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Cutting carbon from the ground up: the hidden opportunity beneath our infrastructure

Posted on by Phuong Ngo Pitkänen

The race to decarbonise infrastructure has reached new heights, but the biggest opportunity lies underground.

The global drive to reach net zero is reshaping the construction industry. Energy networks are expanding, renewable projects are accelerating, and governments are demanding measurable progress on sustainability. Yet while much attention is focused on greener power generation and cleaner materials, one area remains largely invisible – literally.

The foundations beneath our infrastructure are among the most carbon-intensive and least-innovated parts of construction. At Hyperion Robotics, we believe that to truly transform the built environment, we must start by cutting carbon from the ground up.

The carbon blind spot beneath our feet

Concrete is the world’s most used construction material – second only to water – and accounts for around 8% of global CO₂ emissions. A large proportion of that impact comes from cement production, which releases carbon both through energy use and the chemical process of calcination.

While the industry has made progress in reducing emissions through supplementary materials and alternative binders, most innovation has focused on the visible parts of our structures: superstructures, facades, and finishes. Meanwhile, the substructures – the foundations, footings, and plinths – continue to rely on traditional, high-carbon concrete methods.

These elements may represent a small share of total project cost, but they can account for over half of the embodied carbon in a construction site. Every kilometre of buried cable route, every substation, and every wind or solar installation rests on tonnes of concrete that often go unnoticed, but not unaccounted for in the climate challenge.

This is the carbon blind spot of the infrastructure industry. And it’s where the biggest potential for change lies.

Why foundations matter in the race to net zero

Infrastructure owners are under increasing pressure to decarbonise at pace while keeping projects on time and budget. The challenge? Traditional concrete practices are slow to adapt, and the supply chains that feed them are energy-intensive, resource-heavy, and difficult to decouple from carbon.

By addressing the foundation stage, project teams can achieve immediate, measurable carbon savings without disrupting above-ground design or long-term performance.

Foundations are where every project begins, making them the logical place to start a systemic shift toward low-carbon construction. Once a foundation’s carbon footprint is reduced, every other stage of the build becomes cleaner by extension.

Learn more about Hyperion’s role in decarbonising infrastructure

 across utilities, energy, and industrial sectors.

Engineering the change: smarter foundations for a sustainable future

At Hyperion Robotics, we’ve reimagined how foundations are designed, manufactured, and installed – combining robotic 3D printing, low-carbon concrete, and data-driven engineering to create a new standard in sustainable infrastructure delivery.

Our approach replaces the traditional “cast and cure” method with an automated system that produces precision-engineered foundation elements tailored to each project’s structural and geotechnical needs.

The benefits are significant

  • Up to 70% reduction in CO₂ emissions compared to conventional methods
  • Up to 50% cost savings through shorter installation times and reduced logistics
  • Enhanced durability and performance, with proven compliance to structural codes

By optimising design and fabrication simultaneously, Hyperion eliminates unnecessary bulk while maintaining, and often improving, load-bearing capacity. Each foundation is engineered for strength, resilience, and sustainability.

For an overview of our latest technology and process, see our 3D printing for infrastructure page.

Invisible, yet transformative

Foundations are rarely seen, but they carry enormous influence over a project’s environmental footprint. By transforming this unseen layer of infrastructure, we can make meaningful progress toward industry-wide decarbonisation.

Consider a typical renewable energy site. Thousands of support bases and cable route foundations are poured in concrete, each contributing to embodied carbon. By applying Hyperion’s technology across a single project, hundreds of tonnes of CO₂ can be eliminated without changing the design intent or operational outcomes.

That’s not just a sustainability win; it’s a commercial advantage. Faster fabrication, fewer materials, and simplified logistics translate to shorter construction programmes and lower costs – benefits that compound across multiple assets and project phases.

For infrastructure owners managing tight timelines and net-zero targets, these efficiencies make a tangible difference. Read more about how we deliver results in our case studies.

From proof to performance: building confidence through data

Innovation in construction often faces scepticism. That’s why Hyperion’s approach is grounded in engineering evidence and compliance assurance.

Our low-carbon concrete formulations are tested against established structural codes and standards, ensuring safety and long-term performance. Every printed foundation is verified through digital design models and performance data, offering traceable, transparent assurance that sustainability doesn’t come at the cost of reliability.

We work with partners across energy, utilities, and transport to integrate our technology into real-world applications – from pilot installations to full-scale deployments – generating the data and trust needed for adoption at scale.

Explore our ongoing work with National Grid to see this approach in action.

A foundation for the future

The path to net zero requires more than incremental improvement; it demands a rethink of how we build from the ground up.

By starting with foundations, we can achieve faster, smarter, and more sustainable progress across every type of infrastructure – from renewable energy sites to data centres, power networks, and beyond.

The invisible parts of construction are now becoming the most impactful. And that’s exactly where Hyperion Robotics is focused: building what you can’t see, for the future you will.

3D printing construction procurement checklist: How to choose the right partner in the UK

Posted on by Phuong Ngo Pitkänen

Purchasing new technology for construction projects can be complex. With the rise of 3D printing or Additive Manufacturing (AM), procurement professionals are faced with an opportunity and a challenge. How do you select the right partner to deliver 3D printed structures that meet your project’s specifications, timeline, and sustainability goals?

