with one or more alternative models you could build with the primary kit as well.
bluescrn 4 hours ago
Classic Technic was brilliant, but when they switched to 'studless Technic' it became far more difficult to build creatively with it (even if it enabled far more intricate builds with complex mechanisms, like the gearboxes in the supercar sets) - there was no natural 'up' direction any more, and building anything became more of a 3D logic puzzle than just building with bricks.
Real shame that they discontinued Mindstorms, though.
bombcar 3 hours ago
xattt 5 hours ago
They’ve basically adopted the Nintendo model. People have strong emotional connections for both, which can then be exploited for money.
It has momentum because they haven’t let quality and innovation slide. They know customers will be out with pitchforks if quality drops.
jiehong 5 hours ago
Maybe one last thing that sucks is that it’s all plastic.
embedding-shape 5 hours ago
At least LEGO is probably the toy that gets "passed down" the most, my own LEGO parts who I got from an older cousin, is now on its 4th generation (first my sisters children, then some family-friend to theirs), and I'm sure the pile(s) will get further passed down as time goes on.
antonyh 5 hours ago
True, but at least it's not single use. Is there a viable alternative? A non-petrochemical plastic that has the same qualities? It's not like they can whittle them out of wood or cast them with metal so it'll always be some form of polymer, and I'm sure they would jump at a more ecologically sound option.
bombcar 3 hours ago
em-bee 5 hours ago
KellyCriterion 5 hours ago
> a lot what the company does today just sucks. Set prices are outrageou
This was all done planned and implemented by this one consulting guy (MCK?), who became CEO after delivering his report from his consulting company, Lego was near bankrupt back then - he started with all this subbranding shitty stuff and the "colorful" bricks and introduced all these many many "single-use-case-bricks" for more and more sets.
kevinsync 5 hours ago
I was just about to reply about their financial woes over the years too [0][1][2]
Being a collector of stuff ever since I was a kid (toys, comics, cards, physical media, printed collateral, etc), and being in my 40's (target market / demographic for expensive nostalgia) living in 2026 (the world is a casino! everything's a collector's item!), it is a little annoying to see LEGO appear to turn into something that it wasn't .. but objectively that doesn't eradicate the fundamentals of LEGO, and I'd rather see them be a healthy company with longevity (via current product strategy) than wither and die on the vine out of stubbornness.
That said, aside from leaning on the AAA IP that drives prices through the roof in some lines, I do wish they'd stop with the tech gimmicks (Hidden Side, Smart Bricks), renew one of their focuses on real tech/engineering-adjacent platforms (Mindstorms / NXT / a modern version of these), and acknowledge that wealthy adults aren't the only customers. It really prices out young, fertile minds who a lot of their product and ethos should be directed towards.
Of course, that's a huge problem right now with anything that can command aftermarket prices as collectibles! [3]
[0] - https://knowledge.wharton.upenn.edu/article/innovation-almos...
[1] - https://blog.firestartoys.com/how-the-lego-company-almost-we...
[2] - https://www.toypro.com/us/news/710/learn-the-story-behind-le...
basilikum 2 hours ago
Just buy from one of the many way cheaper way better competitors.
vikingerik 2 hours ago
If you're complaining about the prices, remember how capitalism works. The price is set by buyers, not sellers. That's the invisible hand, the seller will set the price to what buyers show they will pay. If you're unhappy about $500 for a Millennium Falcon or whatever, your beef is not with the company for accepting that when people choose to pay it, it's with those other buyers for paying that much.
As the other replies are saying, it's mostly brand power. If your complaint is that $500 for a Falcon is monopolistic because there's no competition because nobody else can legally sell Falcons, the monopoly is really with Star Wars not Lego, they're just delegating it to Lego. You're always free to find your cheapest source of bricks perhaps from other manufacturers and build your own equivalent.
As for stickers and apps and the other stuff... yeah that's the enshittification that also always accompanies capitalism. It's lamentable but it only changes if enough customers vote no with their wallets.
reacharavindh 5 hours ago
I mean it is a business after all, trying to make money..
I must say, the new smart bricks with all sorts of sensors(color, gyro, distance etc) triggers the inner child in me. I can’t wait to get them for my kiddo and teach him how that magic actually works beneath.
