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.
Colour-wise, it is mainly yellow, with only a dash of green and red, and a little more white, there to break it up. The worker has space to stand and drive the vehicle, and has a walkie talkie attached on the side of the car. Around the other side is a coiled-up, what I assume is a, fuel pump. It looks pretty good when coiled up on the side of the car. Stickers come into use again here, this time for the number plates.
Bag 4 finishes the fuselage and all that is left are the engines and tail section. You'll notice that this aircraft has a bathroom on board as well as some storage for a non-existent flight attendant. I think this is the first time that LEGO has put some additional details into aircraft besides just seats. Also there is only one pilot for a 2 seat cockpit in the set.
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.