This guide walks you through the essential criteria for choosing a 3D printing construction supplier in the UK. Importantly, we focus on suppliers that provide finished 3D printed structures for installation, rather than companies selling 3D printers for in-house production.

What type of projects benefit the most from 3D printing

3D printing is particularly effective for projects that:

  • Must meet sustainability or net-zero goals.
  • Demand customisation for specific client needs.
  • Involve site constraints which traditional cast in-situ or precast cannot cope with
  • Require rapid design changes without the cost and lead time of of traditional construction methods

For procurement professionals, these factors highlight the strategic advantage of 3D printing: flexibility, speed, and precision, all while supporting sustainable practices.

Benefits of partnering with a 3D printing construction expert

Aligning with your net zero goals

The UK government’s Construction 2025 strategy sets out ambitious targets for transforming the industry, aiming to reduce both the initial and whole-life costs of built assets by a third, accelerate project delivery by 50%, and cut greenhouse gas emissions from construction by half. Achieving these goals requires more than incremental improvements — it demands innovation at every stage of the building process.

By adopting Modern Methods of Construction (MMC) such as 3D printing, project teams can make significant strides toward these benchmarks. 3D printing minimises waste by using only the material required, reduces reliance on carbon-intensive supply chains, and allows for the incorporation of sustainable or recycled materials.  At Hyperion Robotics, our 3D-printed structures have been shown to cut 30–50% of CO₂ emissions across our projects, demonstrating a measurable impact on environment and sustainability.

Customised for your project requirements

Every project comes with its own challenges, from design complexity to site constraints. Traditional construction often requires compromises, but 3D printing opens the door to complete flexibility. Designs can be adapted with precision to meet functional requirements and technical specifications without the need for costly modifications later. 

Beyond meeting immediate design goals, this adaptability also enables long-term optimisation. Structural elements can be fine-tuned for durability and material efficiency, ensuring that the final build aligns with both the client’s vision and sustainability objectives. By combining precision, flexibility, and efficiency, 3D printing empowers project teams to tackle unique challenges head-on and deliver solutions that are truly tailored to the demands of each project.

Accelerating project timelines while maintaining quality

Time delays are a persistent challenge in the UK construction sector. According to BCG research, many major infrastructure projects in the UK are delivered on average 20–30% slower than comparable projects in other advanced economies, highlighting inefficiencies in planning, coordination, and execution.

3D printing construction offers a solution to this challenge. By automating key building processes and producing components off-site, 3D printing can significantly reduce construction time while maintaining consistent quality standards. Faster assembly, fewer errors, and reduced reliance on complex supply chains help projects stay on schedule, cutting both delays and costs.

A straightforward process from design to delivery

One of the greatest strengths of 3D printing is the simplicity it brings to the construction journey. The process integrates design, production, and delivery into a single streamlined workflow. Once the design is finalised, the printing and assembly follow a predictable and efficient path, reducing the risk of miscommunication or unexpected challenges. For clients, this means greater transparency, fewer delays, and a more straightforward experience from start to finish. Ultimately, it enables project teams to focus on innovation and quality rather than administrative hurdles.

In our case study with Killinghall, from design approval to completion, the entire process took just days. Once transported to the site, installation was completed in just one day, minimising disruption and ensuring a safer, more streamlined process.

6 strategic questions that build a stronger business case for 3D printing infrastructure

Posted on by Phuong Ngo Pitkänen

3D printing is rapidly moving beyond a niche technology to become a practical, sustainable alternative to conventional construction methods. The time has come to move beyond R&D labs and place 3D printing firmly on the boardroom agenda. Adoption and scaling of additive manufacturing should be a strategic priority at the executive level, as leadership is critical in unlocking its full value across the organisation.

In 2024, conventional on-site construction still accounts for 91.2% of the market, while Modern Methods of Construction (MMC), including 3D printing, are projected to grow at a 10% CAGR. Although traditional methods dominate today, MMC is expanding rapidly, signalling a significant shift in how buildings and infrastructure will be delivered in the near future.

One of the biggest challenges in adopting 3D printing is identifying the right business case. This article will focus on hard business value, asking the critical questions that can turn 3D printing from an experimental tool into a genuine competitive advantage.

1. What is the total cost of NOT adopting 3D printing?

Initial capital expenditure is often the first consideration when evaluating 3D printing. However, it is equally important to assess the long-term costs of sticking with traditional methods.

Construction consistently faces project delays.  According to BCG research, many major infrastructure projects in the UK are delivered on average 20–30% slower than comparable projects in other advanced economies. Meanwhile, the UK construction sector is grappling with severe workforce shortages, losing approximately 50,000 workers annually, compounded by high apprenticeship attrition, reduced EU labour mobility post-Brexit, and an ageing workforce anticipating half a million retirements over the next fifteen years.

Additionally, construction remains a significant contributor to waste, accounting for 32% of landfill in the UK, and continues to rely heavily on international supply chains. 