The regular LEGO at this points feels “just plastic” and I won’t feel bad offloading that purchase to AliExpress.
dismalaf 4 hours ago
Basic Lego is actually decently affordable. It's the collector's sets that adults would buy whose prices are jacked sky high, based on demand it seems.
I've bought a decent amount of Duplo and Lego kits for my son (currently 3 years old) and it's great value.
bombcar 3 hours ago
The fact that "10$ a pound for used, 10¢ a piece for new" has remained true as a good rule of thumb for 20+ years tells you something.
gchamonlive 3 hours ago
Isn't that just capitalism? The rule is for companies to keep pushing for higher margins and profit, so given enough time any company will default to shady tactics and product enshitification.
sammy2255 6 hours ago
Maybe if something is too expensive don't buy it?
vidarh 6 hours ago
More than just bricks fitting into each other at a superficial level, it matters how firmly they fit together, and it's one of the areas where LEGO is generally superior to the similar types of bricks.
A detail I didn't realise until I was an adult was the difference between the black and grey technic connecting pins. They look interchangeable, and for a lot of things they are.
But there's a fraction of a mm raised lines on the black one, and it's enough to produce significantly more friction, and that difference is utilised in designs.
And apprently there's now a new version of the black one, and people notice these things, and measure them - this article gives an idea of just how these tiny changes, well below tolerances for some of the "knockoffs", can produce a different effect:
https://ramblingbrick.com/2021/01/27/what-if-they-introduced...
voidUpdate 6 hours ago
Do you mean between black and light grey? Light grey pins have always been the kind you use for rotating connections (low friction), whereas black was for non-rotating ones (high friction). Newer blue pins are also high friction, IIRC. I haven't bought new lego technic in a while, so I don't know if there's been any new colours added
EDIT: I think I also had some dark grey pins, but I don't remember if they were high or low friction
normie3000 4 hours ago
> Light grey pins have always been...
I think the black ones were a later addition, likely late nineties.
vidarh 3 hours ago
fwip 4 hours ago
My memory of twenty years ago says the dark-grey pins were 1 stud wide on one side, and half-wide on the other, and low-friction like the light-grey ones.
MisterTea 2 hours ago
rrr_oh_man 6 hours ago
> it's one of the areas where LEGO is generally superior to the similar types of bricks
Imho, this is, objectively, not true (anymore).
Pantasy with GoBricks are superior in coloring and fit; Cobi are excellent for things that should not be taken apart anymore (like tank models); Lumibricks are excellent in fit and have amazing illumination solutions that are lightyears (haha) ahead of lego.
vidarh 3 hours ago
Interesting - never come across Pantasy/GoBricks, or Lumibricks but then it's a few years since my son decided he was too old for LEGO, and I see Pantasy is just a few years old, and Funwhole/Lumibricks just a few more. Great if there are more options of similar quality.
But "should not be taken apart anymore" fits into an entirely different category for me. If you don't need to be able to take them apart any more, it fundamentally changes requirements.
jonhohle 6 hours ago
I got the Pantasy Neo Geo set a while ago, and was pretty blown away compared to the better known imitators that have been available at retail. The mechanics are not as robust as I’d expect from Lego, but it was about a quarter of the price and externally looks as good with some really fun and well thought out details.
samrus 6 hours ago
True. But lego has stood the test of time. Thats way harder
dfedbeef 4 hours ago
rrr_oh_man 6 hours ago
yonatan8070 3 hours ago
IIRC there's also light yellow pins that are also light friction
ragebol 4 hours ago
Ha, I noticed this too! And even my 3 y/o picked up on this.
We have a set (something with Spiderman IIRC) that attached wheels with yellow pins that allow for better rolling of wheels. The black pins are too tight for this indeed.
wek 6 hours ago
For me, the beauty of Lego was just a huge bin of interconnectable parts that I used to make whatever my imagination came up with. For my kids, Lego is pre-built model airplane set that they build one time and then display. I liked my Lego better :)
Thlom 5 hours ago
You can still buy LEGO Classic which is just a bunch of bricks.
antonyh 5 hours ago
From experience there's a motivation, almost a compulsion, to follow the instructions to build the cool thing. Then... they sit there, those bricks never taken apart.
