OUR PROCESS
It typically takes 3-6 months to complete a project. Each set is made by hand using a specialized process that ensures an extremely low error rate.
You will find more information below about our process along with optional customizations to fit your needs.
DESIGN
With our vast inventory of LEGO® pieces and software, we develop a concept model based on your requirements and wants. The designer, Chris, develops a full and functional concept model first, then isolates and focuses on each area that needs more attention. When every aspect of the design has been resolved, we will share images for your review and feedback. We want you to be excited with the first concept design.
We will send digital renders for your approval as it is a quick way to make adjustments and present to you updated concepts.
PRODUCTION
Our efficient production process ensures accuracy by incorporating three different methods to verify the inventory.
Our parts shop allows your recipients to order replacement parts if they lose anything. If there happens to be anything missing in the product, we'll take care of it! Directions on how to do so are provided in each set.
Environmental Impact
• Our property is powered by 92% clean energy. We're gradually connecting more equipment to our own solar battery generator.
• LED and natural lighting throughout.
• LEGO® parts are primarily pulled from our own inventory and trusted suppliers in the US and Europe. Our investment in maintaining our own inventory has resulted in less waste and less environmental impacts caused by air freight.
• Parts are secured in LDPE plastic #2 reclosable bags, which are reliable, reusable and lightweight. Recycling options vary. We are always exploring alternative options.
Typical contents of a set.
INSTRUCTION MANUAL
The designer of the model carefully photographs and designs the instructions to create a harmonious product that in turn gives the builder a feeling of accomplishment. We feel the extra time involved contributes to a much more special experience.
Many appreciate the mental health benefits of non-digital activities so we removed as much of the digital world possible by photographing real parts in each step and including printed instructions in each box.
Our photos are captured in a custom no-shadow studio with an incredibly unique perspective-control lens. Additional text, close-ups or digital lines are incorporated where necessary.
We use an established print shop to create a high-quality booklet with either staple or glue binding. Smaller sets may use a folded sheet.
Options
• Add your logo to the front cover. $0
• Add a 2-page spread at the beginning of the booklet. $350 + $0.50/set
• Add a 4-page spread at the beginning of the booklet. $700 + $1/set
• Provide a PDF copy of the instructions (we will still include printed instructions in each box). $0
Environmental Impact
• Our booklets are generally more concise than comparable LEGO® set booklets. As a result we use significantly less paper and ink than comparable products.
• Paper is made with at least 40% recycled fibers and FSC certified cellulose.
• Printed in a carbon-neutral facility.
• Fully recyclable (however, we recommend keeping the instructions as a future reference).
STICKER SHEET
Your branding and other smaller details are typically achieved through vinyl stickers. Our specialist print shop uses laser-cutting equipment so we can get precise measurements and unique shapes!
Digital printing is an incredible advancement to reduce cost and time, however it is limited in reproducing vibrant colors. The designer also considers how stickers are used on curved parts and over multiple parts so as to ensure the highest quality in your product.
Environmental Impact
• Sticker sheets are printed and cut in North America, using locally sourced vinyl material.
• Stickers are efficiently arranged to minimize waste materials.
• Backing paper and excess material are generally not recyclable.
PACKAGING
All sets are packaged in Roll-End-Front-Tuck boxes, which minimize waste, are easily recyclable, and requires no adhesives for assembly. We contract a company that uses non-toxic food-grade inks on an HP PageWide C500 Press, which gives the highest resolution we've found from any small-run printer in North America. Although the quality and accuracy does not yet match up with traditional lithography, it is the most practical solution for projects up to 3000 units.
To meet the needs of the LEGO® Company, the box must look like an ICHIBAN Toys product. So a limited amount of our branding will be on the box, along with necessary product details and disclaimers. We utilize a simple but effective design that will feature your logo(s) and one or more photos of the finished model.
A digital proof of the box art file will be emailed to you for approval before it goes to print.
Options
• Would you like to design the box? We can send you a template, and then we'll finalize your art file for printing.
Environmental Impact
• Cardboard packaging is sourced only from SFI Certified suppliers in North America, and includes 30-50% recycled content.
• Packaging is cut and printed in a location only 4 hours drive away from our facility.
• The REFT style box utilizes a design that produces very little waste off-cuts (which are recycled) and requires no glue, tape, or other form of sealing.
• Box sizes are kept as small as possible.
• Non-toxic, food-grade, true water-based inks.
• Fully recyclable.
Custom designed box to resemble the real Xbox Series X packaging.
SHIPPING
Your project is designed and made in Oregon, USA, and then shipped via FedEx Ground or UPS Ground.
Options
• We can split your order for shipment to multiple locations/offices. Prices vary.
• We can direct ship to your recipients. US addresses only. Prices vary.
Environmental Impact
• Product boxes and shipping cartons are carefully sized for maximum packing efficiency. This reduces the space needed on trucks.
• For best protection and cleanliness, we use new boxes for the shipping cartons.
• Any clean cardboard and packaging materials used with incoming shipments are re-used as cushioning materials. As a result, we haven't had to purchase cushioning materials for several years (paper, bubble-wrap, etc) and generate significantly less waste.
• Shipping cartons are fully recyclable.
