The Secret World of Lego: A look at how Lego bricks are actually made – Metro

Go behind-the-scenes at Lego's brick factory
(Picture: Lego)

Documentary The Secret World of Lego is a fascinating insight into how the world-famous bricks are made.

The Danish village of Billund is the birthplace of Lego and where one of the company’s Lego brick factories are based.

Along with factories in China, Mexico and the Czech Republic, Lego produces over 1 billion bricks a week.

And of course the process is a well-oiled machine:

1. The bricks start out as granulated plastic which is then heated up, injected into moulds, then cooled.

2. Each mould has 12-16 needles with colour in it which is pushed through into the brick.

Lego builds from the UK office.
(Picture: Lego)

3. Sometimes old colour gets left in the needle, so when the new colour is pushed through you get a brick with a ‘marbled’ effect made up of two different colours.

4. These bricks, which look pretty cool, are then thrown out because, according to mould technician Anya, they could ‘end up in the wrong hands, and on eBay’.

Lego builds from the UK office.
(Picture: Lego)

5. Each batch of new bricks get sent to quality control for analysis. If a brick’s dimensions are even a 1000th of a millimetre out, it will be rejected.

Lego builds from the UK office.
(Picture: Lego )


6. They are also tested for ‘clutch power’ (which helps the bricks click together).

7. When they pass the quality control tests they are shipped out for kids and AFOLs (Adult Fans of Lego) alike to play with.

The Secret World of Lego is on tonight at 8pm on Channel 4.

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