That compulsion doesn't seem present in freeform building, and there's been zero interest in it in our household. I know that's not true for all, but it seems like a lost art. Maybe it's because the IP sets show how but not the why it's constructed in a certain way, so given a bag of Lego most wouldn't know the process of creating something they can see in their minds eye within the constraints of the available bricks.
wffurr 2 hours ago
beastcoast 43 minutes ago
skrebbel 3 hours ago
Not really. Even LEGO Classic has way too many different colors (and only a few bricks of each), and too many weird shapes. Even if you buy a lot of it, it's hard to make your own designs that actually look nice (as in, not having that one incorrectly-colored brick in that one place, and so on).
I for the love of God can't comprehend why LEGO Classic has 4 shades of blue. It makes everything worse.
brightbeige 6 hours ago
Makes me think there could be a big cognitive difference when playing with Lego as well, for example, divergent vs convergent thinking.
MarsIronPI 5 hours ago
Maybe Lego needs to manufacture sets that are just "collections of bricks". In fact, I think they did that at least for a while. I know my past self would have loved to have a few sets that when put together would provide the kinds and variety of pieces used in books such as The Lego Play Book.
bigstrat2003 4 hours ago
They still do that. I can go to the store right this very moment and get a bin of bricks. There's no problem here: people who want designed sets can get those, and people who want just bricks to use as building material can get those.
MarsIronPI 3 hours ago
butILoveLife 6 hours ago
After working in automotive, this is less impressive than it appears.
Tons of dimensions on 100k/yr injection molded(and otherwise) parts have similar dimensions. (Although admittedly, after testing in pre-production, I don't know if they are tested again and have drift)
Lego has been making the same parts for decades and their parts are extremely simple. I imagine their 1-off parts for intellectual property based sets do not have this requirement.
I think Lego has a huge incentive to promote this idea that they are high quality to justify the enormous price of decades old technology.
adamzwasserman 4 hours ago
The reason this is impressive has less to do with the tolerances themselves and more to do with backward compatibility across decades at scale. That's the genuinely hard part.
The history here is deeper than most people realize. The United States spent fifty years (roughly 1800 to 1853) at the Springfield and Harper's Ferry armories trying to achieve what LEGO now does routinely: parts manufactured to tight enough tolerances that they are truly interchangeable without fitting. In 1853, a visiting British inspector randomly selected ten muskets made in ten different years, disassembled them, mixed the parts, and reassembled ten functional muskets using only a screwdriver. Tolerances of a thousandth of an inch. It was considered impossible by most of the engineering establishment of the time.
The way they got there was by building machines, then using the parts those machines made to build better machines, then using those improved parts to build even better machines. A virtuous circle of transferring skill from human hands to tooling. This is the actual origin story of what historians call the American System of Manufacture, and it's the foundation the entire modern automotive supply chain sits on.
So yes, any competent injection molder holds tight tolerances today. But that's precisely the point: the reason it seems unremarkable now is that two centuries of compounding precision made it so
thowawayko1 5 hours ago
After working both in automotive and at LEGO, I think LEGO is more impressive tolerance wise when it comes to molds, molding and tolerance quality control.
Also to correct you, LEGO has been making most of the parts for decades, some have had changes due to new materials (which you can read upon online) but besides the ones that remained the same (not really), many new system elements got released in the last decades and new I.P tied elements get released on a yearly basis.
hypercube33 4 hours ago
Ill admit that their parts do have higher quality than their competitors (various Chinese and other companies) making similar or compatible parts - some have injection molding blemishes or whatever on them that I've purchased from AliExpress or Walmart so in this space they are above everyone else in their space.
double0jimb0 5 hours ago
Agreed. Same or greater injection molding challenges for bottle caps, small plastic containers, things that also are in the hundreds of millions of parts annually. More challenging as they are often using polypropylene which is harder to mold due to its high anisotropy (shrinks in different rates depending on if it's flow or cross-flow direction).
FarmerPotato 11 minutes ago
>A 2x4 LEGO brick manufactured in 1958 will snap perfectly onto a brick molded this morning..
This is just manifestly NOT TRUE. The outward appearance may be the same. There were intentional improvements to the walls and tubes that make fit less than perfect. Generally, today's brick requires less force to snap and un-snap, because the compression is focused onto fewer points. (I guess this lowers the "hoop strength".)
