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Because of the way ABS plastic injection molding works, it is important that parts have a uniform thickness throughout, and don't just have a large section completely filled with solid plastic. This page explains a little about that: As the plastic solidifies in the mold, it freezes from the outside (near the mold surface) toward the inside. In thick ...


Cost of the brick would raise by 10-20% of the extra material needed, I don't expect the mould to be more expensive. But I think the main reason is the production proces itself. ABS is processed at around 200C (don't know temp used at LEGO). After filling the mould the whole brick must cool down again. To keep the brick shape stable, this process must ...

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