In contrast, 3D printing reduces risks associated with delivery, logistics, and labour dependency. Each missed opportunity to adopt modern methods represents a hidden cost. At Hyperion Robotics, we have demonstrated project cost savings of up to 30%, three times faster delivery and 70% less CO2 emission through additive construction.

 2. How does 3D printing accelerate revenue opportunities?

In construction, “speed is money”.  The speed at which projects are delivered directly influences profitability, cash flow, and competitive advantage. Advanced 3D printing technology is redefining these dynamics by achieving levels of efficiency and continuity that traditional methods cannot match.

Unlike conventional construction, which is often constrained by labour intensity, design, and weather conditions, automated 3D printing delivers rapid, scalable, and precise results. It adapts seamlessly to both high-volume projects and bespoke components, offering contractors and asset owners new ways to accelerate delivery while maintaining quality.

At Hyperion Robotics, we have already proven these advantages through multiple 3D printed reinforced concrete foundations. A standout example is our Killinghall project, where complex chamber structures were completed in just one day — a dramatic improvement on the three-week timeline associated with conventional construction. This not only demonstrated our technological capability but also highlighted the operational and financial benefits of additive manufacturing.

By requiring minimal on-site manpower and only a small HIAB for assembly, we streamlined the process while upholding strict safety standards. The result was lower costs (30%), reduced site disruption, and faster program timeline (94%) — all of which translate into stronger margins for contractors and earlier revenue generation for asset owners.

In an industry where every day saved impacts financial performance, 3D printing represents more than an efficiency gain; it is a strategic enabler for competitiveness, resource optimisation, and accelerated revenue realisation.

3. What competitive advantages can we unlock by investing in 3D printed infrastructure before our rivals do?

Early adoption of 3D printing delivers more than operational efficiencies — it provides a tangible market advantage. Contractors who integrate additive manufacturing into their workflows can deliver projects faster, customise designs at scale, and offer innovative solutions that differentiate them in bids.

Being a first mover allows companies to develop internal expertise and best practices, creating barriers to entry for competitors who are slower to adopt. It also strengthens brand reputation, positioning the company as a technology leader in modern construction, which can attract new clients, partnerships, and investment.

Additionally, early adopters benefit from learning curve effects, reducing production costs, improving workflow efficiency, and uncovering additional revenue streams — such as offering specialised 3D-printed components to other projects or partners.

4. How does 3D printing support ESG and sustainability goals?

Environmental, Social, and Governance (ESG) considerations are increasingly central to procurement, financing, and regulatory compliance in construction. 3D printing directly supports these objectives:

  • Waste reduction: Additive manufacturing places material only where it is needed, minimising waste through robotic precision. In the Esholt Treatment Works project, Hyperion Robotics’ redesigned cylindrical approach reduced concrete use by 10 cubic metres – a 50% material saving on specific elements.
  • Lower carbon emissions: On-site or near-site production reduces transport emissions associated with moving heavy materials. At Hyperion Robotics, our 3D-printed structures have been shown to cut 30–70% of CO₂ emissions across our projects, demonstrating a measurable impact on environment and sustainability.
  • Material innovation: 3D printing can incorporate recycled or low-carbon materials. The EU has funded our research into developing carbon-negative materials designed to produce elements with a net-negative carbon impact.
  • Circularity: Components can be redesigned for reuse or recycling at the end of their lifecycle.

By embedding additive manufacturing into projects, companies demonstrate measurable ESG outcomes, which can strengthen stakeholder confidence, meet regulatory expectations, and improve access to sustainable financing. 

Partner with Hyperion Robotics to turn these sustainability ambitions into practical results on every project.

5. How ahead in the game is our current construction setup compared to one integrated with 3D printing?

Construction markets are evolving rapidly. Clients increasingly demand customisation, faster delivery, and innovative solutions, while regulations and standards continue to shift. Traditional methods are often rigid, making adaptation costly and time-consuming.

3D printing infrastructure ensures flexibility and scalability. Additive manufacturing can be integrated seamlessly into the existing workflow, allowing for rapid iteration on designs, adoption of new materials, and modular construction approaches — all of which enhance long-term competitiveness.

Companies that fail to integrate additive manufacturing risk technological obsolescence, reduced responsiveness to client needs, and higher operational costs over time. Conversely, embracing 3D printing today lays the foundation for a resilient, adaptable, and future-ready construction capability.

6. Are we asking the right questions to fully utilise 3D printing?

A successful business case for 3D printing goes beyond technology;it evaluates financial impact, operational alignment, talent and resource requirements, ESG benefits, and market positioning. Contractors should assess:

  • Do we have the internal expertise to deploy 3D printing, or should we partner with specialists?
  • Which projects will benefit most from additive manufacturing?
  • How can digital inventory and on-demand production streamline our operations?
  • What sustainability goals can be achieved through adoption?
  • How can early adoption secure long-term competitive advantage?

By answering these questions, contractors can transform 3D printing from an experimental tool into a core capability that drives growth, efficiency, and profitability.