Older bricks can be either: completely loose, or clutch so hard to each other they are the devil to take apart.
I have many bricks from 1962 onwards. The oldest 2x4s and 2x2s were made of cellulose acetate (CA) (in North America, intermediated by Samsonite.) CA were softer, and either had less clutch power to begin with, or lost it over time. When I got them in the 70s, they fit but wouldn't reliably stick to each other, nor later 70s-80s bricks (all ABS plastic by then.) (CA bricks were mostly red, and they have a pale orange tint.)
70s-80s bricks did not always age well. Aged 1x4 or 1x8 bricks can have the outer wall bowed inward slightly. This is a mold engineering problem anyway. Later, 80s bricks were improved by slightly thinner walls and some reinforcing tabs. The older, aged bricks can stick brutally to each other and to newer bricks.
The 10x10 baseplates didn't age well (these were once box-tops! Tog'l Toys also had the baseplate as a box-lid.) Possibly made of polycarbonate (PC). Other large plates in ABS-- for instance 6x16 (Auto Chassis, red) -- have warped. They were also more brittle to begin with.
So inside Brick geometry has changed over the decades. 60s-70s bricks are closer to plain boxes with tubes inside - as the Kiddicraft prototype of the 50s. In the 80s, the outer walls got thinner and had tiny studs where the studs contacted the wall. And the tubes changed from cylinders to just slightly clover-leaf inside, so that a tube over a single stud now formed 4 points of contact, and came apart with lower shear force. (I believe this also made it easier to pry a plate off of a larger plate.)
I have Fabuland sets from early 80s, whose plain bricks are so stiff, they are positively brutal to snap onto each other or 90s bricks.
The brick geometry of today is much improved. And the ABS is more "plastic", perhaps more "B" (butadiene rubber) or less "S" (styrene): I can drill it more cleanly.
Mid 80s and 90s bricks will interoperate just fine with today's. But bricks from before that period didn't age so well (and their corners, I believe, used to be harder.)
lqet 6 hours ago
> A 2x4 LEGO brick manufactured in 1958 will snap perfectly onto a brick molded this morning in Denmark, China, Hungary, Mexico, or the Czech Republic.
In the late 90ies, I regularly played with my uncle's old LEGOs from the late 60ies and early 70ies. They were stored in an unheated attic for 25 years. I remember that some of the old bricks didn't "snap" at all anymore to my newer bricks. They were either extremely difficult to stack onto a new brick, or didn't have any friction left.
bombcar 15 minutes ago
There were some bricks from the very early days that were not made from ABS, nor did they have the current box and pin style. Those are often loose (or broken).
kjkjadksj 3 hours ago
In my experience the bricks that didn’t snap well would have too many teeth marks
kspacewalk2 5 hours ago
We use a Lego phantom[0] to control for geometric distortions in a few of our MRI studies. The tolerances are so tight that it works really well. Especially important in multi-site studies.
khalic 4 hours ago
Really cool trivia, thanks for sharing :D
rob74 5 hours ago
Was this written using AI? It does contain some interesting information, but the same information is repeated (with small variations) over and over again in a mind-numbing way that made me stop reading after about half of the article...
Tossrock 3 hours ago
It certainly feels that way. Some tells:
"Precision, for LEGO, isn't an engineering choice, it's a brand promise." - The classic "It's not just x, it's y", just minus the "just".
"One philosophy optimizes for cost, the other for perfection." - Again we see the x/y structure; AI writing often features these forms, eg comparisons (x vs y), conversions (x into y), negated emphasis (not x, but y), etc.
"When you have multiple parts in an assembly, use statistical analysis for tolerance stack-up rather than worst-case math. Traceability matters. Track your defects so feedback turns precision into reliability." - More x/y followed by a short stinger ("Z matters"), and the closing sentence again follows the "x/y" pattern.
