Chloe Zhang
Acrylonitrile Butadiene Styrene (ABS) is a thermoplastic that has been used to make Lego bricks since 1963. It is strong, stable, scratch-resistant, and makes up the vast majority of Lego pieces today. In this article, we will discuss the process of casting ABS Lego plastic, including the steps involved, the equipment required, and the potential challenges and safety considerations. We will also explore the history of Lego's use of ABS plastic and how it has evolved over time.
| Characteristics | Values |
|---|---|
| Chemical Formula | (C8H8)x·(C4H6)y·(C3H3N)z |
| Melting Point | 105 °C |
| Type of Plastic | Thermoplastic |
| Consistency | Strong, stable, scratch-resistant |
| Colour | Translucent-milky when uncoloured |
| Supplier | Bayer AG (until 2004), Lanxess AG (since 2004) |
| Introduced by Lego | 1963 |
| Phase-out of Previous Plastic Complete | 1966 (Europe), 1970 (North America) |
| Previous Plastic | Cellulose Acetate (CA) |
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What You'll Learn
ABS plastic's history with Lego
The history of Lego's use of ABS plastic began in the mid-1940s, when the final form of the plastic was developed as part of the war effort. Lego first introduced ABS plastic in 1963, transitioning away from cellulose acetate (CA), which had been used since the first Lego bricks in 1949. CA is a moderately hard thermoplastic with good transparency and vibrant coloration, but it tends to warp over time and does not hold its colour as well as other plastics.
ABS, or Acrylonitrile Butadiene Styrene, is a thermoplastic consisting of a styrene monomer with the addition of an acrylonitrile monomer and a butadiene monomer. The butadiene component, a synthetic rubber mainly used in tires, is largely responsible for the strength and impact resistance of the plastic. ABS provided Lego with a plastic that was more stable, impact-resistant, and colourfast than CA. It could also be easily injection-moulded to more exacting tolerances.
Lego introduced ABS in 1963 and fully phased out CA by 1970. Many sets from the 1960s contain both CA and ABS elements. The German chemical company Bayer AG was the exclusive supplier of ABS to Lego for many years, until 2004 when Bayer spun off most of its plastics business to Lanxess AG. Lanxess now provides Lego with ABS under the brand name Novodur, coloured with Lanxess's Macrolex dyes.
Today, virtually all plastic used by Lego is a proprietary version of Lanxess' Novodur ABS, Makrolon polycarbonate for transparent elements, and Macrolex dyes for colouring. Lego uses a variety of other plastics depending on the specific application, such as HIPS for base plates, PA for gears and connectors, MABS for transparent parts, and MPO for flexible elements.
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Melting and moulding ABS plastic
ABS plastic is a thermoplastic polymer with no real melting point. When heated, it liquefies, making it easy to mould. It is used in a wide variety of products, including automotive parts, musical instruments, and Lego.
To melt and mould ABS plastic, you can use direct heat or chemicals. When melting plastic at home, it is generally safer and more accessible to use direct heat. You can use an oven, a heat gun, or boiling water.
If you use an oven, preheat it to around 300 °F (149 °C) and place the plastic in a heat-proof container that will not spill when the plastic melts.
If you use a heat gun, you can purchase one at a home improvement or hardware store, or online. Heat guns typically have low and high settings, with the low setting heating up to about 500 °F (260 °C) and the high setting to about 1,000 °F (538 °C).
If you use boiling water, the water's temperature will remain at 212 °F, which is 9 degrees below the ABS melting point. This will allow you to heat the ABS enough to make it easily mouldable, but prevent it from exceeding 212 °F, no matter how long it is left in the water.
You can also use chemicals to melt ABS plastic. Acetone, for example, will melt ABS plastic on contact. To use this method, place the plastic in a non-plastic container, as the acetone will dissolve plastic. Then, apply acetone to the plastic using a cotton swab. This is useful if you are melting hard ABS plastic together to fix a crack. Once the plastic has melted, remove it from the acetone, and rinse the acetone off with cold water, or wait for it to evaporate.
After melting and moulding the ABS plastic, you can use techniques like trimming, sanding, or machining to achieve the desired finish.
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ABS plastic's benefits over CA plastic
Acrylonitrile Butadiene Styrene (ABS) is a thermoplastic polymer that is widely used across various industries. It is known for its versatility, durability, and ease of processing. Here are the benefits of using ABS plastic over CA plastic:
Durability and Impact Resistance
ABS plastic is known for its excellent impact resistance, making it suitable for applications that require toughness and durability. It can withstand significant blows without suffering any damage. This makes it ideal for products that need to be durable and impact-resistant, such as Lego bricks.
