BIRMINGHAM, Mich. — A Boeing engineer’s garage-built LEGO model of the International Space Station has drawn attention from NASA, turning a personal project into a showcase at a major industry event.
Doug Hughes, a product development engineer at Boeing Commercial Airplanes, spent about 18 months building an 8-foot-wide, 1:42-scale model of the ISS. The structure is composed primarily of LEGO components, along with painted cardboard solar panels and a metal support frame.
Hughes said he was drawn to the project as a way to complete a design from start to finish, in contrast to his day-to-day work, where projects are often handed off to other teams.
“Why do I build LEGO models? Well, I like having something tangible that I’ve created and completed,” Hughes said.
The build process included physical mock-ups, sketches and digital modeling, mirroring engineering workflows used in aerospace product development. Hughes also incorporated moving elements into the design, including rotating solar panels and a traversing mobile base system.
He previously used LEGO Technic components to study the kinematics of a landing gear concept, an exercise he said highlighted the complexity of aerospace systems.
“To tell you the truth, we found it incredibly difficult to recreate the complex gear design developed by our mechanical systems friends, and it gave me a much deeper appreciation for the incredible work they do,” Hughes said. “It also inspired me to tackle more ambitious moving LEGO projects in the future.”
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After Hughes shared the project on Instagram, NASA invited him to display the model at a “25 Years of Human Presence on the ISS” celebration in Houston. The event included NASA personnel, international partners and industry representatives.
Hughes said the display led to detailed discussions with engineers and provided an opportunity to tour NASA facilities.
“The trip was one of the most unique and fun experiences in my life,” Hughes said. “It was a happy convergence where my favorite hobby … let me geek out with like-minded NASA engineers at their incredible facilities.”