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.
There are 3 cardboard boxes with more Easter eggs. We get a few references to Marvel organisations such as A.I.M., who you may remember from Iron Man 3 as an R&D agency run by Aldrich Killian, Hammer, one of Stark Industries primary rivals which made an appearance in Iron Man 2, bankrolling Whiplash and finally a box with the Stark Industries logo on it.
Manufacturing of Lego bricks occurs at several locations around the world. Moulding is done in Billund, Denmark; Nyíregyháza, Hungary; Monterrey, Mexico and most recently in Jiaxing, China. Brick decorations and packaging are done at plants in Denmark, Hungary, Mexico and Kladno in the Czech Republic. The Lego Group estimates that in five decades it has produced 400 billion Lego blocks. Annual production of Lego bricks averages approximately 36 billion, or about 1140 elements per second. According to an article in BusinessWeek in 2006, Lego could be considered the world's No. 1 tire manufacturer; the factory produces about 306 million small rubber tires a year. The claim was reiterated in 2012.
The set has an impressive assortment of minifigures - I quite like that it has six, allowing for a lot of play opportunities. All the major parts of the plane - the wing, cockpit, tail and body - are new to this set in their colours. The inside of the plane has a minimal amount of details, with five seats, a galley and a lavatory. The outside of the plane looks quite smart with all the stickers applied.
Billund Airport had its beginning in 1961 when the son of the founder of the Lego Group, Godtfred Kirk Christiansen, established a private 800-meter long runway and hangar north of his factory in Billund. With Christiansen as a key driver, more of the neighbouring municipalities were included in the group of owners, and it was planned that the airport should be expanded to a regular public airport.
The final two minifigures are the Biplane Pilot and the intrepid Wing Walker. Both of these minifigures share the same white torso which is printed with a flight suit design overlaid with dark red and bright light orange flames plus a logo over the left breast. The torso design is superb and it can at present only be found in this set. Both minifigures are provided with a reddish brown aviator cap and dark bluish grey goggles, and the pilot (below left) also gets an alternative to this headgear in the form of medium dark flesh mid-length hair which has only ever appeared in five sets in this colour.