Case Study: LEGO achieves faster, safer product development with MSC Software simulation

Virtual Product Development Helps LEGO Engineers Stretch Their Own Creativity

LEGO Group, the Danish toy maker, needed a way to improve the safety, quality, and cost efficiency of its plastic parts while reducing dependence on physical prototypes and late-stage tooling changes. To meet this challenge, LEGO used MSC Software simulation tools, including MSC.Marc, MSC.Patran, and MSC.Nastran, to test designs virtually during product development.

MSC Software helped LEGO implement virtual product development for compression, drop, torque, and other structural safety tests, allowing engineers to identify problem areas earlier and try more design options with confidence. The results included reduced cycle time from concept to finished part, fewer tooling changes, lower manufacturing costs, and significant material savings, including about $625,000 in annual savings on just five parts.

Lego

Jesper Christensen

CAE Consultant