Toys
Exclusive Video: How Lego Builds the Minifigs
Posted by Jesus Diaz at 2:05 PM on August 25, 2008
One of the best parts of my trip to Lego and exploring their factory was the minifig production lines, where the head and body of the most famous toy citizen in world gets painted and assembled at uncanny speeds. To celebrate its 30th Anniversary, here's a video showing how they are built, from raw plastic to final assembly.
You already saw part of the process in the article about the Lego Storm Troopers cloning facility, but here's the whole process:
• First, the raw plastic material gets into the molds to create all the parts: the head, the torso, the miniscule hands, the hips, and the left and right arms and legs, plus any minifig complements, like helmets or tools.
• The head and torsos are always decorated. This is a complicated process that makes the minifig the most expensive part of any Lego set. This is why sets like the Death Star diorama are among the most expensive. The stamping of the colours is usually made in several passes. In older times, the faces always had the same designs. Today, however, they have different features that require different layers (personally, I like the classic ones more than the ones with different faces).
• Once they are decorated, the torsos get into the body assembly machine, where the left and right arms are put into them mechanically. The same machine then places the hands inside the arms with absolute precision at lightning speed.
• The torsos are then taken to the packaging production line, where they are put together in the bags along with the head, hair/helmet/hat, and legs with hips. Before, the machines also connected the heads and legs, so the Lego aficionado would find the minifig complete inside the box. Now, however, this is left for the player except for the vintage minifig set, which comes with the minifigs completely built.
Stay tuned for tomorrow special features on the 30th Anniversary of the Lego minifig. We have some amazing surprises coming, including an exclusive Gizmodo contest that will let you win some of the most famous Lego sets in history. [Go Miniman Go]

One of the best parts of
Comments (AU Comments · US Comments)
There are currently no AU comments for this post.
J0hnP
Posted 1:58 PM 25/8/08
Out of curiosity, is the extra "color" on the neck due to a process that determined that the head wouldn't fit quite snugly enough?
J0hnP
MrBubbuls
Posted 1:53 PM 25/8/08
i loves me soem minifig blanks for cutomizing
MrBubbuls
Helicoprion
Posted 1:34 PM 25/8/08
Love it!
Grew up with LEGO.
Helicoprion
Mike918
Posted 1:34 PM 25/8/08
Forget the bucket i am waiting with a freaking huge truck!
Mike918
enchantedgoose
Posted 1:33 PM 25/8/08
i wouldve snatched a handful of them :)
enchantedgoose
citizensmith
Posted 1:31 PM 25/8/08
Awesome
citizensmith
UniComp
Posted 1:30 PM 25/8/08
omg omg omg awesome!
UniComp
Kaiser-Machead's WALL-E fetish
Posted 1:28 PM 25/8/08
I am not the only one that wants to be on the end of the assembly line with a big ass bucket.
Kaiser-Machead's WALL-E fetish
Git Em SteveDave displays attention-grabbing vanity
Posted 2:19 PM 25/8/08
Wow, no posts from LJ or purpledave? Is this a sign of the Apocalypse?
Git Em SteveDave displays attention-grabbing vanity
rudeadly
Posted 2:50 PM 25/8/08
this is the first new beastie boys track I've heard in like 4 years that I've liked
rudeadly
Charging_Mooses
Posted 2:43 PM 25/8/08
@J0hnP: maybe, but i think its so the machine can tell witch side of the torso it's stamping
Charging_Mooses
LazyPanda
Posted 2:38 PM 25/8/08
@J0hnP: good question. I always just assumed it was a proof, like registration lines in printed graphic design works.
LazyPanda
gyffes
Posted 2:34 PM 25/8/08
I'm waiting for Carmen's "I just love how they have no pants on..." comment.
My boy is 6. It's just a wonderful excuse to cover the floor of his room with legos. And, although I deeply mourn the days when I had to craft a sword and shield from a flat 1x4 and 2x4, there are some blessings in todays' kits: anyone seen the latest green-faced "orc" minifigs? They're terrific!
gyffes
Con Seannery
Posted 3:19 PM 25/8/08
@Con Seannery: Wow, I didn't clarify that first sentence, I love the topic, hate the regrets they spawn.
Con Seannery
Con Seannery
Posted 3:19 PM 25/8/08
O M G!
I love these posts and hate them as well... Lego is the one of the best creations ever, and I loved my gigantic foot locker full of them, but I ended up passing the joy down to my younger cousin, where they live a neat and organized life in plastic boxes sorted by set, under the eye of my uncle. There is no dumping of the bricks, and the wonderful clinks do not grace their ears. I miss my Lego sets...
