Since 1963, Lego pieces have been manufactured from a strong, resilient plastic known as acrylonitrile butadiene styrene (ABS). As of September 2008, Lego engineers use the NX CAD/CAM/CAE PLM software suite to model the elements. The software allows the parts to be optimised by way of mould flow and stress analysis. Prototype moulds are sometimes built before the design is committed to mass production. The ABS plastic is heated to 232 °C (450 °F) until it reaches a dough-like consistency. It is then injected into the moulds at pressures between 25 and 150 tonnes, and takes approximately 15 seconds to cool. The moulds are permitted a tolerance of up to twenty micrometres, to ensure the bricks remain connected. Human inspectors check the output of the moulds, to eliminate significant variations in colour or thickness. According to the Lego Group, about eighteen bricks out of every million fail to meet the standard required. Lego factories recycle all but about 1 percent of their plastic waste from the manufacturing process. If the plastic cannot be re-used in Lego bricks, it is processed and sold on to industries that can make use of it. Lego has a self-imposed 2030 deadline to find a more eco-friendly alternative to the ABS plastic it currently uses in its bricks.
The remainder of the build is the control tower and terminal building. First there is a metal detector screener leading to the waiting/secure area of the airport, which seems taller than it needs to be for the minifigures. I think the same effect could have been made with half the height, except that would not allow for an impressive height for the overall tower. However it does seem to be similar to many modern airports with the high ceilings. This area also seems to be someplace to check luggage as evidenced by the rather nifty conveyor belt that comes in a full part. The moving parts of the set include a revolving door (a very tall one, for the first floor) that leads from the secure area of the airport out to the tarmac, and of course the conveyor belt.
The mechanic is a rather basic design, with an all-blue colour and a work shirt pattern. He comes equipped with a walkie-talkie and a full tool truck, containing every piece of equipment a mechanic could need. The airport worker looks like every other workman from The LEGO Movie that joined Emmet in a chorus of Everything is Awesome, and is a nostalgic hark bark to the old construction figures that I grew up playing with.
Copenhagen Airport is a compact airport with two terminals for check-in, but with a common post-security departure and transfer area, thus making transfers very smooth. The airport handles in excess of 25 million passengers a year, which puts it in the same league as Zurich and Vienna. It has also consistently topped the charts for Nordic airports, serving as a European and intercontinental hub for all of them due to its location.
Lego also initiated a robotics line of toys called 'Mindstorms' in 1999, and has continued to expand and update this range ever since. The roots of the product originate from a programmable brick developed at the MIT Media Lab, and the name is taken from a paper by Seymour Papert, a computer scientist and educator who developed the educational theory of constructionism, and whose research was at times funded by the Lego Group.
After World City's discontinuation in 2004, it was replaced with City as System's primary town-life related theme in 2005. However, unlike its predecessor, it was not limited to sets involving rescue services like Police, Fire or Coast Guard, but also introduced the first new construction site related sets since the discontinuation of City Center in 2000. In 2006, the first new airport set that included the first jetway since 6597 Century Skyway (1994) was released, as well as the first new hospital since 6380 Emergency Treatment Center from 1987. These releases expanded City to a scope only comparable to the original Town theme, and in 2009 it even went slightly beyond that, by introducing the first farm-related System sets. Also, in that year, City followed this route to release more truly civilian town life sets such as 7641 City Corner and 7639 Camper. In 2010 City released more civilian sets including 8403 Family House and 8404 Public Transport. In 2011 City re-introduced the Space sub-theme along with some new Harbour sets. In the first wave of 2012, City had forest police and fire sets as well as some more commercial/civilian sets. The second wave of 2012 featured the introduction of the Mining theme and respective sets, as well as a hospital. In the winter of 2013, Police and Fire sets were once again focused on but, contrary to those released in the previous year, were set in the city. In the summer of 2013, the Coast Guard and Cargo subthemes were brought back.