LEGO is looking for a replacement for ABS plastic

It's no longer a secret that LEGO is looking to do without ABS plastic, used since the 60s, by 2030 and to replace the raw material of its products with an equally durable substance. But the constraints are numerous and the quest for the miracle material has only just begun, as Allan Rasmussen confirms, Senior Project Manager at LEGO to the Plastic News website.

LEGO currently uses more than 6000 tonnes of plastic per year, 70% of which is ABS plastic, and powers more than 5000 molds and over a thousand presses at its various production sites located in Denmark, Mexico, Hungary and soon in China. .

The cornerstone of the LEGO system is the "Clutch Power", in other words the ability of the different parts to fit together and separate, while retaining this property over time. LEGO has already tested different materials that could replace ABS plastic but the results are not for the moment not convincing: PLA (Polylactic Acid) tested could have been a good candidate but it loses its "Clutch Power"after a few weeks.

LEGO wants a resin that is economically attractive and meets the environmental commitments the manufacturer has made for years to come. But it is also necessary that this material does not come from a production which is used for food purposes so as not to have to face the food / consumer good dilemma as is currently the case in the field of biofuels for example. .

In addition, LEGO wants to be able to ensure the consistency and continuity of its range by respecting the backward compatibility of its products in terms of colors. Not to mention the major changes in the production chain, which will involve very heavy investments to adapt the tools to a new raw material with physical properties different from those of the polymer currently used, and the obligation to comply with the legislation in force in the toy sector and its health constraints.

There is no doubt that the day when LEGO will replace the good old plastic in its toys with a new material will eventually arrive. There will then be a before and an after, a date which will mark the end of one era and the beginning of another. And we, the LEGO fans of the time "polluting plastic"will probably spend our time explaining to newcomers to the world of LEGO that"it was still better before"...