Pioneering the future with 3D Concrete Printing

At Hyperion Robotics, we believe in building the future of construction together – smarter, faster and greener. Contractors who champion 3D printing today will accelerate delivery, reduce costs, and strengthen resilience, while positioning themselves as market leaders in innovation and sustainability.

Next steps:

  1. Identify where 3D printing can deliver the most value across your projects.
  2. Assess internal capabilities and explore partnerships for rapid implementation
  3. Integrate additive manufacturing into strategic planning, ESG goals, and operational workflows.

By taking action now, contractors move from observing the future of construction to shaping it, unlocking tangible benefits for both clients and their own business.

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Modernising the UK’s water sector through smart infrastructure and 3D printing

Posted on by Phuong Ngo Pitkänen

Water companies are not like other businesses. They operate critical infrastructure that underpins public health, community wellbeing, and economic resilience. As major landowners and environmental stewards, they manage the rivers and seas that supply drinking water to over 28 million homes and businesses, while ensuring wastewater is treated and returned safely to the environment.

For asset owners, the imperative is clear: ageing assets must be renewed and modernised to maintain reliability and efficiency in the face of intensifying customer demand. This calls for smarter, low-carbon infrastructure, tailored to the specific needs of different communities and operational environments. Advanced manufacturing, including 3D printing, can accelerate delivery, enable customised designs, reduce material waste, and create assets that are both more sustainable and adaptable.

Hyperion Robotics specialises in delivering low-carbon 3D-printed chambers that can be used in water treatment plants. By combining smart design, DfMAs, and cutting-edge manufacturing techniques, we help asset owners modernise ageing infrastructure faster, more efficiently, and more sustainably. Our approach produces bespoke, resilient assets that meet unique operational requirements while minimising environmental impact.

Challenges facing the UK’s water sector

The UK water industry is facing mounting pressures as ageing infrastructure, rising demand, and environmental impacts converge to challenge its long-term sustainability. Much of the country’s water network – pipes, treatment plants, and reservoirs – is over 100 years old. At the current rate of replacement, it would take an astonishing 700 years to fully renew the system. This ageing infrastructure contributes to high levels of leakage, with around 1 trillion litres of water lost annually, equivalent to 19% of the total supply.

At the same time, demand for water continues to grow. The UK abstracts 18 billion tonnes of water annually from rivers, reservoirs, and aquifers, with domestic use accounting for six billion tonnes. Industry consumes 2.1 billion tonnes, electricity generation 9 billion tonnes, and agriculture 0.2 billion tonnes. Population growth, urbanisation, and increasing industrial activity are driving this demand upward, creating pressure on already stretched resources.

Meeting these challenges requires investment in sustainable water infrastructure—systems that not only replace ageing assets but also improve efficiency, reduce leakage, and adapt to future demand. Embracing innovation in smart infrastructure such as smart monitoring, digital twins, and low-carbon technologies will be essential to tackling these challenges and securing a resilient, reliable, and sustainable water system for the future.

Enter smart infrastructure

Smart infrastructure uses sensors, automation, and data-driven management to enhance essential systems – including water networks – enabling intelligent operation, improved service delivery, and better resource management.

Within this context, 3D-printed water infrastructure represents a significant opportunity. By combining smart design, robotic precision, and process optimisation, 3D printing allows construction of water system components with lower CO₂ emissions and faster delivery timelines. This approach not only addresses ageing assets but also supports increasing demand in a sustainable and cost-effective way.

Digitally enabled methods like 3D printing offer the water industry several advantages:

  • Automate and accelerate prefabrication of reinforced concrete structures
  • Customise and standardise components using parametric design
  • Reduce on-site labour and disruption through off-site production and plug-and-play installation
  • Enhance traceability and quality control with data-rich digital workflows

By integrating 3D printing into infrastructure programmes, the asset owners gain greater control over time, cost, and carbon -key priorities as the sector modernises.

Evidence in action: How 3D printing delivers for water infrastructure

3D printing in water infrastructure has moved well beyond the proof-of-concept stage. Across Europe and the UK, early adopters are generating measurable results that demonstrate the technology’s potential to transform how utilities build, maintain, and upgrade critical assets.

One notable example is Hyperion Robotics’ work with Yorkshire Water, where four cylindrical drawpits were delivered for the utility’s largest treatment facility. By replacing the traditional box-shaped design with an optimised cylindrical form, Hyperion achieved significant engineering and environmental gains. The design, better at resisting soil pressure, used 50% less material – saving 10 cubic metres of concrete – while maintaining full strength and functionality.

The benefits are wide-ranging. 

  • Carbon savings: Embodied carbon was cut by 40% (a saving of 2,630 kg CO₂) by reducing concrete and steel reinforcement and eliminating the need for formwork. 
  • Speed: The project was delivered in just two months – 70% faster than conventional methods – and each drawpit was printed in only two hours. 
  • Reduction in labour: Off-site manufacturing minimised on-site labour, reduced safety risks, and allowed installation to be completed in under two days. 
  • Cost savings reached 30% compared to cast-in-situ methods, driven by faster production, lower material use, and streamlined logistics.

Furthermore, the hybrid structures combined 3D-printed concrete faces with reinforced concrete cores, built to EN1990 and EN1992 standards. 