For funsies I tossed the whole thing into a purported AI detector and it said 90+% confidence of AI. I don't trust those types of things very much and suspect they have high false positive rates, but I have read that AI writing generally has measurably lower entropy, so maybe it's plausible, and in this case it aligns with my existing beliefs, so it obviously must be true.
pubby 5 hours ago
Lego's original moat was their patent. This expired in the 80s, and so their new moat became their manufacturing tolerances. None of their competitors could match the quality of their product. This lasted until about the 2010s when clone brands in China finally caught up, and coincidentally, Lego's own quality started slipping. Thus, they needed a new moat, and the choice was obvious: licensing.
mejutoco 5 hours ago
I wish Lego would find a digital equivalent as universal as the bricks for programming. I think it could be another moat for them. But it seems they keep changing it and it does not seems as simple or as universal as it could be. I am thinking more programming with blocks than using a tablet etc. to program the blocks. IMO it is a wasted opportunity.
herpdyderp 5 hours ago
What knock off brands come even close in quality? Everything I’ve tried that isn’t name brand LEGO is hot garbage.
operation_moose 5 hours ago
I've ordered 2 sets off of AliExpress (the Stargate BC303 and BC304 MOCs) and was quite impressed. No box, digital instructions, and a few minor color swapped pieces; but complete and everything went together very well.
nayuki an hour ago
Upvoted, and the English prose is pretty good in spelling and grammar, but the metric units in the writing need improvement.
> 10 microns
"Micron(s)" is a deprecated word since 1967 and "micrometre(s)" must be used instead. The reason is that it is a non-standard word; if "micron" is accepted, then we should also accept the nonsensical words "millin", "nanon", "kilon", etc. The metric system is supposed to be easy to learn with consistent rules and as few special cases as possible.
> 4.8mm ... 0.01mm ... "0.002mm tolerance"
These numbers are correct, but it's harder to quickly skim the text and make comparisons because the number of decimal places vary. It would be better to write 4.800 mm, 0.010 mm, 0.002 mm to make the reader's job easier. Or convert everything to whole micrometres, like 4800 μm, 10 μm, 2 μm.
> withstand over 4,000 Newtons
Almost correct, but the unit must be decapitalized to "newtons". This is similar to how other name-based units are decapitalized - like "100-watt light bulb", "12 amps", "3 gigahertz".
> 2-3 Newton insertion force
It must be written as "2–3 newtons". When the unit name is written out in full, it follows normal English pluralization rules (e.g. metres, seconds, volts, pascals, kelvins, ohms, teslas). The only exceptions are hertz and siemens, because they already end with -s or -z.
jjk166 an hour ago
This is why we measure things in baby elephants per football field.
Thorrez 6 hours ago
>The frequently cited "0.002mm tolerance" is misleading without context. LEGO's actual mold precision is 10 microns, but different features have different critical tolerances.
The article never mentions what piece has a 0.002mm tolerance. Is there any such piece? If there's no such piece, then "0.002mm tolerance" is not just "misleading without context", it's straight up false.
ozlikethewizard 6 hours ago
Is it a language mixup, ±0.001mm being called a 0.002mm tolerance? Otherwise I cant figure it out either lol.
Karliss 5 hours ago
0.001mm is 1 micron not 10.
rkangel 5 hours ago
The tolerance for interference fit ("clutch power" in Lego terminology) is important, but that's fairly simple. It's the cumulative tolerance when you assemble large structures that's important. Knockoff bricks can be fine for the first few you assemble, and then as the structure gets larger things don't quite fit together.
Also interesting is that in very large models, there is decoupling between sections. Lego has design rules for how large a well connected chunk of Lego can be, which are driven by the tolerances. Above that you are then loosely coupling those large "chunks".
perfmode 3 hours ago
This is the most interesting point in the thread to me. Tolerance stack-up is the reason tight per-part tolerances matter at all. A single brick being precise is table stakes for injection molding. The hard problem is what happens when you compose hundreds of them. The decoupling strategy you're describing is really similar to how you handle error accumulation in any large composed system. You can't make individual components perfect enough to avoid drift at scale, so you introduce boundaries where the accumulated error gets absorbed rather than propagated. In Lego's case that means designing joints between sections that are forgiving enough to accommodate the stack-up from each chunk independently.
It's also why knockoff bricks can feel fine for small builds and then fall apart (sometimes literally) on larger ones. If your per-part tolerance is 3x worse, it doesn't matter much for a 20-piece build, but for a 2000-piece build your cumulative error budget is blown long before you're done. The failure mode isn't that any individual brick is bad, it's that the composition doesn't hold.
I'd be curious whether Lego publishes or talks about those chunk size design rules anywhere. That seems like the actually interesting engineering story, more so than the per-part tolerance numbers that get repeated in every article about them.
nmeofthestate 5 hours ago
"A minifigure head mold evolved from 8 cavities in 1978 to 128 cavities today."
