Engineering news
“I obviously jumped at the opportunity when I was asked if I'd like to work on a life-size Lego P1,” said the senior vehicle engineering manager from McLaren Automotive to Professional Engineering. “To get the opportunity to emulate that in Lego was just a once-in-a-lifetime opportunity to combine a childhood passion for Lego engineering with my adulthood passion for automotive engineering.”
That opportunity came as part of a project between the Danish construction toy company and the luxury automotive firm. The work reached a successful conclusion in September, when McLaren Formula 1 team driver Lando Norris drove the car – made of 342,817 Lego parts – around the Silverstone track. Celebrating the launch of the 1:8 scale Lego Technic P1 set, the full-size version also used components from the engineering-focused product line.
But, as with any build, getting the pieces together was only part of the challenge.
Clutch power
Seven months would be a long time for most Lego builds – but not much time to design and build a working sports car replica. The two companies had collaborated before, including making full-size McLaren 720S and Senna models, but the P1 project brought some new challenges.
It was to be the first full-size Lego car capable of steering, with a fully-functioning steering system. It would have a top speed of 50km/h, according to Beaumont, and more of the vehicle was to be built from Lego than ever before.
The car needed a metal structure to work, said Lego model designer Lubor Zelinka, with non-Lego axles, steering, brakes and some other “critical elements”. These included genuine P1 wheels and tyres. Everything else, however – including the seats, wing mirrors, rear wing and even the batteries – were “pure Lego Technic builds”, held together by only the ‘clutch power’ of the pieces.
The build was based on designs from McLaren, which shared 3D geometry of interior and exterior surfaces that the Lego team then pieced together with Technic parts.
“They managed to completely recreate the P1 interior so ergonomically. Lay-out wise it was an exact match. It was amazing to sit in it, it really honestly does feel like you’re sitting in a genuine P1,” Beaumont said. “And the Lego seats were surprisingly comfortable!”
The build was created by 23 design, engineering and building specialists from the two companies, taking 8,344 hours of development and construction and requiring 393 different types of LEGO Technic elements.
The next set
McLaren ran simulations to make sure the electric technology would manage the planned distance and speed that Lego hoped to achieve – and then Norris proved them correct, with a successful run around the 5.9km track. Pace was not a priority, however, and Zelinka said the team did not record the laptime or top speed. The Lego team now plans to develop the “very promising” drivetrain further, Zelinka added.
For Beaumont, the main aim of the project was to inspire a new generation of automotive engineers. “I don't think you ever meet anyone that didn't play with Lego as a child,” he said. “If the Lego P1 can inspire the next set of automotive engineers, and push children towards automotive engineering, that really would be the dream for me, to inspire that next generation.”
Want the best engineering stories delivered straight to your inbox? The Professional Engineering newsletter gives you vital updates on the most cutting-edge engineering and exciting new job opportunities. To sign up, click here.
Content published by Professional Engineering does not necessarily represent the views of the Institution of Mechanical Engineers.