Collection: Injection Molded Custom LEGO® Parts

Real Injection Molded Custom LEGO® Parts, Not 3D Prints

Most custom LEGO® parts you find online are 3D printed. Every part in this collection is different: it was injection molded from solid ABS plastic in a mold we designed and machined ourselves in Washington. That is the same basic process used to make the building toys you grew up with, which is why BrickTactical guns, helmets and gear have the smooth finish, sharp detail and clutch power collectors expect.

What Is Injection Molding?

Injection molding is how nearly every plastic toy in the world is made. Plastic pellets are melted and forced under high pressure into a metal mold that holds the exact shape of the part in reverse. The plastic cools in seconds, the mold opens and a finished part is ejected. Then the machine does it again, producing identical parts every time.

How We Make Custom LEGO® Parts, Step by Step

1. Design

Every part starts in CAD. Founder Payton Dean designs each weapon or accessory in 3D, scaling real world gear down to minifigure size while keeping it compatible with minifigure hands, studs and clips.

2. Prototype

Before we cut any metal, we print high resolution SLA 3D prototypes and test them on real minifigures. Designs get refined here, sometimes for weeks or even months, until they are ready for a mold.

3. Mold Design

A LEGO® compatible mold is two halves that close together to form a hollow cavity in the shape of the part, plus a path for the plastic to flow in, vents to let air escape and pins to push the finished part out. Designing all of that for a part smaller than your fingernail takes serious precision.

4. Machining the Mold

Most of our molds are machined from aluminum on our own CNC mill. As Payton puts it, aluminum is "Strong, lightweight, and fast to machine! Not to mention a LOT cheaper than EDM cutting steel molds." A single mold can still take up to 48 hours of machine time, and a complex multi part kit like the BrickTactical M2 machine gun cost around $20,000 in tooling.

5. Testing

The finished mold goes into our injection molding machine for test shots. We check fill, fit, surface finish and clutch, and adjust the mold until every detail comes out crisp.

6. Production

Once the mold is dialed in, we run production in ABS, check the parts, pack them and ship them from Washington.

Injection Molded vs 3D Printed Custom LEGO® Parts

• Strength: molded ABS is solid all the way through, while printed parts are built in layers that can split or snap.
• Finish: molded parts come out smooth with sharp detail, while prints often show layer lines.
• Consistency: every molded part is identical, so the thousandth rifle fits exactly like the first.
• Feel: molded parts have the weight, color and clutch collectors expect from real building toys.

The tradeoff is up front cost. A 3D print costs almost nothing to start, while a mold costs thousands before the first part is made. That is why molded custom LEGO® weapons are something special.

Shop by Category

• Rifles, pistols, shotguns and sub machine guns
• Machine guns and launchers
• Melee weapons and saber hilts
• Helmets, vests and pouches
• Two color overmolded parts
• Weapon packs for building a whole squad

From a Garage CNC to Made in the USA

BrickTactical started in 2012, when a 12 year old Payton and his grandfather bought a $2,000 desktop CNC mill and taught themselves to make injection molds in the garage. "We didn't know what an endmill, CAD/CAM, or even a parallel was," Payton says. It took about a year to machine their first working mold. Today every part in this collection is designed, machined, molded and shipped from Washington. Read the full story on our About Us page.

Injection Molded Custom LEGO® Parts FAQ

How are LEGO® pieces made?

Building toy pieces are injection molded: melted ABS plastic is injected into a precision metal mold, cooled and ejected. BrickTactical custom parts are made the same way, using molds we design and machine ourselves.

Are these parts 3D printed?

No. We use 3D printing only for prototypes. The parts in this collection are injection molded from ABS plastic.

Will these fit my LEGO® minifigures?

Yes. Every part is designed and tested on real minifigures to fit minifigure hands, heads, studs and clips.

How much does a custom LEGO® mold cost?

It depends on the size and complexity of the part. A simple aluminum mold costs far less than a steel production mold, while a complex multi part kit like our M2 machine gun cost around $20,000 in tooling.

Can I make my own custom LEGO® pieces?

You can. Start by learning CAD, 3D print your designs to test fit, then experiment with a small benchtop injection molder and an aluminum mold. Expect a learning curve, because it took our founder about a year to make his first working mold.

Can BrickTactical mold my custom part?

We also offer custom printing and manufacturing services, including injection molds, CNC machined parts and prototypes. Reach out through our contact page with your idea.

Where are they made and shipped from?

Every part is molded in Washington and ships from the USA.

Are these safe for kids?

They make great gifts for kids who build, but they contain small parts and are not suitable for children under 3.

Watch New Molds on YouTube

See new molds as they come off the machine on the BrickTactical YouTube channel, or browse all custom LEGO® guns and weapons and custom minifigures.