Maya Ellison
Lego is the world's largest toy manufacturer by sales. The company began producing plastic toys in 1947, and the first plastic Lego bricks were made from cellulose acetate (CA) in 1949. Lego switched to acrylonitrile butadiene styrene (ABS) in 1963, and fully phased out CA by 1970. Today, Lego uses a variety of plastics and other materials, including polystyrene, SEBS, PET, and nylon. The company has also been working to make its products more sustainable by using recycled and renewable materials, such as sugarcane, recycled engine oil, and old fishing nets.
| Characteristics | Values |
|---|---|
| Main type of plastic used | Acrylonitrile butadiene styrene (ABS) |
| Other types of plastic used | Polystyrene, Polyethylene terephthalate (PET), Styrene-butadiene-styrene (SBS), and SEBS |
| Additives | Rubber |
| Plastic properties | Strength, impact resistance, heat-resistance, and flexibility |
| Plastic sourcing | Hydrocarbons from plants, recycled plastic bottles, sugarcane, recycled kitchen worktops, and old fishing nets |
| Manufacturing process | Injection moulding |
| Manufacturing temperature | 230-232°C |
| Manufacturing time | 10-15 seconds |
Explore related products
What You'll Learn
- Lego uses ABS plastic, which replaced cellulose acetate in 1958
- The butadiene component of ABS is derived from natural rubber and is responsible for its strength and impact resistance
- Lego is working towards using more sustainable materials, such as recycled plastic bottles, sugarcane, and old fishing nets
- Lego's plastic formulations are trade secrets, but it is known that they use a proprietary version of Lanxess' Novodur ABS
- Historically, Lego has used a variety of other plastics, including polystyrene and SEBS, and other materials like wood, metal, and fabric
Lego uses ABS plastic, which replaced cellulose acetate in 1958
Lego bricks have been made from plastic since 1949, when the company first expanded into plastic toys. The first plastic Lego bricks were made from cellulose acetate (CA), a moderately hard thermoplastic that softens when heated and hardens when cooled. However, CA has a tendency to warp over time, and Lego bricks made from this material are often no longer compatible with modern bricks due to deformation.
In 1958, the modern Lego brick design was developed, and Lego switched to acrylonitrile butadiene styrene (ABS) as its manufacturing material in 1963, fully phasing out CA by 1970. ABS is a proprietary version of Lanxess' Novodur ABS, with the butadiene component derived from natural rubber providing strength and impact resistance to the plastic. Lego also uses Makrolon polycarbonate for transparent elements and Macrolex dyes for colouring.
Lego's plastic bricks are made through injection moulding. The plastic is heated to 230°C (450°F) until it reaches a dough-like consistency and is then fed into moulds using forces of between 25 and 150 tonnes. The bricks take approximately 10 to 15 seconds to cool and are then ejected from the moulds.
Carbon Fiber vs Plastic: Lighter and Stronger?
You may want to see also
Explore related products
The butadiene component of ABS is derived from natural rubber and is responsible for its strength and impact resistance
Lego bricks are primarily made from Acrylonitrile Butadiene Styrene (ABS), a common thermoplastic polymer. ABS is a terpolymer, made by polymerising styrene and acrylonitrile in the presence of polybutadiene rubber. The butadiene component of ABS is derived from natural rubber and is responsible for its strength and impact resistance.
The proportions of the components can vary, with butadiene content ranging from 5% to 30%, but the basic structure is a long chain of polybutadiene crisscrossed with shorter chains of poly(styrene-co-acrylonitrile). The nitrile groups from neighbouring chains attract each other due to their polarity, binding the chains together and making ABS stronger than pure polystyrene.
The butadiene component is crucial for the impact resistance of ABS, and this can be amplified by increasing the proportion of polybutadiene in relation to styrene and acrylonitrile. However, doing so causes changes in other properties, as the overall characteristics of ABS depend on the ratios of its monomers and how they are polymerised and formulated. For instance, while butadiene contributes to impact resistance and general property retention, acrylonitrile provides chemical resistance, fatigue resistance, hardness, and rigidity, and styrene gives gloss, mouldability, strength, and rigidity.
The versatility of ABS is further enhanced by its ability to be blended or alloyed with other polymers, such as polycarbonate, which combines the toughness and high heat resistance of polycarbonate with the ductility and processability of ABS. Lego's exact plastic formulations are trade secrets, but the company has been experimenting with different materials, including recycled plastic bottles, and aims to make half of the plastic in bricks from renewable materials by 2026.
The Mystery of Amber: Plastic or Precious?
You may want to see also
Explore related products
Lego is working towards using more sustainable materials, such as recycled plastic bottles, sugarcane, and old fishing nets
Lego is known for its plastic toy blocks, and the company is now taking steps towards sustainability by aiming to use more sustainable materials, such as recycled plastic bottles, sugarcane, and old fishing nets. The Danish company has committed to using sustainable materials in all of its products by 2030. As part of this initiative, Lego has developed prototype bricks made from recycled polyethylene terephthalate (rPET) derived from discarded plastic bottles. These bricks are the result of three years of development and testing of hundreds of plastic variations and formulations to ensure compliance with the company's quality, safety, and play requirements.