Not only that but Hyperion’s parametric design tools allowed for last-minute adjustments without delaying production, showcasing the flexibility of digital manufacturing.

This project earned Hyperion Robotics multiple awards, including Technology Solutions Provider of the Year, and demonstrated how advanced technology, precision engineering, and sustainable practices can be applied to modernise water assets. 

By delivering lower carbon, faster timelines, and greater efficiency, 3D printing is emerging as a powerful tool for tackling ageing infrastructure and meeting the rising demand for reliable water services.

Unlock net-zero water future with us 

Achieving a net-zero water future requires smarter, more sustainable solutions for ageing infrastructure and growing demand. 

Hyperion Robotics helps water utilities and asset owners harness 3D printing to modernise assets, cut carbon emissions, reduce material use, and accelerate project timeline. Our team of engineers, designers, and project managers can guide you in selecting the right pilot, aligning with operational and regulatory standards, and delivering measurable impact, turning ambitious sustainability goals into actionable results.

Get in touch to explore a pilot project and start building smarter with Hyperion Robotics.

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Smarter, safer, faster: a practical guide to DfMA in construction

Posted on by Phuong Ngo Pitkänen

The construction and infrastructure sector stands as one of the UK’s largest sources of employment and a key contributor to national economic growth. But, it’s under strain. A growing backlog of critical projects, an escalating shortage of skilled workers, and shrinking delivery capacity are stretching teams thin. Add to this persistent delays, razor-thin margins, and one of the most complex and high-risk working environments of any industry, and it’s clear something needs to change. 

But with every challenge comes an opportunity to build better.

At Hyperion Robotics, we believe the future of construction lies in a smarter approach: one rooted in Design for Manufacture and Assembly (DfMA) and powered by advanced robotics. 

Borrowed from automotive and aerospace industries, DfMA helps us rethink how buildings are designed and delivered. Instead of the usual unpredictability on-site, we bring precision off-site, making projects faster, safer, and more sustainable, and more predictable.

With the UK facing growing pressure to hit environmental goals and deliver big infrastructure projects, DfMA offers a smarter, cleaner, and more reliable way to build for the future.

What is Design for Manufacture and Assembly (and why is it a game-changer for construction)?

Design for Manufacture and Assembly (DfMA) is a design philosophy that simplifies how components are made and assembled. It’s all about thinking ahead – optimising designs so they can be manufactured efficiently in controlled environments, and then assembled with ease on site. 

Originally pioneered in the aerospace and automotive industries, DfMA is now gaining momentum in construction, where the stakes are higher and inefficiencies more costly. 

By tackling smart design with off-site manufacturing, DfMA helps tackle many of the industry’s most persistent challenges, from cost overruns and delays to safety risks and material waste. 

And the UK Government is backing it. Its Construction 2025 strategy sets out bold goals: 

  • 33% reduction in the initial and whole-life costs of built assets
  • 50% faster delivery of projects
  • 50% reduction in greenhouse gas emissions associated with construction

DfMA is key to achieving them.

What are the benefits of adopting DfMA in construction?

Minimising waste with smarter design

The construction industry is one of the UK’s biggest waste contributors, accounting for 32% of landfill waste. DfMA combats this by using smarter design, reducing over-ordering, and ensuring efficient use of materials. Off-site processes mean what little waste is produced can be recycled more easily. 

Using tried-and-tested, digitally validated designs

DfMA relies on pre-validated digital prototypes, which are designs that have been tested and refined in virtual environments before any physical work begins. This allows teams to identify and resolve clashes early, rehearse construction sequences, and plan logistics thoroughly. This ensures a “right first time” approach, avoiding costly on-site surprises and smoother handovers.

Consistent, repeatable quality

Manufacturing components in a controlled environment leads to consistent, repeatable quality. Research shows that off-site production environments significantly outperform traditional sites in terms of quality assurance and defect rates. For example, prefabricated structural elements, such as floor slabs or wall panels, are produced to exact tolerances, ensuring uniform performance across hundreds of units.

Reduced on-site time and labour risk

Studies by the UK’s Construction Innovation Hub suggest that modular construction can shift up to 80% of site activity off-site. This means fewer high-risk activities like working at height or in hazardous conditions, and shorter build times overall. 

Accelerated construction timelines

The integration of DfMA and modular construction can cut project timelines by 50% to 90% compared to traditional methods. This has enormous implications for sectors like housing, healthcare, and infrastructure, where speed of delivery is critical.

DfMA and sustainability: Hitting your targets without compromise 

For contractors, meeting sustainability targets is no longer a “nice to have”, it’s a project requirement. 

That’s where DfMA comes in.

By moving construction activities off-site, DfMA gives contractors more control over material usage, energy consumption, and waste management. Fewer deliveries, less on-site equipment, and shorter timelines all contribute to a smaller carbon footprint from day one. 

Most importantly, DfMA makes it easier to stay ahead of evolving regulations around embodied carbon and resource efficiency, saving time on compliance and strengthening bids for future work.

In short, DfMA makes sustainable construction scalable, without sacrificing cost or speed. 

