How to Develop Your Own Custom Building Block Toy (From Sketch to Shelf) - Part One

Welcome to Part 1 of our in-depth guide for anyone dreaming of launching their own building block toy line. Whether you're a toy entrepreneur, a designer, or a brand looking to branch into construction sets, this blog series will walk you through each step of the journey—from idea to production-ready project. And as always, Awen Hollek is here to help you every step of the way.

Why Building Blocks? Why Now?

Building blocks are more than just toys—they’re a proven format that fosters creativity, spatial awareness, and problem-solving. From classic LEGO-style sets to STEM-themed and collectible designs, they’re a growing category in both Western and Asian toy markets. But creating your own? It takes much more than inspiration.

Let’s break it down.

Step 1: Start with a Strong Concept

Every successful project begins with an idea—but not just any idea. The most engaging building block sets are those that combine originality with buildability. Whether it’s a real-world object, a fantasy creature, a licensed character, or an architectural model, you need to start with a clear theme.

Some creators begin with a hand-drawn sketch, while others find inspiration in digital images or existing physical models. The important thing is to understand your core concept: what are you building, who is it for, and how complex should it be?

Pro tip: Simpler builds appeal to younger users and require fewer bricks. More advanced builds are better suited for hobbyists and adults (AFOL—Adult Fans of LEGO).

Step 2: Convert Your Idea Into a 3D Model

Once your concept is locked in, it’s time to turn it into a digital model. You’ll need to create a 3D version using software designed specifically for building block design.

There are several free and paid tools available:

• Studio 2.0 by Bricklink: A favorite among hobbyists. It has an extensive library of LEGO-compatible parts and renders beautiful 3D previews.

• LEGO Digital Designer (LDD): An older but still useful free tool by LEGO, though it has limited support. NO LONGER EXISTS.

• Mecabricks: A browser-based tool that allows collaborative block-based modeling.

• Paid tools like Blender (with plugins) or Autodesk Maya may also be used for advanced visualizations, although they’re more complex and not dedicated to building blocks.

With these tools, you can start placing bricks, testing stability, and tweaking aesthetics. Remember to optimize part counts and connection logic to ensure that the model can actually be built in real life.

Step 3: Create a Bill of Materials (BOM)

As your model develops, you’ll need to track the number and types of bricks used. This becomes your BOM (Bill of Materials), which is essential for budgeting and production.

Most tools like Studio 2.0 allow you to export a parts list automatically. This file can be cross-checked with compatible inventories from brick manufacturers or used to quote pricing from Chinese factories.

At Awen Hollek, we help validate BOMs, optimize parts for cost and availability, and ensure compatibility with factory capabilities.

Step 4: Generate Instructions

User-friendly, visual step-by-step instructions are critical for customer satisfaction. Whether your target users are 6-year-olds or AFOLs, clarity matters.

Studio 2.0 and Mecabricks both offer instruction-generation tools, allowing you to create printable booklets or PDFs. You may also hire illustrators to create branded, custom visuals for added polish.

Tip: Well-designed instructions reduce customer frustration and minimize returns.

Step 5: Choose the Right Materials and Compatibility

Not all bricks are created equal. If you want LEGO compatibility, you must source ABS plastic of a certain grade, maintain tight tolerances, and test clutch power (how well bricks connect).

Some factories offer proprietary molds or even custom color options. If you want something eco-friendly, you may need to request bio-plastic options or sustainable packaging solutions.

How Awen Hollek Helps

Developing a building block set isn’t just about creativity—it’s about execution. At Awen Hollek, we:

• Connect clients with vetted factories specializing in injection-molded bricks

• Audit and certify supplier quality (EN71, ASTM F963, ISO standards)

• Review and refine your 3D designs and BOMs

• Assist in sourcing specialty parts, packaging, and eco-materials

• Manage the entire production cycle from prototype to final shipment

We're based in Guangdong, home to China’s biggest hubs for toys—including Shantou, the unofficial “capital of toys.”

Coming Up in Part 2

In Part 2 of this series, we’ll dive deeper into:

• Testing and compliance for international markets

• Packaging design and unboxing experience

• Branding, licensing, and retail positioning

And if you’re ready to build your block toy dream now, don’t wait—contact us today.

Awen Hollek — From napkin sketch to shelf-ready magic.