Initially I thought this meant a lego minifig head has 128 internal cavities, but finally realised it means a single mould now makes 128 heads.
solidsnack9000 3 hours ago
I would like to better understand the reasoning behind what the author says here:
A balanced 16-cavity mold costs 3-4x more than a single-cavity mold but only produces 16x the parts, which is why they only make economic sense above 500,000 units.
s0rce an hour ago
I guess if a single cavity mold costs $30,000 and a 16 cavity mold costs $110,000 you have an additional expense of ~$80,000, divided over half million parts is 16 cents. So lets say somewhere from 5-10cents per part to go 16x faster. My numbers might be off a bit but seems in the ballpark. I also don't know much a lego brick costs to make in terms of materials/opex.
yubainu 4 hours ago
I always thought it was amazing how Lego pieces fit together so perfectly that they wouldn't come off even if you lifted them, but if you wanted to remove them, they came off so easily, and I had no idea they were that precise.
lich_king 5 hours ago
This is an LLM-written article. It also doesn't say anything. I get it that it's a cue for us to reminisce about childhood and say that LEGO isn't what it used to be, but we're being played for clicks. Open the article and look for a single statement that actually tells us something meaningful. It's just a sequence of impressively-sounding factoids like this:
> A 2x2 brick can withstand over 4,000 Newtons of force, which lets children build tall structures.
> But in an assembly system like LEGO's, small errors accumulate. Stack ten bricks end-to-end and the cumulative tolerance is ten times larger. This is why LEGO models larger than 1 meter become difficult to build
> The lesson isn't that everyone should match LEGO's tolerances. It's to understand what your product actually requires, then build your manufacturing system to deliver that at the scale and cost your business model demands.
I know I'm tilting at windmills, but come on.
rkangel 5 hours ago
I agree, it doesn't say a lot. It also very confidently specifies a series of tolerances with no citations.
Lego does indeed have very tight tolerance, but I don't know if the numbers are in the public domain.
isoprophlex 5 hours ago
I too hate it when my kids apply 4 kN of force to off-brand construction bricks and they turn to ABS paste. Only LEGO (R) for my spawn!
twodave 4 hours ago
Both of my boys (9 and 11) still enjoy both the sets and the classic Legos. They're constantly building trucks, trailers, etc. One even designed his own working dump-truck. They're still great toys for imaginative play, and the fact that the sets can be broken down and used in new ways just keeps the fun alive. My oldest even designed and had his grandpa build him a lego table with a removable/reversible top so he could paint different geographies for his cities and whatnot that he likes to build.
WillAdams 6 hours ago
Curious how this might have played out over the long-term with their licensed/abandoned/revived/then bought to kill permanently "Modulex":
https://archinect.com/features/article/149974598/the-brief-a...
I wish one of their competitors would take up this dimension standard --- it would be a lot more useful for making structures which interact across dimensions/rotations.
Normal_gaussian 6 hours ago
"that familiar click is the sound of a carefully engineered interference fit designed to hold firm but still be easy for small hands to pull apart."
My recent experience calls bs on pulling them apart.
doubled112 6 hours ago
I always remember the small, weird pieces being hard to get apart.
What I don't remember was every kit being made up of so many small, weird pieces.
ralferoo 6 hours ago
When I was a kid, the first "special" Lego kit I remember was the Star Wars sets in 1983 (and especially that everybody wanted a Millenium Falcon but I didn't know anybody who had parents that could afford one!)
Apart from those Star Wars kits, everything I had were generic blocks and strips (not sure what they're called, the ones that are 1/3 the height of a block) and some different designs of people. The closest I had to previous special sets was a town thing that my brother and sister had before me (they were 10 years older), which was a bunch of large floor tiles with roads and grassy areas with studs, some flowers pieces (single stud) and a handful of special buildings. But they were designed to be relatively generic, and the fun was using those building blocks to make a new city each time, not trying to recreate exactly someone's model. Apart from the flowers and the men, basically everything was a standard part, except perhaps a different colour.
