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Category: Collaboration

Hyperion Robotics partners with National Grid and the University of Sheffield to run UK-first 3D-printed low-carbon sub-station trial

Posted on by Fernando

Hyperion Robotics, the technology company driving smarter, faster and greener construction, has entered an innovative partnership with National Grid in a UK-first trial to manufacture, install and test low-carbon 3D-printed substation foundations.

The innovation has the potential to reduce construction-driven carbon emissions and reduce costs to consumers of network construction, and, if rolled out across National Grid substations, could save up to 705 tons of concrete and 323 tons of CO2 and deliver £1.7 million in consumer savings versus traditional methods over a 10-year period.

National Grid is trialling Hyperion Robotics’ cutting-edge technology and design expertise for use on its infrastructure. This collaboration aims to optimise grid development through the automated production of low-carbon foundations.

The low-carbon foundations will be designed and produced in Finland by Hyperion Robotics and tested for serviceability by the University of Sheffield. Further field testing will then be carried out at National Grid’s state-of-the-art testing facility, the Deeside Centre for Innovation in North Wales, later in 2025.

First batch of low-carbon foundations for National Grid delivered to University of Sheffield

The 3D printed foundation’s optimised design saves 70% of the material, resulting in 80% less soil displacement and reduced weight for easier transportation. Throughout the lifecycle from design to installation, 65% less CO2 is produced.

Despite using fewer materials, Hyperion Robotics’ foundations have been proven four times stronger than traditional methods. Previous on-site structural tests of printed specimens have demonstrated significantly higher resistance compared to conventional foundations, ensuring enhanced durability and long-term reliability. Hyperion Robotics’ approach to Design for Manufacture and Assembly (DfMA) reduces site operative hours by 50%, streamlining production and minimising the risks associated with manual labour.

Fernando De los Rios, Hyperion’s CEO and founder, commented, “Collaborating with National Grid, one of the world’s largest utility companies, marks a pivotal moment for Hyperion Robotics as we advance our mission to help the industry build smarter and greener. This partnership accelerates our efforts to decarbonise the construction sector through cutting-edge engineering and low carbon 3D-printed concrete structures.  Through this collaboration, National Grid is setting an inspiring global benchmark for innovation and sustainability in the energy sector.”

Dr Muhammad Shaban, Lead Innovation Engineer at National Grid Electricity Transmission, said: “Our collaboration with Hyperion Robotics is a real step forward in achieving more innovative construction practices which align with our bold and ambitious commitments on sustainability. This trial of low-carbon 3D printed alternatives to concrete for substation foundations is the first of its kind in the UK, and has the potential to transform construction activities across the industry. The project has been funded by Ofgem’s Network Innovation Allowance, which provides an allowance to energy network licensees to fund innovation projects that have the potential to deliver longer term financial and environmental benefits for consumers.”

Dr. Behzad Nematollahi, Lecturer in Concrete Technology at the University of Sheffield at the University of Sheffield, said: “We are delighted to be collaborating with Hyperion Robotics and National Grid on this innovative project. To ascertain the load-bearing capacity of the 3D-printed concrete foundations, we will conduct full-scale testing using state-of-the-art engineering testing facilities at the Intelligent Infrastructure Laboratory located at ICAIR, the Integrated Civil and Infrastructure Research Centre at the University of Sheffield.”

The project has been funded by Ofgem’s Network Innovation Allowance, which provides an allowance to energy network licensees to fund innovation projects that have the potential to deliver longer term financial and environmental benefits for consumers.

For more information or to explore potential partnerships, contact contact@hyperionrobotics.com.

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Hyperion Robotics partners with Norwegian SINTEF manufacturing to develop next generation low-carbon concrete

Posted on by Fernando

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

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Hyperion Robotics secures over €2.3 million in funding from the EIC Accelerator programme to advance carbon negative construction

Posted on by Fernando

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.

Read more about the program here

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Pioneering 3D-printed innovation for water industry delivers major carbon savings

Posted on by Fernando

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
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.

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The collaboration has provided invaluable learnings and insights into 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.

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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.
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.

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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.

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