Case Study: DfMA in action with Hyperion Robotics for Yorkshire Water 

When Yorkshire Water needed to deliver a major treatment facility with tight carbon and time targets, it turned to us. 

By combining Modern Methods of Construction (MMC) and DfMA,we delivered four cylindrical drawpits with: 

  • 40% lower embodied carbon emissions, saving 2,630 kilograms of CO2. 
  • 50% material reduction, (10 cubic metres less concrete) 
  • 70% faster delivery (from 6 months down to 2)
  • 30% cost savings compared to conventional cast-in-situ methods
  • Minimal on-site labour, reducing the risks associated with working 2.5 metres underground. 

The result? A safer, cleaner, faster project, delivered on time and under budget.

Ready to build better? 

The future of construction isn’t just coming; it’s already here. And at Hyperion Robotics, DfMA is at the core of how we design and deliver projects. We help clients unlock:

  • Shorter build times
  • Lower emissions and material use
  • Improved safety and site performance 

Whether you’re delivering infrastructure, utilities, or commercial projects, we’re here to help you build smarter.

Accelerate your next project with sustainable, scalable design.  Contact us today.

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Why 3D printed foundations are the future of infrastructure construction

Posted on by Fernando

There’s a quiet revolution unfolding beneath our feet and it’s emerging layer by layer.

As infrastructure owners and contractors face increasing pressure to cut carbon emissions, trim costs, and enhance delivery timelines, 3D printed foundations are proving to be a game‑changer. At Hyperion Robotics, our mission is to make this pioneering technology the backbone of sustainable infrastructure.

This post explains what 3D printed foundations are, why they matter, especially in the context of our ongoing pilot with National Grid, and what the future holds.

What are 3D printed foundations?

3D printed foundations are structural concrete bases created using automated, additive manufacturing rather than traditional poured or precast methods. Using a robotic arm and proprietary software, the concrete is extruded layer by layer directly from a digital model, allowing for complex geometries and optimised material use.

Unlike traditional precast elements, which are typically over-engineered and require steel formwork, 3D printed foundations use just the right amount of material, precisely placed, without moulds or waste.

Hyperion’s robotic 3D printing system is specifically designed for infrastructure-grade concrete, engineered for performance, compliance, and sustainability.

The problem with traditional foundation construction

Foundations are critical to the performance and safety of infrastructure, but traditional methods are costly, carbon-heavy, and often inefficient. Some of the major challenges include:

  • Material waste from overdesign and offcuts
  • High CO₂ emissions, especially from cement-heavy mixes
  • Manual labour constraints, site delays, and weather disruption
  • Transport and logistics of large precast units from factory to site
  • Complications caused by variations in size and dimensions depending on soil types and specific site constraints

This is particularly true for utilities and infrastructure operators managing complex, multi-site upgrade programmes, where even small gains in efficiency and carbon reduction scale significantly.

How 3D printed foundations work

At Hyperion Robotics, our process begins with digital design and structural engineering, followed by robotic printing at or near the site. Here’s how it works:

  1. Digital twin foundation design – tailored to exact site conditions
  2. Optimisation – structural analysis and material minimisation using FEA
  3. Automated printing – robotic arm extrudes low-carbon concrete in precise layers. Steel reinforcement is efficiently integrated at pre-programmed points, ensuring structural integrity without interrupting the print workflow.
  4. Curing and QA – monitored for strength, tolerances, and compliance
  5. Installation – ready to install with no formwork or complex logistics

This workflow cuts manual effort, removes waste, and allows for repeatable, scalable deployment across multiple sites.

National Grid partnership — a live pilot

In early 2025, Hyperion Robotics partnered with National Grid to field‑test 3D printed foundations for substations. The foundations are being designed and produced in Finland, with physical testing planned in partnership with the University of Sheffield and National Grid’s Deeside Centre in 2025.  

While this is still an active pilot and benefits are projected, it’s worth noting that if scaled across the network, the initiative could deliver:

  • Up to 705 tonnes less concrete
  • Around 323 tonnes in CO₂ savings
  • An estimated £1.7 million in consumer benefits

This is in addition to reductions in soil displacement, foundation weight, and site labour.

Environmental benefits — what studies show

Concrete 3D printing offers strong sustainability credentials when done right:

  • Hyperion’s micro‑factories use 75 % less structural material, and support recycled industrial waste (slag, fly‑ash, tailings) to lower embodied CO₂ by up to 90%.
  • UKGBC confirms our method combines large‑scale robotic printing with low‑carbon mixes (zero‑cement options) to deliver ~70 % lower embodied carbon, ~50 % faster lead times and ~30 % cost savings.
  • Academic reviews note that optimised 3D printed concrete structures can halve material use and reduce LCA global warming potential, even more so in complex shapes.

These findings support how Hyperion’s approach – combining material science, structural optimisation, and automation – can significantly advance sustainability goals.

