The design on the jet pilots’ outfits are very good, with a darker blue colour scheme offset with a red/white/yellow stripe pattern on the torso. The requisite wings and plane emblem complete the look, with the star-emblazoned helmet the icing on the cake. However, as good as those outfits are, I think the bi-plane pilots’ attire is even better, with a swish darker red colour on the legs and above the waist, culminating in a flame-effect design merging into a white torso. The old-fashioned flying helmets and goggles look great and really compliment the overall figure design.
A minifigure can comfortably fit seated inside the cockpit, and it is here that I found the first issue with the set. I had no issue inserting and removing the figure from his seated position, but my seven-year old struggled to get him out, deciding to leave him onboard instead of disembarking after she brought the jet back into the hangar. The physical connection between LEGO pieces in the cockpit and the pilot minifigure didn’t seem to present an issue, so whether or not this was just a one-off issue remains to be seen.
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 first few bags build the small truck with carts that you see on airport runways. The truck has a "follow me" sign that I confess I have not seen at any airport. There is also a fueling tank and a rolling staircase that sits next to the plane to allow for boarding. Both the tank and the staircase are additional carts for the truck, though I am guessing not both at the same time.
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.