Play out real-life scenarios in LEGO DUPLO Town: a recognizable world with modern DUPLO figures. Help your little pilot get ready for take-off at the LEGO DUPLO Airport! It's easy for preschoolers to build the boarding gate, luggage slide and revolving air traffic control tower. Makes an ideal gift for preschool children. Contains 29 pieces. Airport measures over 8 (22cm) high, 5 (14cm) wide and 4 (11cm) deep. Plane measures over 3 (9cm) high, 7 (18cm) long and 6 (17cm) wide.
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.
Primary concept and development work takes place at the Billund headquarters, where the company employs approximately 120 designers. The company also has smaller design offices in the UK, Spain, Germany, and Japan which are tasked with developing products aimed specifically at these markets. The average development period for a new product is around twelve months, split into three stages. The first stage is to identify market trends and developments, including contact by the designers directly with the market; some are stationed in toy shops close to holidays, while others interview children. The second stage is the design and development of the product based upon the results of the first stage. As of September 2008 the design teams use 3D modelling software to generate CAD drawings from initial design sketches. The designs are then prototyped using an in-house stereolithography machine. These prototypes are presented to the entire project team for comment and for testing by parents and children during the "validation" process. Designs may then be altered in accordance with the results from the focus groups. Virtual models of completed Lego products are built concurrently with the writing of the user instructions. Completed CAD models are also used in the wider organisation, for marketing and packaging.
In 1997 they had an architectural competition for a new 430,000 ft² (40,000 m²) passenger terminal, designed to serve 3.5 million passengers a year, north of the original airport. KHR Architects won the assignment and completed the construction in co-operation with COWI, and at the end of May 2002 the new passenger terminal was put to use, as the first phase of the future expansion, which is scheduled to take place north of the start and runway, while air cargo services, business and private aviation will continue to be served from the existing buildings south of the runway. In connection with this expansion, the largest since the beginning of the airport, it was with effect from 1 January 1997 turned into a Joint-stock company, Billund Airport A/S, with the former members Vejle County and municipalities Vejle, Kolding, Grindsted, Billund, and Give as shareholders.
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.