Lego, Engineering & Low Fidelity Prototyping
Prototyping is a crucial first step in transforming your projects from concepts into final products and it doesn’t always require complex nuts and bolts or expensive tools either. Low-fidelity prototypes, often called low-fi prototypes, offer a fast, cost-effective way to test core designs and identify potential flaws early.
One surprisingly simple yet effective prototyping tool is LEGO. By using Lego for prototyping, engineers and designers can quickly create and adjust models, making it ideal for initial concepts.
In this article, we’ll explore how Lego engineering plays a key role in low-fidelity prototyping, from mechanical engineering Lego kits to real-world Lego prototype examples. We’ll cover the advantages of low-fidelity prototype methods, like faster iteration, cost savings and show how Lego engineering kits can be a great fit for prototyping.
Let’s dive in!
Contents:
What Is Low-Fidelity Prototyping?
Low-fidelity prototyping is a method of quickly visualising and testing the core functionality of a product or system using simple, inexpensive materials. Rather than aiming for a polished, high-spec model, this approach focuses on identifying major design considerations and potential flaws early on through user testing.
Common low-fidelity prototype examples might include basic sketches, paper prototyping, cardboard models or as we'll cover more in this article, made from Lego. The goal is to gather rapid feedback and refine ideas before investing heavily in detailed CAD models or advanced manufacturing processes. By prioritising speed, flexibility and minimal cost, using Lego to create low-fidelity prototypes makes it easier to iterate and pivot when necessary, which can save significant time and expense down the line.
Middle Image: Reddit User u/dudelouis, Right Image: Reddit User u/Mykola_MrHardGuitar
Why Lego Is Ideal for Low-Fidelity Prototyping
Lego stands out as a low-fidelity prototyping tool because of its versatility, accessibility in education environments and ease of modification. Lego engineering sets come with modular pieces that snap together seamlessly, letting designers experiment with structural layouts and simple design ideas including mechanical functions at a minimal cost.
When something doesn’t work, you can quickly disassemble and rebuild it, making iterations both fast and intuitive. This hands-on approach also helps you to spot potential design challenges early, well before moving on to more complex stages of product design and development.
Lego also has more advanced modules such as gears, hubs, axels, motors and even sensors. These can allow an even greater level of prototyping, allowing both physical and motion prototyping.
Practical Examples of Lego Prototyping
Practical examples of Lego prototyping often involve building simple mechanisms or structural models to quickly test an idea’s feasibility. For instance, you could assemble a basic gear train from a Lego engineering kit to see if the gear ratios function as intended, or create a small robotic arm to observe how pivot points and linkages might behave under motion. You can then take the information gathered at this stage into 3D modelling.
Another perfect example of using Lego for prototyping is the fantastic videos produced by the Brick Experiment Channel on YouTube which exemplifies the use of Lego to prototype ideas to solve problems such as bridging a gap with a vehicle. They even have an incredible video showcasing 20 mechanical engineering principles, all using Lego.
These hands-on low-fidelity prototype examples allow you to validate core concepts with minimal time and cost, making lego for prototyping an excellent fit for early-stage design.
Step-by-Step: Building a Low-Fi Prototype with Lego
1. Define the Prototype’s Purpose
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Identify Your Goal: Write down what you want to learn from this prototype. Whether it’s testing a gear ratio, exploring structural stability or examining how different parts move together and interface.
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Set Design Constraints: Include size limits, load requirements or motion ranges so you know exactly what you must accommodate in your build.
2. Gather the Right Lego Engineering Components
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Pick the Best Sets: Aim for Lego engineering sets such as Lego technic or a Lego engineering kit featuring gears, beams, axles and connectors. These are ideal for building mechanical structures and testing functional movements.
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Sort Your Pieces: Lay out similar components together so you can find and swap parts with ease during the build.
3. Sketch a Rough Blueprint
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Map the Layout: Even a hand-drawn sketch of your design can help you picture the arrangement of moving parts on a 2D plane.
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Mark Key Interactions: Identify where gears connect, which beams act as supports and any pivot points or joints critical to the design.
4. Assemble a Basic Frame
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Start Simple: Build a sturdy base or frame to anchor your moving parts. This gives you a consistent foundation to work from and tweak as needed.
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Focus on Core Functions: If you’re testing gear movement, begin by assembling the gear train or axle connections first. Likewise, if you have interface parts such as buttons or levers, include these in your design concept.
5. Add and Adjust Moving Parts
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Attach Components Gradually: Add gears, levers or other elements one step at a time, testing each mechanism for smooth operation as you go.
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Make Quick Iterations: If something doesn’t align, dismantle just that section and rebuild. The modular nature of Lego allows you to test different configurations fast.
6. Test for Basic Performance
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Check Movements: Manually turn gears or pivot joints to ensure nothing jams. For more complex assemblies, use any available Lego motors if you need a simple drive mechanism.
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Assess Stability: Press gently on support beams or joints to see if they can handle the intended load or forces. If possible, try attaching simple items with string to act as a load such as a ziploc bag or pre-weighed flour.
7. Refine and Repeat
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Gather User Feedback: Ask team members or other stakeholders to interact with the prototype and offer input to the user flow.
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Record Findings: Note any issues, like wobbly sections or misaligned gears and make improvements.
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Iterate as Needed: This is where you adapt, rebuild and retest, ensuring you address all concerns before moving on to more advanced prototypes. This final part is what makes Lego bricks ideal for lo-fi prototypes.
By following these steps, you’ll end up with a Lego prototype that highlights core functionality without overcomplicating details. This approach keeps costs low, feedback cycles short and design possibilities wide open, exactly what low-fidelity prototyping is all about.
