Today we bring you more Bionicle Set Designer Q&A fun. Don't forget to check out the first, second, and third parts if you missed them, and now read on for the the next round of questions and answers! Thanks Bink and all you Lego designer in Billund!

DEVELOPMENT PROCESS QUESTIONS

• (All): We start with a secret meeting where we all get together - designers, marketing people, story people, and so on - where we agree on an overall framework, or theme. We need to make sure it's different from launch to launch. For example, for the Barraki, we knew we'd be underwater. So we do some research and find all the big icons for that theme. Like underwater - who lives underwater, equipment, general style, and so on. Then for each individual character, we make character sheets. It's a description of the character: what he looks like, skills, weapons, etc. We'll brainstorm and create sketches, etc. We'll then assign each character to a designer. Each designer chooses a set to design. At that point, we start to make "sketch models" with existing elements. We create our own elements by cutting old ones up and gluing them together, and also do something called "rapid prototyping" that forms a sample element from a computer file. Once we get a design, we'll spray paint them and try to get the best differentiation between characters. We often place them side by side to see how they look as a group, to make sure they are different enough. Then we're off to test with the consumers, specifically kids, all around the world. When we all come back from the test, we'll look at the findings: what did the kids like and dislike, then we tweak or revise the models, or even start over if it wasn't liked. From that, we'll calculate cost and estimate the need for new elements and colors. We have limitations on new colors and elements, and we need to work with that. After that, it's all about working with engineers and building instructions and marketing and packaging departments. Putting it all together is a big balancing act. For example, the parts need to fit inside the packaging; you can't always make a big weapon, because it might not fit into the package. Once we think it's ready, the model goes through review by a committee of experts to check for safety, quality, and playability. Once it passes there, we sign it off and the process continues for building instructions, marketing, production, etc.
• MTJ: Then we celebrate with hot dogs.
• (all) We won't say the "cake" word.

• MTJ: For sets, we don't use computers. I just use my bricks.
• JD: We have shelves full of elements that we use to prototype sets. Massive compartmentalized shelving systems with elements in every color!
• LT: If we don't have the element in the right color, we paint it.
• EF: I was surprised when I got here how much we cut and glued elements together.
• LT: Sometimes we cheat by cutting and gluing.
• JD: JD: Normally we like to make prototypes and draw them on computer, then do rapid prototypes
• CR: We sketch a lot on new elements before we start building.
• MTJ: That's both in clay and in drawing. And mashed potatoes.
• CR: Yeah, we use different type of material, sometimes just paper or clay.
• KM: How about the differences between elements and sets?
• EF: For the big sets, we just build sketch models first using existing elements
• JD: A lot of sketches, especially for masks.
• MTJ: We also have a whole department helping us with producing sample 3D elements from our computer designs
• LT: It's not only computer designed, but also handmade prototypes or sketches

• LT: Depends on the size and how many new elements are included
• JD: There are really two big phases: overall concept design, and actual set development. Overall concept takes maybe a month and a half, and each set itself takes about four months.
• MTJ/LT: Depends on testing - normally we get it just right the first time!

• All: We work about a year and a half in advance.
• JD: Because we work so far in advance, my perception of time is so skewed.
• EF: And all the sets we get on discount are REALLY old to us
• MTJ: Mentally, I look forward way in advance. I'm planning for 2020.

• KM: I'll answer for Christoffer... he's been working directly with the movie company for a long time. So there's a lot of interaction.
• MTJ: None of your business how close.
• EF: We don't actually get to work with them, just Christoffer.
• CR: We make the models and they get sent to the movie company.
• LT: The movie does have some influence on the character design, like masks and hands.
• JD: We did a lot of character approvals from what the movie people created. We worked a lot on how the masks should move when the characters talked.
• All: The movie influenced the design, but didn't drive the design.

• CR: Depends.
• MTJ: Between 5 and 20. On some of the tests we had between 6 and 10 prototypes.
• JD: We go through a lot of prototypes for individual elements. We need a LOT of adjustments, because of safety and production requirements.
• MTJ/JD: Shooting functions also require a lot of testing and revising, for function and safety.

• All: Both.
• CR: Most of the sets include new elements, so we design both together

• MTJ: We don't use the computer for sets.
• JD: We do a lot of research on the computer.
• MTJ: Element design is done on computer, usually.
• JD: Yeah, element design is what we predominantly use the computer for.
• LT: Sometimes we do sketches and hand them over to a prototype designer.
• CR: Later in the process, we refine it on the computer or build it in 3D, but at first we build it in real life.
• LT: The computer is just one of our tools.

• All: Various CAD and graphics programs. Can't be more specific.

• MTJ: We always improve them. It's the first step on the ladder of set evolution.
• LT: Prototypes change throughout the whole process.
• JD: Early prototypes are of course a lot different than later stage prototypes.
• MTJ: Prototypes are like sketches.
• CR: We have to make sure they're safe and work in production.
• EF: We also bring out features that worked.
• JD: And eliminate the ones that didn't!
• EF: Sometimes we mix prototypes.
• MTJ: Yeah, sometimes the final is a combination of different prototypes.
• LT: And sometimes the prototypes don't change at all.

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