LEGO to Boost Capacity 35% at Expanded Mexico Manufacturing Facility

The LEGO Group plans to invest more than $400 million to expand its manufacturing site in Monterrey, Mexico, adding production, packing, and warehousing capacity. The project is expected to increase the factory’s production capacity by 35% and add approximately 1,300 jobs through 2029.

Expanding Production Capacity

The expansion will add a new packing hall and a fully automated high-bay warehouse, increasing the site’s built-up area by 62,000 square meters to 210,080 square meters. Construction is expected to begin in early 2027 and finish in 2029.

The Monterrey facility currently employs about 7,300 people and handles multiple stages of LEGO product manufacturing, including molding, element processing, decoration, and packaging. The site has expanded several times since opening in 2008.

Automation Enters Warehousing

The new automated high-bay warehouse will add material-handling and storage capacity alongside the expanded production areas. The project follows a separate expansion announced in 2023 that added 59,000 m² of built-up area and 900 employees to the facility.

For manufacturers, combining automated warehousing with production expansion can help coordinate material flow as output increases. The approach also gives the site additional infrastructure to support higher production volumes without relying solely on additional floor space.

Building a Regional Manufacturing Network

The Monterrey investment is part of LEGO’s broader expansion across the Americas. The company is also investing more than $1.5 billion in a factory and regional distribution center in Virginia, with both facilities expected to open in 2027.

The Monterrey site’s precision manufacturing processes also remain central to production. LEGO says each brick is molded to an accuracy of 5 microns (0.005 mm) to provide the dimensional consistency needed for connections between elements.

Image credit: LEGO Group

credit: Thomas