Johor has been a hub for building models using universal interlocking bricks the past 16 years.
Miniature versions of global iconic buildings, including towering skyscrapers, are put together piece by tiny Lego brick piece by dozens of specialists.
Tucked away in an industrial factory in Bandar Indahpura, Kulai, the Merlin Magic Making (MMM) Lego Production Hub, also known as Merlin Entertainment Studios (M) Sdn Bhd, serves as a creative and technical hub for Lego model production in the Asia-Pacific region.
Its Asia senior Lego model production manager Leina Rahim, 44, said the completed models were shipped from the MMM hub in Johor to Legoland parks around the world.
The Merlin Magic Making team installing a Singapore Flyer replica at Legoland Malaysia. — Photos: THOMAS YONG/The Star
“Our latest project was to deliver 529 replicas for Miniland in Legoland Shanghai (China), which just opened this month.
“We have a team of 91 people, almost all locals, who are involved in the process from the beginning until the end.
“This includes the concept and design stage, building of the models, testing, putting in lighting and installation of the model at the parks,” she said in an interview with StarMetro at the hub.
The hub supplies to 11 parks around the world, including Germany and the USA.
A technician putting finishing touches to a Marina Bay Sands replica.
Leina said some models would need reinforcement with steel inside to ensure the replicas, like the 11m Lotte Tower in South Korea Miniland, were safe and secure.
She said another major project was the construction and installation of 16 large-scale models for their new Singapore-themed Miniland in Legoland Malaysia, which would open to the public tomorrow.
Legoland Malaysia in Iskandar Puteri is located about 30km from the MMM Kulai facility.
“It is an exciting time as some of the models will come with interactive features comprising sound, lights and moving parts,” she said, adding that all models were built using Lego bricks flown in from abroad.
Asked about the time taken to build each model, Leina said it varied as some could take up to 500 hours from design to the finished product.
(Clockwise from front right) Leina, Chai, Muhammad Fais, Syed Mohd Izzudin and Muhammad Nazrin at the production hub with a completed Cloud Forest replica.
She said each Legoland park was unique as the team would design its Miniland based on landmark buildings or structures in the country.
“We even get a feel of the people and culture in that place and incorporate these elements when we design our Minilanders (people) and their outfits,” she explained.
On the work culture at MMM, Leina said, “Basically we breathe, eat and play with Lego every day”.
Building models
The facility was established in 2009 and officially named the Asia hub for Lego model production in 2018.
MMM production hub serves as the creative force behind the intricate model designs at Legoland Malaysia.
It oversees the creation of Miniland models, from design to installation, for Legoland parks operated by Merlin Entertainments across the Asia-Pacific region.
Lego model production team leader Muhammad Fais Isa, who has a degree in Teaching English as a Second Language, joined MMM 10 years ago when he made the switch from a teaching career.
The 34-year-old said the 16 Singapore models took about 16,000 hours to complete and it consisted of 1.5 million Lego bricks.
“The Marina Bay Sands was quite a challenge, as our usual models comprise just one tower. But for this, it involved three separate towers with a skydeck on the top,” Muhammad Fais said, adding that the model was about 4m tall and weighed 1.426 tonnes, including 260kg of steel to reinforce the structure.
For MMM design developer Muhammad Nazrin Kamarul Bahrin, 38, each design journey begins not just with blueprints, but with real-life experiences.
A Merlin Magic Making technician inspecting each component assembled, ensuring every detail is accurate.
“Once we have chosen a landmark, we send a team to the actual location.
“We take thousands of photographs during the day and night.
“We observe everything – from the buildings and colours to what people eat. We will even take note of their rubbish bins.
“It is about capturing a city’s essence and identity,” he said.
Muhammad Nazrin said each Miniland took around three years to complete, involving research, approvals, 3D modelling, technical development and on-site testing before final assembly.
Structural safety and stability is paramount to technical delivery manager Syed Mohd Izzudin Syed Abu Bakar, 42.
“We had to put in steel frames so that they could support the load of the Marina Bay Sands model safely,” he said.
He added that lighting, sound and automation were also important when building a replica.
Lego model designer Chai Shu Ling, 29, said beyond ensuring that the structure would hold, her focus was on making a replica stand out.
“The first thing we ask is what grabs people’s attention?
“For the Cloud Forest replica, we knew it was the waterfall.
“It must be visually striking yet structurally stable.
“We test techniques, explore new colours and solve challenges together,” she said.
With 1,600 Minilanders featured throughout the project, Chai said even the tiniest details were carefully considered.
“We make sure each plant is unique, yet does not distract from the main structure.
“It is all about balance. Even with bricks, we want our models to feel alive,” she said.