Con Seannery
addiktion
Posted 3:44 PM 25/8/08
legos are one hell of a business!
addiktion
Mammoth
Posted 3:42 PM 25/8/08
I like the older designs as well. (Although I'm hardly old enough to have used them)
Mammoth
laio
Posted 4:07 PM 25/8/08
world would be so much better if i could get chicks by playing with lego
laio
Purple Dave
Posted 5:44 PM 25/8/08
@J0hnP:
Well, let's ask the Joker goon (he'd never lie, because his boss is a firm believer in the idea that telling the truth is much too fun). The Joker goon has a dark-purple torso with no paint deco. That includes the neck. Painted necks seem to be limited to painted torsos, so, while I've never had this officially confirmed, my guess would be that they're there solely for the assembly process. See, the torso has no molded front or back, but when you paint a torso, one side is now clearly identified as the front surface. The paint aps are done before the torso is assembled, so the machine needs a simple way to make sure that the arms are pointing the right way when they're plugged into the holes (keeping in mind that The LEGO Company actually believes that arms, legs, and hands are not supposed to be interchangable). The neck is the largest exterior surface that's not visible on an assembled minifig, so it's the best place to put a common marker that the assembly machines can use to identify the backwards torsos. It's either that or teach the machine _every_ unique torso front design.
Purple Dave
Skorpius
Posted 6:33 PM 25/8/08
I really wish they would sell all the figures independently of the sets.
Skorpius
simi510
Posted 7:43 PM 25/8/08
fells like im watching how its made but with good music
simi510
strider_mt2k
Posted 8:24 PM 25/8/08
Well, if I have to have a first day back from vacation, at least it started with one of Jesus's Lego stories.
...and a big cuppa coffee.
Thanks, Jesus!
strider_mt2k
Git Em SteveDave displays attention-grabbing vanity
Posted 9:32 PM 25/8/08
@AlphaPepper: Let's get serial. You've been around Giz long enough. In your 7 posts, two are anti-Lego. Do not be surprised if you wake up with a bed full of mini-fig heads.
Git Em SteveDave displays attention-grabbing vanity
AlphaPepper
Posted 9:22 PM 25/8/08
Enough with the Legos already!
AlphaPepper
stryder100
Posted 9:57 PM 25/8/08
I don't see what the big deal is about Lego.
Frodo Lives!!!
stryder100
TBM-Fan
Posted 9:54 PM 25/8/08
I didn't know Kamino was on Earth
TBM-Fan
DONAR
Posted 11:58 PM 25/8/08
Can't wait for the day when Lego and Marvel cosy up to make minifigs of the entire Marvel universe.....
Go Lego Thor!
DONAR
J0hnP
Posted 1:32 AM 26/8/08
Thanks, all, on your replies to my neck color question. I checked some minifigs, and you're right: they all have the color on the printed side! I never really noticed that before. Sure seems like something that would be used to help identify/orient the approprite side when attaching the arms.
J0hnP
gizmodohomepage
Posted 1:23 AM 26/8/08
Is that Beastie Boys on the track, which song?
gizmodohomepage
HfAsianInvasion
Posted 1:59 AM 26/8/08
Not gonna lie, makes me wanna go buy some LEGOs.
HfAsianInvasion
twilight-arc
Posted 3:58 AM 26/8/08
Seeing this I think Gizmodo should assign a section to gadget manufacturing. I am always fascinated to see what goes into making our favourite gadgets.
twilight-arc
--Tito--
Posted 4:27 AM 26/8/08
The paint is like a glue. Its so the heads dont move or come off to easyly. You don't want Vader's head coming off right after you win over the rebellion. . . . .
--Tito--
DARSFOG
Posted 5:30 AM 26/8/08
@DONAR: I thought they already made something like that? Becuase I swear I have seen a Lego sentinel before, tho it could have been fan made.
DARSFOG
FritzLaurel
Posted 8:17 AM 26/8/08
Oh, the Humanity!! Look at all those arms and legs!!
Reminds me of one time in high school (in the 80s mind you) when a friend drove up to my house. He rings the bell, I come to the door, he says "come here, I have to show you something."
We walk to the back of his car, he pops the trunk and has dozens of mannequin ams and legs. Dude looked like a serial killer when in actuality, he had just been fired from his jorb at the local department store...
FritzLaurel
Purple Dave
Posted 7:33 PM 26/8/08
So, I finally remember to actually, you know, watch the video. Am I the only one who finds it curious that, while all of those hands are clearly installed in the upright position, by the time the torsos actually come out of the box in my living room, a bare minimum of hands are still in that position, while most are pointed off into all kinds of painful-looking directions?
@Skorpius:
www.bricklink.com
Just be forewarned that the market sets the prices here, so Star Wars minifigs that are in high demand or low supply or that have been out of production for a while can jump in price.
@Git Em SteveDave displays attention-grabbing vanity:
If I could pick the heads beforehand, I would welcome that wake-up gift...
@DONAR:
That _other_ company currently holds the Marvel license.
@J0hnP:
While it would originally have been the painted side, now it's just the front side. Though rare, there are actually minifigs with printing on both sides of the torsos. I think it started with the Soccer sets, but C-3PO was the first minifig from the Star Wars line to get that treatment. Now, pretty much all of the SW troopers have painted backs (I think only Two-Face and Bane do from the Batman line).
Purple Dave
Gino Camaro
Posted 10:59 PM 26/8/08
I'm going to buy a lego set right now!
Gino Camaro