Hyperion has joined the SCENE-B project, coordinated by Norwegian SINTEF Manufacturing, to develop a novel 3D-printed concrete material reinforced with aluminum fibers. The project has secured over €3.5 million in funding from the European Commission’s EIC Pathfinder programme, which supports the early-phase development of breakthrough technologies addressing global challenges.
Concrete, the most widely used construction material in the world, offers numerous untapped benefits, such as free-forming capabilities, excellent acoustic and structural properties, and high durability. However, it is also a significant contributor to global CO2 emissions. SCENE-B aims to create a new concrete mix with reduced cement content, compatible with aluminum fiber reinforcement and optimized for 3D printing. The project also explores the use of unwashed sea sand as a sustainable alternative to increasingly scarce river sand. Additionally, the production process will be optimized by leveraging material and design data to fine-tune production parameters. This approach facilitates the rapid deployment of highly customized prefabricated designs, ensuring both high quality and advanced customization capabilities.
To demonstrate the feasibility of this innovation, the project will produce a functional demonstrator showcasing the new concrete construction elements. The SCENE-B project will also address key aspects such as standardization and scalability, laying the groundwork for the commercialization of this innovative concrete solution.
Background information
Spanning the course of three years 2024-2027, the project, ‘Sustainable Concrete Freeforming for the New European Bauhaus’ (SCENE-B), aims to develop sustainable material and design tools with focus on additive manufacturing and automation. SCENE-B consortium consists of SINTEF Manufacturing AS (NO), SINTEF AS (NO), Mechatronics Innovation Lab (NO), Warsaw University of Technology (PL), and Hyperion robotics Oy (FI). Read more about SCENE-B project:SCENE-B
In July 2024, Hyperion Robotics, a Finnish technology company, was selected as one of 68 deep-tech startups to join the European Innovation Council’s (EIC) Accelerator programme. The funding includes a €2.37 million grant, along with equity investment from the European Union, to support the development of carbon-negative materials for the construction industry.
Founded by experts in engineering, construction, 3D printing, and robotics, Hyperion Robotics has pioneered low-carbon structural elements for the infrastructure sector. Over the past few years, the company has successfully delivered projects in water, energy, and transportation infrastructure.
To further reduce the carbon footprint of concrete structures, Hyperion is advancing carbon-negative materials designed to achieve a net-negative carbon impact. The EIC recognized the transformative potential of this innovation, awarding funding to accelerate the company’s efforts in this domain.
Concrete production accounts for 8% of global CO2 emissions, and the construction industry faces increasing pressure to meet net-zero CO2 emission targets by 2050. To address this challenge, many industry players are adopting innovative solutions like prefabricated elements, which can be efficiently produced using automation and carbon-negative materials.
Hyperion Robotics offers a groundbreaking technology poised to revolutionize the construction industry. By manufacturing green, carbon-negative structural elements that meet building codes and standards, automating production to reduce costs, and introducing a new design methodology that optimizes material usage and shortens design timelines, the company addresses critical bottlenecks in the industry.
Background information
The EIC Accelerator offers start-ups and SMEs grants of up to €2.5 million combined with equity investments through the EIC Fund ranging from €0.5 to €15 million or more. In addition to financial support, all projects benefit from a wide range of Business Acceleration Services that provide access to leading expertise, corporates, investors and ecosystem actors.
Hyperion Robotics has teamed up with sustainable building materials and construction solutions business Tarmac to bring structural 3D-printed concrete to the UK.
In partnership with fully-integrated design and build company Mott MacDonald Bentley (MMB) and Yorkshire Water, the innovation is being brought to life in a 3D-printed concrete design to replace standard applications for a major project at Yorkshire Water’s largest sewage treatment works in Esholt, near Leeds.
Following Yorkshire Water’s inaugural net zero partner event in January 2023, lead contractor MMB joined up with Hyperion and Tarmac to explore the latest sustainable construction solutions and techniques. As a result, four bespoke drawpits – traditionally heavy, box-shaped structures placed underground for the containment of electrical cabling – have been designed and put in place at Esholt thanks to the new robotic technology.
Four bespoke drawpits delivered to Yorkshire Water’s largest sewage treatment works in Esholt, near Leeds
The drawpits, which meet Eurocode standards for structural engineering, have been positioned to allow for cabling to be installed from a new motor control centre leading to a set of newly-refurbished deep bed sand filters and the site’s backwash pumping station. Together, the equipment combines to control and ensure high-quality water filtration on-site. The 3D-printed design has resulted in a 40 percent reduction in embodied carbon when compared to a conventional, in-situ drawpit.
Robert Gossling, head of commercial engineering solutions at Tarmac, said: “We’re proud to be at the forefront of innovation in the industry, meeting our customers’ needs for sustainable solutions and accelerating progress towards a net-zero built environment. Together with MMB and Hyperion Robotics, we’ve unlocked new opportunities to embrace exciting new 3D-printing technology and remote construction techniques for Yorkshire Water.”
When structurally designed 3D-concrete printing is combined with dry silo mortar factory production methods and the latest low carbon cement technology this new model offers multiple benefits. By continuing to provide expertise to Hyperion, we’re excited to explore how the key learnings from the project and how 3D-printing technology could be extended across the wider construction industry.
The collaboration has provided invaluable learnings and insights into how 3D-printing technology could be extended across the wider construction industry.
Serving 760,000 people in Bradford and Leeds, Esholt Waste Water Treatment Works is undergoing a capital improvement programme in a bid to reduce the amount of phosphorus present in treated wastewater. The initiative forms part of Yorkshire Water’s performance on environmental commitments– ensuring effluent water quality meets and exceeds the most stringent requirements.
Marc Lupton, capital delivery programme manager for Yorkshire Water, said: “This pioneering piece of technology allows us to reduce our carbon footprint and has the opportunity to replace our traditional methods of construction.”
It’s exciting to see this 3D concrete printed structure and we are looking forward to seeing how we can develop further applications for expanding its use across our Capital Programme. We’d like to thank MMB, Hyperion Robotics and Tarmac for the work they have put in to bring this together. We are always looking at innovative new technologies to help us reduce our carbon footprint as we continue our journey to net zero.”
Tom Lewis, MMB operations director, said:
Innovative ways of working are at the core of how as a business MMB commit to deliver both low carbon and low-cost solutions for our clients. It has been a pleasure for our teams to collaborate in such a fast-paced way to bring these solutions to life and look forward to the continuing partnership bringing even greater gains.
There is more than just drawpits; they are just a small part of the catalog of cost-competitive and low-carbon structures that Hyperion has developed.
Drawpits are only a small part of the catalogue of cost-competitive and low-carbon structures Hyperion has developed. Hyperion’s on-demand manufacturing approach supports the construction industry in its transition to net zero, as together we work to tackle the climate emergency.