In addition to recycled plastic, Lego has also introduced sustainable bricks made from sugarcane ethanol, a plant-based bioplastic. The company sources its bioplastic from responsibly produced sugarcane, addressing concerns about soil erosion and poor working conditions in sugarcane-producing regions. Lego's use of sugarcane-based bioplastics is a step towards its goal of solely using plant-based polyethylene by 2030. The company acknowledges the potential environmental impact of sugarcane production but believes that the long-term benefits of sustainable practices will outweigh these challenges.
Lego's commitment to sustainability extends beyond the materials used in its products. The company has also announced plans to remove single-use plastic from its packaging. Additionally, Lego aims to generate little to no waste in its manufacturing processes and ensure that its products are fully recyclable. By defining a sustainable material as something that is "responsibly produced, using renewable or recycled resources," Lego is encouraging a new wave of manufacturers to embrace creative approaches to sustainable production.
The company's sustainability efforts are not limited to the materials it uses but also extend to its product packaging. Lego has announced that it will start removing single-use plastic from its boxes, further reducing the environmental impact of its products. Through these initiatives, Lego is working towards creating a more sustainable future for generations to come, inspiring both children and manufacturers alike to embrace creative and environmentally conscious practices.
Plastic Bumper Brackets: Understanding Their Composition and Material
You may want to see also
Explore related products
Lego's plastic formulations are trade secrets, but it is known that they use a proprietary version of Lanxess' Novodur ABS
Lego bricks have been made with a variety of plastics since their creation in 1949. The exact formulations are trade secrets, but it is known that Lego uses a proprietary version of Lanxess Novodur ABS, a plastic known for its strength and impact resistance.
The first Lego bricks, produced in 1949, were made from cellulose acetate (CA), a moderately hard thermoplastic that softens when heated and hardens when cooled. However, CA has a tendency to warp over time, and Lego fully phased it out by 1970. In the mid-1940s, Bayer AG, a German chemical company, developed the modern formula for ABS as part of the war effort. Bayer AG was the exclusive supplier to the Lego Group until 2004 when it spun off most of its plastics business into the newly formed Lanxess AG.
Today, Lego uses a variety of plastics in addition to ABS, including Makrolon polycarbonate for transparent elements and nylon for cloth and string elements. Lego is also committed to sustainability and has been working to incorporate recycled and renewable materials into its products. For example, Lego has been prototyping bricks made from PET plastic, and in 2021, they created a prototype brick made from recycled plastic bottles. While this prototype did not deliver the desired carbon reduction, Lego continues to develop new materials and explore ways to make its bricks more sustainable. By 2032, Lego aims to have its products made from more materials that are renewable or recycled.
Restoring Black Plastic on Cars: Tips and Tricks
You may want to see also
Explore related products
Historically, Lego has used a variety of other plastics, including polystyrene and SEBS, and other materials like wood, metal, and fabric
The Lego Group began in the workshop of carpenter Ole Kirk Christiansen, who started making wooden toys in 1932. The company was named Lego in 1934, derived from the Danish phrase "leg godt", which means "play well". In 1947, Lego expanded into plastic toys, purchasing a plastic injection-molding machine. The first plastic Lego bricks, marketed in 1949, were made from cellulose acetate (CA).
Over time, CA tended to warp, and Lego switched to acrylonitrile butadiene styrene (ABS) around 1963, fully phasing out CA by 1970. ABS is non-toxic, less prone to warping and discolouration, and more resistant to heat, acids, salt, and other chemicals. Lego has since used ABS for its bricks, although the company has been prototyping bricks in PET, a readily recyclable type of polyester.
Lego has also used other plastics, including polystyrene for some early bricks and modern baseplates, and SEBS, a thermoplastic that behaves like rubber, for its tyres. In addition, Lego has used other materials such as wood, metal, fabric, foams, and rubber bands to complete its sets, providing play functionality, textures, and motion that plastic alone cannot.
Lego has made efforts to improve the sustainability of its plastic production. The company recycles almost all of its plastic waste from the manufacturing process, and in 2018, it set a self-imposed 2030 deadline to find an eco-friendly alternative to ABS. Lego also plans to make half of the plastic in its bricks from renewable materials by 2026, and it has experimented with recycled plastic bottles, although these did not reduce carbon emissions as intended.
Printing on Plastic Cards: A Step-by-Step Guide
You may want to see also
Frequently asked questions
Most Lego bricks are made of ABS or acrylonitrile butadiene styrene. Lego switched to using ABS around 1963, fully phasing out the use of cellulose acetate (CA) by 1970.
Lego uses a variety of other plastics, including polystyrene for some early bricks and modern baseplates, and SEBS for tires. Lego has also been working on creating more sustainable products, with some bricks already made with recycled and renewable materials like sugarcane, recycled kitchen worktops, and old fishing nets. In 2021, Lego created a prototype brick made from PET plastic bottles, but it did not meet their carbon reduction goals.
While the base plastic has remained the same, the manufacturing process has been refined and improved over the years. The molds are more detailed, the printing is better, and the plastic is more consistent.
