LEGO Reveals Krusty Burger Set Design Process

The Krusty Burger set is every health inspector's worst nightmare, featuring iconic items like the infamous Ribwich, The Clogger, and Principal Skinner’s so-called "Steamed Hams." This LEGO creation includes seven minifigures: Krusty the Clown, Sideshow Bob, Homer Simpson, and Officer Lou among them. Priced at $209.99, it launches June 4, but LEGO Insiders get early access starting June 1. Sign up for free membership here.

LEGO The Simpsons: Krusty Burger

Available June 1 for LEGO Insiders, June 4 for all. $209.99 at LEGO Store.

To uncover the behind-the-scenes development, we spoke with Ann Healy, the senior designer behind the set. A LEGO veteran of six years, Healy shares insights on creating the first Simpsons-themed LEGO set in nearly ten years.

What other LEGO projects have you designed?

Healy: I spent three years on the LEGO Friends line before tackling Disney favorites like The Sanderson Sisters’ Cottage from Hocus Pocus—a passion project years in the making. Currently on the LEGO Icons team, I designed last year’s McLaren MP4/4 & Ayrton Senna and the Poinsettia LEGO Botanicals set.

Why revive The Simpsons LEGO line now?

Healy: Despite the decade-long gap, fan enthusiasm remained strong. Market research confirmed global brand loyalty, making Krusty Burger a natural revival piece. Plus, it allowed us to introduce never-before-seen minifigures.

Fun fact: The original Simpsons House and Kwik-E-Mart sets were among my last personal LEGO purchases before joining the company. During my first week, I stumbled upon an early Krusty Burger prototype—proof designers often tinker with personal projects hoping they’ll become official sets. Five years later, that shelved prototype got greenlit, and I jumped at the chance.

Walk us through the design process. How many iterations were needed?

Healy: I refined the prototype digitally first, testing layouts and instruction flows before physical builds. Collaboration was key—feedback came from our Creative Lead, IP partners, and internal teams reviewing construction steps and durability. While I lost count, I’d estimate rebuilding it at least 20 times. The final build was for quality assurance using production samples.

Unlike Moe’s Tavern or the Simpsons’ house, Krusty Burger lacks consistent on-screen detail. How did you source references?

Healy: Disney provided assets, but I binge-watched episodes for accuracy. Key inspirations include Season 20’s "Coming to Homerica" (featuring the Mother Nature Burger) and Season 14’s "I'm Spelling as Fast as I Can" (showcasing the Ribwich). Other nods:

• Season 6’s "Homie the Clown" – Homer performs at Krusty Burger.
• Season 12’s "Day of the Jackanapes" – Bart and Sideshow Bob visit.
• Season 10’s "Lard of the Dance" – Homer sells grease.
• Treehouse of Horror XX" – Zombie outbreak at Krusty Burger.

Favorite hidden Easter egg?

Healy: The drive-thru screen shows an order for 700 burgers—a callback to Season 5’s "Boy-Scoutz 'n the Hood," where Krusty opens an ill-advised oil-rig location.

Biggest design challenge?

Healy: Perfecting Krusty’s oversized sign. The IP partners scrutinized his facial proportions, even supplying hand-drawn sketches. A colleague’s illustration background helped nail his features in bricks. Stabilizing the heavy sign on a single axle required a prototype axle sleeve—now a new LEGO element.

Is this a one-off or the start of more Simpsons sets?

Healy: While I can’t confirm future plans, I’m optimistic fans will love this revival.

LEGO The Simpsons: Krusty Burger (Set #10352) includes 1,635 pieces for $209.99. Launching June 4 (June 1 for Insiders). Join LEGO Insiders free here. Stay tuned for our hands-on review later this month.