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 final two minifigures are the Biplane Pilot and the intrepid Wing Walker. Both of these minifigures share the same white torso which is printed with a flight suit design overlaid with dark red and bright light orange flames plus a logo over the left breast. The torso design is superb and it can at present only be found in this set. Both minifigures are provided with a reddish brown aviator cap and dark bluish grey goggles, and the pilot (below left) also gets an alternative to this headgear in the form of medium dark flesh mid-length hair which has only ever appeared in five sets in this colour.
The cockpit, including the stickers on the sides and the canopy, is identical to that of the first jet, as is the front of the aircraft. As previously noted, however, the wing configuration is different, as is the tail design which features twin tail fins and a pair of fuselage-mounted tailplanes. The red 4 x 1 x 3 tail fins, which have appeared in a total of seven sets including this one, are angled outwards similar to the arrangement on an F/A-18 Hornet. Overall, it’s another sleek design but once again the smooth lines are somewhat spoiled by the prominent canopy.
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.