Advantages of Low-Fidelity Prototyping in Engineering
Low-fidelity prototyping extends far beyond simply saving time and money, it creates a sandbox for creative thinking and problem-solving in engineering. By stripping away complexity, teams can focus on functionality and user experience, facilitating agile decision-making. The added benefit? It also aligns well with STEM-focused learning, making prototyping more accessible for younger audiences eager to explore science, technology, engineering and mathematics. Below are some key advantages.
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Rapid Feedback Loops: When prototypes are quick and cheap to produce, it’s much easier to gather feedback from team members, stakeholders or end-users. These short cycles of build, test and iterate help refine core concepts faster.
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Minimal Financial Risk: Relying on inexpensive materials (like paper, cardboard or Lego) keeps costs down. If the design has to be scrapped or dramatically altered, the investment loss is minimal compared to CAD models or high-end prototypes.
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Encourages Collaboration: Simplicity allows anyone on the design team to contribute or modify a low-fi model. This helps break down communication barriers between design, engineering and other departments. Teams are also more willing to experiment and take risks. This open-minded approach can lead to unconventional, yet highly effective, design solutions.
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Facilitates Early Problem Identification: Low-fidelity prototypes make it easy to spot structural weaknesses or potential flaws in functionality. By catching these issues early, teams avoid the substantial costs of major redesigns later.
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Promotes Hands-On STEM Learning: Younger audiences can use basic materials or Lego to grasp fundamental engineering principles without feeling overwhelmed. This tangible, playful approach fosters curiosity and confidence, helping students connect theory with real-world applications.
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Builds Confidence in Problem-Solving: Children and beginners can see immediate cause and effect by making small changes to a prototype. This immediate feedback loop demystifies engineering, encouraging them to keep iterating and innovating.
Choosing the Best Lego Sets for Engineers
When it comes to choosing Lego engineering sets for prototyping, mechanical experimentation or straightforward STEM learning, a few standout options meet the needs of both beginners and advanced builders. Here are some best Lego sets for engineers:
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Lego Education SPIKE Essential Set (45345): Featuring programmable motors and sensors, this Lego engineering kit merges robotics with practical coding skills. Ideal for testing motion-based concepts and creating interactive prototypes.
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Lego Education BricQ Motion Prime Set (45400): This 562-piece kit comes with moving pneumatics, gear mechanisms, wheels and weights to provide hands-on insight into real-world machine structures involving motion, perfect for mechanical engineering Lego projects.
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Lego Serious Play Connections Kit (2000431): A huge set totalling 2455 pieces consisting of bricks, gears, rods and leadscrews. The set allows builders of all ages to engage and explore prototyping rotary and linear motion with load-bearing aspects or simply utilise the bricks.
Each of these sets serves as a low-fi prototype platform, allowing you to assemble, test, dismantle and rebuild quickly. By blending creative fun with Lego and engineering, they open the door to hands-on experimentation, making it easier than ever to jumpstart real-world design challenges.
Wrapping Up Lego, Engineering & Low Fidelity Prototyping
So there we have it, by reaching the end of our journey, you should now have a solid grasp of how Lego seamlessly fits into low-fidelity prototyping and how both can be leveraged for rapid, cost-effective design solutions.
Key Takeaways:
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Low-Fidelity Prototyping Saves Time and Resources: Simpler models let you test core functionality and refine your ideas fast, minimising financial risk.
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Lego Facilitates Quick Iterations: Modular pieces mean you can easily assemble, disassemble and rebuild your concept, ideal for mechanical tweaks or structural changes.
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Perfect for STEM Learning: From children to newcomers in engineering, Lego-based builds demystify complex concepts, providing a tangible, hands-on way to learn.
Additional Reading:
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“What is Engineering?” - Discover the foundations of Engineering and what disciplines it is related to.
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"What is STEM?' - Learn all about the meaning of STEM and how it aims to help inspire the next generation of engineers.
By understanding the unique benefits that Lego engineering, low-fi prototype methods and a creative mindset bring to early-stage design, you’ll be better positioned to develop effective, user-focused solutions. Keep experimenting, stay curious and don’t be afraid to iterate your way toward ingenious designs.
Thanks for reading!
FAQs
Q: What is a Lego prototype?
A: A Lego prototype is an early-stage model created with Lego bricks to explore core functions, mechanics or structural layouts before committing to more advanced design approaches. It provides a quick, hands-on way to test ideas without the complexity and cost of high-end prototyping methods.
Q: How to turn a 3D model into Lego?
A: If you prefer to stay digital, there are 3D-modelling Lego programs such as Bricklink Studio where you can attempt to re-create your model with digital Lego before going physical. These programs help match available brick types to the geometry of your model. If you prefer a more hands-on approach, study the 3D model’s form and reconstruct it manually with standard LEGO bricks, approximating shapes and sizes as closely as possible.
Q: What are the 3 levels of prototyping fidelity?
A: Low-fidelity prototypes use simple materials (paper, cardboard or LEGO) to test fundamental concepts. Medium-fidelity builds add more detail and partial functionality to refine interactions such as 3D prints. High-fidelity prototypes mimic near-final designs, often including advanced features or close-to-production parts for realistic testing.
Q: What are the disadvantages of low-fidelity prototypes?
A: They lack advanced detail, making it harder for stakeholders to visualise the final product. Some features, such as precise tolerances or material properties, can’t be accurately represented. This may lead to miscommunication or misinterpretation by those unfamiliar with early-stage prototypes.