Building Dreams: The ABB Lego Project Story

When ABB Automation approached me about creating Lego models of their robots, I knew we were in for an exciting challenge. As a Lego master builder, I’ve tackled my fair share of complex projects, but this one promised to push the boundaries of what’s possible with those beloved plastic bricks. Let me take you behind the scenes of this month-long adventure that merged industrial robotics with the world of Lego.

The Client’s Vision

ABB Automation, a global leader in robotics and automation technology, had a unique request. They wanted two distinct robot models built entirely from Lego, with a special twist – one model needed to showcase an extendable arm feature. This wasn’t just about creating static displays; these models had to capture the essence of ABB’s cutting-edge technology in a fun, interactive way.

Facing the Challenges Head-On

The Extendable Arm Dilemma

The extendable arm feature presented our first major hurdle. We needed to design a system that allowed builders to adjust the arm’s length while maintaining structural integrity. After numerous prototypes and late-night building sessions, we cracked the code by including additional parts that let builders customize the arm’s length to their liking.

Stability vs. Flexibility

Another significant challenge was ensuring the models weren’t just accurate representations but also functional ones. We wanted people to be able to manipulate the arms just like the real robots, without fearing them falling apart. Achieving this balance between stability and flexibility in a small-scale Lego model was no small feat.

To overcome this, we:

1. Experimented with various connection techniques
2. Reinforced key stress points without compromising movement
3. Tested different gear systems for smooth arm rotation
4. Fine-tuned the weight distribution to prevent toppling

The Building Process

With our challenges identified and initial solutions in place, we dove into the building process. Here’s a glimpse into how we brought ABB’s robots to life in Lego form:

1. Research and reference gathering
   • Studied technical specifications of ABB robots
   • Analyzed photos and videos of robots in action
2. Digital prototyping
   • Used STUD.io for initial designs
   • Tested various build techniques virtually
3. Physical prototyping
   • Built and rebuilt key sections multiple times
   • Stress-tested joints and moving parts
4. Fine-tuning and detailing
   • Added color-accurate elements to match ABB’s branding
   • Incorporated subtle details to enhance realism
5. Final assembly and quality control
   • Ensured all functions worked smoothly
   • Double-checked stability and durability

Bricks and Pieces

For this project, we primarily used Lego System bricks – the classic bricks most people know. These versatile pieces allowed us to achieve the precise shapes and functions required for the ABB robots. While I can’t disclose the exact number of pieces used (trade secrets and all), let’s just say it was enough to make any Lego enthusiast’s eyes light up!

We carefully selected each brick type:

• Technic pieces for internal structures and mechanisms
• Smooth tiles for sleek, industrial surfaces
• Specialized joint elements for articulation points
• A mix of colors to accurately represent ABB’s design aesthetic

The Month-Long Journey

This project spanned an intense month, from the initial concept discussions to the final model reveal. Here’s a rough breakdown of how that time was spent:

• Week 1: Planning, research, and initial prototyping
• Week 2: Refining designs and solving major engineering challenges
• Week 3: Building the core structures and mechanisms
• Week 4: Detailing, testing, and final adjustments

Throughout the process, we maintained open communication with ABB, ensuring that every aspect of the models met their expectations and accurately represented their brand.

The Big Reveal

The reaction was amazing when we finally presented the completed Lego robots to ABB. Seeing their cutting-edge technology reimagined in Lego form made everyone smile. The extendable arm feature was a particular hit, with ABB team members eagerly adjusting and posing the model.

But the real magic happened when people started interacting with the models. Watching engineers and executives play with these Lego versions of their creations reminded me why I love what I do. It’s not just about building with bricks; it’s about bringing ideas to life and sparking joy and creativity in others.

Lessons Learned

This project reinforced some valuable lessons:

1. Communication is key – Regular check-ins with the client ensured we stayed on track.
2. Embrace the challenges – Often, they lead to the most innovative solutions.
3. Details matter – Small touches can make a big difference in the final product.
4. Never underestimate the power of play – Even in a corporate setting, the ability to interact with a physical model can be incredibly impactful.

Looking to the Future

The ABB project is one of my favorite corporate collaborations to date. It perfectly encapsulates the potential of Lego as a medium for bringing complex ideas to life in a tangible, engaging way.

For businesses, government agencies, or organizations looking to make a lasting impression, custom Lego projects offer a unique opportunity. Whether it’s for marketing, education, or team-building exercises, Lego’s versatility allows us to create truly one-of-a-kind experiences.

Interested in bringing your ideas to life through the power of Lego? Let’s chat about how we can create something amazing together. From product launches to interactive displays at corporate events, the possibilities are as endless as your imagination. Reach out today, and let’s start building your vision, brick by brick!