Lego Expands Plastic Production and Quality Control in the 1950s

The LEGO Group significantly advanced its manufacturing capabilities and quality standards throughout the 1950s in response to increasing global demand and a commitment to its founding principles.

In 1953, LEGO established its own mold production facility in Billund, Denmark. As sales rapidly climbed, the Billund facility faced capacity constraints. To address this, the company opened LEGO Form in Vejle in 1959, supplementing the existing mold production and a tooling department established in Hohenwestedt, Germany, the previous year.

To bolster its technical expertise, LEGO hired specialists in key areas during the early 1960s. The recruitment of Swiss plastics expert Hans Schiess in 1961 was instrumental in improving raw materials, mold design, injection molding machinery, and the molding process itself.

A pivotal shift occurred in 1963 when LEGO transitioned from cellulose acetate to the more durable and color-stable ABS (acrylonitrile butadiene styrene) plastic. This material allowed for greater precision in molding, achieving tolerances of 1/200 mm. That same year, a dedicated quality control department with 13 employees was established to ensure that increased efficiency did not compromise product integrity.

These strategic investments in materials, technology, and expertise solidified the quality and consistency of LEGO products, reinforcing the company's long-standing motto: 'Only the best is good enough.'