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.
The railway station, 1 Københavns Lufthavn, Kastrup Station (sometimes called CPH Airport Station and wrongly Kastrup Station), is located in Terminal 3. The station has frequent connections to Copenhagen and Malmö, as well as InterCity trains for the rest of Denmark and a few daily SJ 2000 express trains for Stockholm. The frequent Øresund trains between Copenhagen and Malmö continue in Denmark to Elsinore and in Sweden to a number of destinations in Scania and other parts of Götaland. The travel time to Copenhagen Central Station is 12 minutes, and 20 minutes to Malmö Central Station.
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.
The capabilities of the Mindstorms range have now been harnessed for use in Iko Creative Prosthetic System, a prosthetic limbs system designed for children. Designs for these Lego prosthetics allow everything from mechanical diggers to laser-firing spaceships to be screwed on to the end of a child's limb. Iko is the work of the Chicago-based Colombian designer Carlos Arturo Torres, and is a modular system that allows children to customise their own prosthetics with the ease of clicking together plastic bricks. Designed with Lego's Future Lab, the Danish toy company's experimental research department, and Cirec, a Colombian foundation for physical rehabilitation, the modular prosthetic incorporates myoelectric sensors that register the activity of the muscle in the stump and send a signal to control movement in the attachment. A processing unit in the body of the prosthetic contains an engine compatible with Lego Mindstorms, the company's robotics line, which lets the wearer build an extensive range of customised, programmable limbs.
Lego has an ongoing deal with publisher Dorling Kindersley (DK), who are producing a series of illustrated hardback books looking at different aspects of the construction toy. The first was "The Ultimate Lego Book", published in 1999. More recently, in 2009, the same publisher produced The LEGO Book, which was sold within a slipcase along with Standing Small: A celebration of 30 years of the LEGO minifigure, a smaller book focused on the minifigure. In 2012, a revised edition was published. Also in 2009, DK also published books on Lego Star Wars and a range of Lego-based sticker books.
As is the norm with LEGO sets these days, there are a fair few stickers in use for this item. I’m still not a fan of their use, but at this point in time, it is something I have come to expect and just get on with it now. In their defence, they do add to the overall presentation, making it that little bit harder to complain. As I said, this is my favourite of the three planes in the set, mainly because it looks superb and offers a great build experience. Seriously, I had so much fun building this. The instructions – as always – are clear, and it is not going to provide any major issues. Stability-wise, there are no concerns here, with the finished product very sturdy and, as proved by my daughter, can handle itself when being flown around the room by an excited seven-year-old. One minifigure can be seated at the controls, with suitable space for application and removal. The other pilot has its place on the top of the plane, with a single piece of black fencing to provide support for the death-defying pilot.
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 differences between the two jets mainly come on the top and rear of the builds. One has a larger single rear fin and two larger wings at the back, while the other has two smaller fins and the large wings positioned in the middle of the vehicle. The nose and cockpit areas are identical on both jets, and both come with stickers; the airshow logo on the wings, and a plane motif on the sides.
City is the thematic title under which most Town-related System sets were released from 2005 and onward. There are numerous sets that are associated with Construction, Police, Fire, Emergency, Train, Airport, Transportation, Cargo, Traffic, Coast Guard, Farm, Great Vehicles, Mining, and Space. European catalogs featured another theme called City in the years 1999 to 2000, which was referred to as City Center in American catalogs.