Corrosion Resistance
ABS plastic is not susceptible to corrosion like metals are. It is incredibly resilient and can withstand disintegration from many common agents. This makes it a good choice for components that need to safeguard other parts of a device or product.
Manufacturing Simplicity
ABS plastic is easy to manufacture and develop in a lab. It can be melted and molded easily, making it suitable for injection molding, thermoforming, and 3D printing. The simplicity of manufacturing ABS plastic translates into lower production costs and consumer prices.
Colourfastness
ABS plastic is more colourfast than CA plastic, meaning it holds its colour better over time. This is especially important for products that need to maintain their aesthetic appearance, such as toys and consumer goods.
Stability
ABS plastic is more stable than CA plastic, which has a tendency to warp over time. This warping can cause CA plastic bricks to become incompatible with modern bricks. ABS plastic, with its stability, helps ensure the longevity and compatibility of Lego bricks.
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Identifying ABS plastic Lego pieces
ABS (acrylonitrile butadiene styrene) is the plastic used in most modern Lego elements. It is a thermoplastic that consists of a styrene monomer with the addition of an acrylonitrile monomer and a butadiene monomer. The butadiene component, a synthetic rubber mainly used in tires, is largely responsible for the strength and impact resistance of the plastic.
Since 1963, most Lego pieces have been made of ABS. Lego introduced ABS in 1963 and slowly dropped cellulose acetate (CA), the previous plastic used, over the next few years. By 1966 in Europe or 1970 in North America, all CA stockpiles had been depleted, and all sets since have been exclusively ABS.
You can identify Lego pieces made of ABS plastic by their high gloss and vibrant colours. ABS Lego pieces are also known for their unique connective grip, or "clutch power". The plastic is strong, stable, scratch-resistant, and meets a long list of safety, durability, and quality rules.
However, it is important to note that Lego uses a variety of plastics depending on the purpose of the element. For example, transparent Lego elements are made from polycarbonate, and tires are made from a soft material called SBS or SEBS.
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ABS plastic's limitations
ABS plastic is widely used for its versatility, durability, and ease of processing. It is known for its excellent impact resistance, making it suitable for applications that require toughness. However, despite its popularity and advantages, ABS plastic does have certain limitations.
One of the main limitations of ABS plastic is its low melting point, which makes it unsuitable for high-temperature applications and medical implants. Its melting point is approximately 105 °C, which is significantly lower than that of other plastics. This also contributes to its poor thermal stability, which can lead to degradation when subjected to high temperatures during recycling. Thermal decomposition of ABS can release toxic fumes and further degrade the material properties.
ABS plastic also has poor solvent and fatigue resistance. It is susceptible to degradation when exposed to oils, chemicals, and food contaminants, which can pose health risks if not properly removed during the recycling process. Additionally, ABS plastic may not be suitable for outdoor applications as it does not withstand UV exposure and weathering well unless properly protected.
Another limitation of ABS plastic is its lack of conductivity, which can be a hindrance in certain electrical or electronic applications. Furthermore, burning ABS plastic can result in high smoke generation, raising concerns about air pollution.
Due to these limitations, as well as the environmental impact and recycling challenges associated with ABS plastic, there is a growing demand for sustainable alternatives. New legislation is also being introduced to restrict the use of ABS plastics, with a focus on reducing their environmental footprint.
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Frequently asked questions
Acrylonitrile Butadiene Styrene, often abbreviated as ABS, is the plastic used in most modern Lego elements. It is a strong, stable, scratch-resistant thermoplastic with a melting point of about 105 °C.
Unfortunately, I cannot find the exact process for casting ABS Lego plastic. However, I can tell you that Lego introduced ABS in 1963, phasing out the previous plastic, CA, by 1970. Lego used to receive raw ABS granules from Bayer, which became Lanxess in 2004. Lanxess now provides Lego with ABS under the brand name Novodur.
Transparent CA bricks can be somewhat brownish, while later transparent bricks, made from polycarbonate, can have a bluish cast. CA bricks also tend to have less clutch (stickiness to other bricks) than ABS bricks. Additionally, CA bricks have older logos and are made using older moulds, so they have an older Lego font on the studs.