Economic benefits – reducing cost across the value chain

3D printed foundations offer multiple cost-saving levers across design, production, and installation:

  • No formwork or steel moulds, which reduces materials and setup costs
  • Optimised structural design means less concrete per unit, lowering material spend
  • Digital fabrication removes costly human error and rework
  • On-site or near-site production using localised micro-factories reduces transportation costs and crane hire
  • Faster installation helps contractors avoid penalty charges or liquidated damages

When deployed across asset portfolios, these savings can translate into millions in avoided costs, as demonstrated in the projected savings from the National Grid pilot.

Operational benefits — speed, precision, and flexibility

For contractors and asset owners managing complex site logistics or tight upgrade timelines, 3D printed foundations bring clear operational advantages:

  • Rapid production cycles — foundations can be printed in a matter of hours
  • Just-in-time delivery — eliminates the need for stockpiling or waiting for precast supply
  • Repeatability and standardisation — identical components can be reproduced with zero deviation
  • Customisation — geometry, height, or cable channels can be adapted digitally
  • Fewer site workers — ideal for constrained or remote sites with limited crew access

By integrating seamlessly into modern project workflows, Hyperion’s technology helps de-risk deployment, especially across multi-site infrastructure programmes.

Structural integrity and reinforcement – built to code

One of the most common misconceptions about 3D printed concrete is that it doesn’t include steel reinforcement, which leads some to assume it isn’t compliant with structural codes.

Let’s be clear: Hyperion’s 3D printed foundations are reinforced and code-compliant.

Our designs are developed in line with UK building regulations and Eurocode requirements, with reinforcement incorporated strategically during the printing process.

By starting from a digitally optimised model, we reduce not just the volume of concrete, but the volume of reinforcement as well, maintaining correct structural ratios. In most cases, we use less steel in proportion to the material reduction, without compromising performance or durability.

This approach ensures our foundations remain strong, lightweight, and fully certifiable, ready for real-world infrastructure deployment.

Why utilities and infrastructure providers are paying attention

The utility sector is under mounting pressure to modernise its asset base while cutting emissions. The UK’s Net Zero Strategy and Ofgem’s RIIO framework both reward innovation and carbon reduction.

3D printed foundations offer a low-disruption, high-impact solution that aligns with:

  • Net Zero infrastructure goals
  • Cost-efficiency mandates
  • Resilience and safety standards

With thousands of asset upgrades planned across power, water, and transport, the potential for rollout is massive.

Hyperion Robotics – built for scale, ready for impact

Hyperion Robotics is one of the few companies globally – and the only one focused on critical infrastructure – delivering code-compliant, 3D printed concrete elements at scale.

Our approach combines:

  • In-house robotics and automation systems
  • Low-carbon concrete R&D
  • Structural engineering aligned with Eurocode and UK standards
  • Digital design, QA, and delivery under one roof

With plans to establish a dedicated UK manufacturing and R&D hub, we’re actively scaling our offering to meet growing demand across the utilities, energy, and infrastructure sectors.

What’s next for 3D printed foundations

From substations to renewable energy platforms, from transport infrastructure to industrial sites, the opportunity for additive manufacturing in civil engineering is enormous.

We’re already exploring applications with leading contractors, asset owners, and government agencies. If you’re interested in partnering with us on pilot projects or scaling rollout across your network, let’s talk.

Contact us to explore what 3D printed foundations could do for your projects.

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Strength & Code Compliance: The Hyperion Robotics Advantage

Posted on by Fernando

In an industry where infrastructure strength and safety are paramount, the materials and methods used to build foundations can make all the difference. Hyperion Robotics, with our cutting-edge 3D printing technology, offers a solution that is not only stronger than traditional methods but also more sustainable.

In this blog post, we’ll explore how our foundations provide unmatched strength, reduce material waste, and meet rigorous code compliance standards, ensuring safety, efficiency, and regulatory adherence.

The strength of Hyperion Robotics foundations

When it comes to building infrastructure, the strength of the foundation is non-negotiable. Our 3D printed foundations are up to 10 times stronger than traditional concrete. This immense strength comes from a blend of advanced material science and state-of-the-art design, which ensures that every foundation we create can withstand the test of time and the harshest conditions.

While conventional construction methods rely on mass and traditional reinforcement techniques, our 3D printing technology offers optimised reinforcement where it matters most. This results in foundations that don’t just meet, but exceed the structural requirements of most infrastructure projects.

Compared to the competition, many 3D printed solutions fail to meet these strength standards, often due to lack of reinforcement. Our approach, on the other hand, ensures that our foundations are built to last and handle heavy loads, making them an ideal choice for critical infrastructure like data centres, power stations, and utilities.

What do we mean by “built to last”?  All of our foundations, chambers and drawpits have a 100 year design life for multiple classes, and are built with the flexibility to accommodate future alterations or maintenance, ensuring long-term value for your projects.

The advantage of using less material

Not only are our foundations stronger, but they are also more sustainable.

Hyperion Robotics’ technology reduces the amount of material used by up to 75% compared to traditional construction methods. This dramatic reduction in material waste means fewer resources are consumed, lower transportation costs, and reduced carbon emissions.

The environmental benefits of using less material are substantial, as construction is one of the largest contributors to global waste. By utilising 3D printing, we can create structures that are both efficient and eco-friendly. This is not only a win for your projects but also for the planet.

