@DrDave : My thoughts were not that the hangar should be big enough to hold *all* aircraft simultaneously - which would, indeed, make it huge! - but that it should at least be big enough to hold any one of them. Just a few studs wider should cover the wingspan of either jet (judging from the photos). Add a few centimetres to the height - by whatever construction means - and that'll accommodate the oversized tail on the Viggen-styled plane. If/when I pick up this set, that's the mods I'll be making to it.
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.
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.
Structurally, the plane model is sound and very well-built. A little too well-built in some areas you would say, but they are necessary measures like the awkward humps in the interior of the plane you will discover. Space is very wisely used in this model as they’ve managed to fit a proper looking cockpit for 2 pilots and even managed to squeeze in a sink, a mini-bar with the one drink, seats for 6 more passengers and even a tight little space of a washroom. That door hinge though, is a work of art.
Attention then shifts to construction of the three aircraft. When I first spied this set I assumed that the two red jets were the same, but closer examination reveals a number of differences. First up is a red jet with a canard wing configuration as seen in the Saab Viggen amongst others. The lower fuselage is fashioned from a number of double and triple inverted 45 degree slopes with a pair of 1 x 14 Technic bricks running through the centre; there’s no obvious reason for Technic bricks to be used in this situation – standard 1 x 14 bricks would have done the job just as well - so I assume that LEGO just happened to have a bunch of them lying around…. A printed black 1 x 2 tile in the cockpit represents the instrument panel, while a substantial air intake is attached on either side of the fuselage at a 90 degree angle by way of brackets.
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.
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.
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.