Case Study: The LEGO Group achieves faster, safer product development with Hexagon simulation software

Virtual Product Development Helps LEGO Engineers Stretch Their Own Creativity

The LEGO Group, a leading consumer products company, faced the challenge of validating the safety and structural integrity of its plastic toy parts while also aiming to reduce material usage and manufacturing costs. To achieve this without over-relying on costly physical prototypes, the company turned to vendor Hexagon's MSC Software division, utilizing their MSC.Marc, MSC.Patran, and MSC.Nastran simulation software for virtual product development.

By implementing Hexagon's Finite Element Modeling (FEM) solutions, LEGO engineers could simulate safety tests like compression and drop tests to identify problem areas in designs virtually. This solution from Hexagon provided the confidence to try more creative solutions and optimize parts before physical tooling was made. The results were significant, including a reduction in the overall product development cycle time, substantial annual material savings of $625,000 on just five parts, and increased productivity from more reliable molds.

The LEGO Group

Jesper Christensen

Group CAE Consultant