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As of September 2008 the design teams use 3D modeling software to generate CAD drawings from initial design sketches.
The designs are then prototyped using an in-house stereolithography machine.
The machines that manufacture Lego bricks have tolerances as small as 10 micrometres.
When two pieces are engaged they must fit firmly, yet be easily disassembled.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 optimized by way of mould flow and stress analysis.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.
These prototypes are presented to the entire project team for comment and for testing by parents and children during the "validation" process.