Get insights into the design of 43019 Football, the new set that captures the beautiful game with LEGO elements, from Model Designer Zio Chao.
LEGO Model Designer Zio Chao opens up about the process of creating LEGO Editions 43019 Football, sharing details about how he was able to capture the shape and include all the necessary details.
Building a circle out of LEGO bricks is no small feat — building a whole sphere is a nigh-impossible challenge. But giving up wasn’t an option for LEGO Model Designer Zio Chao, who had the extra challenge of having to build a sphere that is a 1:1 replica of the world’s most popular piece of sporting equipment.
When LEGO designers tackle a new project, they begin by creating various sketch models to get a feel for what the product could look like. The sketches help the designers to understand not just what’s possible within the LEGO System, but what makes sense to include in a set, especially one that’s 10+ like 43019 Football.
“I did several different sketches,” Zio shares. “One is really close to the real football structure, using pentagons. And this structure is strong enough, but it’s too difficult to be built by the target audience. It’s also really hard to show in the instructions, plus it will cost a lot. So that’s why we needed to find another solution.
“So we talked about how to make a better ball for our LEGO football and we found a different design that’s easier to achieve for us and for the fan builders. I also did some research on 21332 The Globe, and this ended up being a little similar, but still different. We used the dish elements because the dishes already have some curvature to cover every side panel. I was quite surprised we can achieve something so curved in a LEGO product.”
With such a challenging shape to capture with LEGO bricks and Technic elements, it’s natural to expect to need some new pieces. Designers are limited in what they can request for a set, as it raises costs and the LEGO System is always expanded with deliberate intention. But for Zio, this turned out not be an issue. “We do have some colour changes,” Zio says, “but we don’t have any new moulded elements. Only new decorations and colours.”
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Having figured out how to create a sphere that can reasonably be built by the set’s target age range, Zio now had the task of adding a little extra flare to the model. Ordinarily, footballs are pretty surface-level affairs — the exterior is all you’re every really going to see. This is not the case with 43019 Football: There’s a hidden scene on the inside, revealed by opening up a section of the exterior panels.
“Why did we need to put something inside?” Zio smiles. “I think it’s always fun to have some surprise when you open something, and it adds more value to a display model. In the beginning, it was too difficult to open it. After we changed to the different structure, it helped us to make it something that can have a hatch.”
As for the scene that’s included — a team hoisting the championship trophy — it was always an easy decision for Zio to have that be the secret surprise.
“We made several sketches for the small stadium, but we always thought, ‘what’s the best moment in football?’ I think that’s when the team has the championship. So they are celebrating.”
With a completed, 1:1 build, there was one question that Zio knew builders would have: Can the LEGO football be kicked?
“We actually have a sticker here,” Zio laughs, pointing to a decoration on the football, “that says you can’t kick it. Only for display. We did not do a kick test.”
Even still, fans young and old alike might not be able to resist giving 43019 a test on the pitch. Though Blocks assumes no responsibility for any broken sets or lost pieces.
43019 Football is set to release on March 1, 2026, alongside 43020 FIFA World Cup Official Trophy as part of the new LEGO Editions theme. To find out what the designer of the trophy had to say about his experience with the set, check out this article.
And if you’re interested in purchasing either of the sets when they become available, please consider doing so via our affiliate links to help support the work we do here at Blocks, online and in print.
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