DESIGN

The design process is the most fun aspect of creating news sets, yet is also the most arduous.  At the very beginning, we designed through trial & error with actual, physical LEGO® bricks.  Then we found the digital designed software called STUDIO 2.0.  This free software allows you to design sets digitally.  There is a steep learning curve in learning to use the software well, however, it is quite amazing once you get the hang of it.

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EDITING

Sets undergo hundreds of edits before we settle on the final design.  And the process is more complicated than just getting it to look good.  There is also the process of ensuring it will be a stable build (one that will not fall apart) and that the pieces are still available from LEGO®.  This final portion often must take into consideration color variations and also cost for each piece.

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BUILDING INSTRUCTIONS

Then comes the design of the building instructions.  This process can also be quite painstaking as we try our best to make the instructions clear and easy to follow. 

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ELEMENT PROCUREMENT

Obtaining the correct pieces ("elements" in LEGO® terminology) is a process that requires much cost comparison.  We procure elements from three main sources:

1. Suppliers on BrickLink (mostly based in Germany, Poland, the Netherlands).

2. Physical Pick-A-Brick walls in US-based LEGO® stores.

3. Directly from LEGO® online Pick-A-Brick service (shipped from Illinois or Denmark).

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SORTING & PACKING

When shipments arrive, pieces are counted, sorted, and separated into different storage bins.  We've become quite good at counting!  At any given time, we have approximately 100,000 LEGO® elements on hand.

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Aesthetics.  Stability.  Color.  Cost.

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FAILED DESIGNS

As stated above, the design process goes through hundreds of different iterations.  Below are examples of 'bad/wrong' prior versions of various components:

Crown

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Collar

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Mouth/Nose/Eyebrows