When I was a teenager, the trend had become sets with lots of specialised parts for one specific model, such that they didn't really make sense as generic pieces. I enjoyed the technics kits because the early ones were just generic building blocks (apart from the wheels and rack and pinion, but again they could be re-used in lots of subsequent designs), but more and more the kits in the shops were for specialised models with unique pieces that were never designed to fit aesthetically with anything other than the model they came with. I'm sure _some_ people built other things with them, but equally I'd bet than probably 90% of those kits were built exactly once following the instructions and then never disassembled again.
bena 6 hours ago
Zanfa 5 hours ago
Having grown up playing with LEGOs, I can still distinctly remember the feeling of sore fingers pulling tiny pieces apart after a long session. It wasn't until a few years ago I learned there's an official brick separator tool [1]. Would've changed my life as a kid.
[1] https://www.lego.com/en-us/service/help-topics/article/lego-...
bombcar 6 minutes ago
There are multiple brick separators, with different strengths and weaknesses.
intrasight 6 hours ago
The tolerance is definitely more applicable to the getting them apart then putting them together.
exabrial 5 hours ago
Backwards compatibility is something lost today. Incredible they've kept it this long.
jimmar 5 hours ago
I've never regretted buying Legos for my kids. Yeah, the kits can be expensive, but they last forever. We've thrown out or donated lots of old toys, but the Legos will never be given away.
yubainu 4 hours ago
Rather than worrying about accuracy, please do something about the pain that will make you cry if you step on it!
joering2 3 hours ago
there is a solution for that, its called flip-flops. But it would be hilarious if LEGO would add a pair in one of their sets :)
jlv2 2 hours ago
https://www.lego.com/en-us/product/brick-clog-5010203
Pricing is on-par for LEGO.
antonyh 5 hours ago
This is why Lego has nothing to fear from 3D printing.
spatular an hour ago
The trick is to redesign the bricks for worse tolerances. With 3D printers you can print very nuanced springy elements that are impossible to achieve with injection molding. I got some reasonable bricks years ago on cheap printers with PETG, should work even better now with modern printers and ABS.
wongarsu 5 hours ago
Not in terms of people printing lego bricks. But at least as an adult, designing things in Fusion and printing them scratches a similar itch as building lego. And 3d printing is now pretty accessible to the 14+ age group. I doubt this will completely replace legos, or that it's even their biggest threat, but I'd be surprised if it had no impact
antonyh 5 hours ago
Framed that way yes, but wouldn't it be cool to 3D print interlocking parts that can be reassembled in different ways?
tmaly 5 hours ago
It would be interesting if 3D printers could reach this tolerance
antonyh 5 hours ago
I'm sure they will if they can't already, but the price of the tech & the materials could be the limiting factor. How much would a hobbyist be willing to spend on consistent 10-micron 3D printing?
SV_BubbleTime 2 hours ago
Something that took me years of working with custom plastic injection part experience to notice still kind of shocks me…
Legos don’t have draft.
That means nothing to 99% of you, but someone else here must understand what the implications of that are for releasing from molds at a mass scale.
lvl155 3 hours ago
Worth mentioning that tolerance is that low for multi-stud pieces. For an individual stud it’s closer to 0.02mm but as you add more studs tolerance spec goes up.
m3kw9 6 hours ago
If you buy any knock off legos, you are guaranteed 3 things, 1. Crappy instructions 2. Noticing the snap pressure is inconsistent and often too tight our bouncy. 3. Swearing at that manufacturer after every page.
em-bee 5 hours ago
not true at all for most alternative brands (they are not knock offs, the patents are expired so they are legal, and comparable in quality), same for cloned sets (shady companies cloning lego sets using alternative bricks (the bricks are legal, the cloned sets aren't). the quality of alternative bricks is good. the quality of the instructions as well.
zvqcMMV6Zcr 6 hours ago
For me it is 1. Terrible quality of all rubbery/soft elements. 2. If it is original model (instead of ripping of existing set), it often contains huge, shell like elements, that can't be easily be in custom designs. 3. I guess the previous point doesn't really matter, when bricks are designed to be assembled once and are impossible to pull apart without hurting your fingers.
lnsru 6 hours ago
The 2. is very annoying. Especially when big sets fall apart due to this issue.
Let me add this: 4. no spare parts available. So when I break weird Chinese invention the whole set becomes useless without that very special part. It happened few times and I got back to used Lego sets.