What does TLG use?

[Willy Tschager]

Q: Just out of curiosity does anyone know what TLG uses to design new parts (I would guess SolidWorks), and what do their model designers and instruction book people use to make digital versions of the official models?

A: In an article published in 2008 at develop3d.com, Mike Ganderton, then creative director for three lines - Bionicle, Racers and Technic gave an insight into the process. The following is an abstract:

The designers kicked off the developing phase by creating mood boards to help identify the type of vehicles they would like to create. They then sketched ideas and in order to visualise and conceptualise these sketches they built models using LEGO elements or bricks. From here they moved into 3D and used Rhino to create new LEGO elements, which were then prototyped using an in-house SLA machine. “We created a number of special SLA elements from CAD files in order to create an aerodynamic look,” confirms Ganderton.

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The next step was to build the model virtually, which also allows the designers to create the step-by-step building instructions for the user manual explaining how to construct the Axalara T9. “From this virtual model we also create a Bill of Materials in order to be able to plan how to manufacture the elements and pack the final product,” adds Ganderton. The finished CAD model is also used extensively by the wider organisation; for instance, the communication department can use it to create the design for the packaging as well as other marketing materials.

When the product is ready for mould manufacture the engineers model the elements in Unigraphics. Using this software tool they can optimise parts by conducting mould flow and stress analysis. “If we are uncertain about how a plastic part will perform we make a prototype mould to test it before committing to mass production. We make moulds with up to sixteen cavities so it’s important to get it right,” says Ganderton. As all Bionicle elements are moulded at the factory in Billund, the design team can very easily communicate with the production team and see the moulding process first hand.

However, as Ganderton points out, although having the factory onsite makes communication much easier, the real communication takes place in the project team itself with the designers, the part designers, the mould designers and the mould technicians all working very closely, quite often around the same desk or computer screen.

Job announcements for 3D Designer/Modeler by the LEGO Group also call for:

- have proficiency in Rhino or the ability to convert to Rhino

Navigate to http://www.rhino3d.com/ if you wanna know some more about the software tool. According to some pictures in the press kit of the LEGO group they use a heavily customized version of Autodesk Maya for building instructions and art work.