PROJECT INFORMATION
Location
UK
Client
National Grid
Year
2025
Project Duration
10 months
Water Sector
National Grid partnered with Hyperion Robotics to develop and validate the UK’s first 3D-printed substation foundations, supporting faster grid delivery while reducing material use and embodied carbon. The programme focused on proving that additively manufactured foundations can meet the structural and operational demands of transmission-scale infrastructure.
Hyperion designed and manufactured a series of full-scale foundation units using its automated 3D-printing process, optimising geometry to remove unnecessary mass while maintaining structural integrity. The foundations were produced offsite to ensure consistent quality, reduce on-site labour requirements and enable repeatable deployment across multiple substation layouts.
To validate performance, the system underwent a comprehensive programme of laboratory and field testing in collaboration with leading engineering partners. Full-scale structural tests assessed tension and overturning behaviour under controlled conditions, followed by on-site load verification to confirm real-world suitability.
The results demonstrated strong structural performance alongside significant material and carbon reduction potential. The trial marks an important step toward scalable, lower-carbon foundation solutions for the UK electricity transmission network.