Code Compliance: The backbone of reliable construction

When constructing critical infrastructure, safety and adherence to regulations are non-negotiable. We understand the importance of meeting stringent code compliance standards in every project. Our 3D printed foundations are not only strong but also fully code-compliant, ensuring they meet all relevant building codes and safety standards.

Our foundations undergo rigorous testing and certification processes, giving clients confidence that their projects are built to last and adhere to all legal requirements. Hyperion’s technology is specifically designed to meet local and international construction codes, ensuring that every project is safe, reliable, and up to industry standards.

Code compliance is particularly crucial for long-term infrastructure, where any structural failures could lead to costly repairs, downtime, or even safety hazards. By choosing Hyperion Robotics, you’re choosing a solution that is built to be safe, reliable, and future-proof.

What sets Hyperion Robotics apart from competitors

While there are other companies offering 3D printed structures, many of them fall short in one key area: reinforcement and code compliance.

Competitors may offer solutions that appear innovative but fail to meet the rigorous standards required for critical infrastructure. Some 3D printed structures are not reinforced to the extent needed for heavy loads, and others may not have the necessary code compliance certifications.

This can be a huge risk for developers and contractors, especially when building infrastructure that needs to meet safety and performance standards.

Hyperion Robotics, however, ensures that every structure is reinforced for maximum strength and built with complete code compliance, providing peace of mind that your project will stand the test of time and meet all regulatory requirements.

Real-world applications

Hyperion Robotics’ foundations have already been successfully implemented in a variety of high-stakes infrastructure projects. Whether it’s for power utilities, data centres, or transport infrastructure, our 3D printed foundations offer the strength and compliance necessary for long-lasting structures.

Severn Trent Water

When asked by Severn Trent Water to design and manufacture  32 pipe support foundations for the world’s first net-zero wastewater treatment facility, we reimagined the conventional box-shaped foundation with an optimised ribbed design calculated to Eurocode 7 standards. The hybrid structure combined 3D-printed concrete faces with a reinforced concrete core, ensuring durability and compliance with EN1990 and EN1992 codes while using less material.

Learn more about our work with Severn Trent Water.

National Grid

Another notable example is our collaboration with National Grid on a UK-first trial to manufacture, install, and test low-carbon 3D-printed substation foundations.

This project has the potential to reduce construction-driven carbon emissions and lower costs to consumers of network construction. If rolled out across National Grid substations, it could save up to 705 tons of concrete and 323 tons of CO₂, delivering £1.7 million in consumer savings over a 10-year period.

Not only that, but despite using 70% less material, Hyperion Robotics’ 3D-printed foundations have been proven to be four times stronger than traditional methods. Previous on-site structural tests have demonstrated significantly higher resistance compared to conventional foundations, ensuring enhanced durability and long-term reliability.

Read more about the National Grid project.

Iberdrola/Scottish Power

And let’s not forget our collaboration with Iberdrola/Scottish Power on a pilot project to develop sustainable concrete structures using 3D printing and recycled materials.

In this project, we applied our innovative 3D printing technology to create a concrete base for an electrical substation. The structure was designed and printed at our Helsinki facility and then transported to Peikko Group’s test location in Lahti, Finland, for installation and testing. The live test demonstrated that the sustainable infrastructure could withstand three times its design load – using only a quarter of the material normally required. This achievement underscores the potential of our technology to optimise construction processes by reducing material usage and associated carbon emissions. Learn more.

A strong, compliant future with Hyperion Robotics

At Hyperion Robotics, we don’t just build foundations; we build strong, sustainable, and safe foundations that meet the highest standards of code compliance.

Our 3D printing technology allows us to deliver foundations that are up to 10x stronger than traditional methods while using significantly fewer materials.

By choosing Hyperion Robotics, you are ensuring that your infrastructure project will be built to last, stay within budget, and meet all regulatory requirements. Our technology offers the perfect blend of strength, efficiency, and compliance.

If you’re looking for a stronger, more sustainable, and code-compliant foundation solution for your next infrastructure project, get in touch with us today. Explore our product catalogue to learn more about our offerings, or contact our team for a consultation on how Hyperion Robotics can help bring your vision to life with the most innovative 3D printed solutions available.

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How 3D printed construction can support the UK Utilities sector

Posted on by Fernando

The UK utilities sector is at a critical juncture. Water, gas, and energy networks are under intense pressure to modernise rapidly, while also hitting net-zero targets, improving resilience, and minimising public disruption. These pressures are converging just as the sector faces significant challenges around skilled labour shortages, material inflation, and ageing infrastructure.

To keep pace, utility providers and their contractors must embrace new methods of infrastructure delivery – methods that are faster, greener, and smarter. One such innovation gaining traction across Europe and now making its mark in the UK is 3D printing for utilities infrastructure.

At Hyperion Robotics, we’re at the forefront of applying robotic 3D printing with low-carbon concrete to real-world infrastructure challenges. Our technology offers a powerful tool for utilities seeking to streamline delivery, cut carbon, and future-proof their assets – all while maintaining high structural integrity and compliance with UK and EU standards.

Why digital construction Is a game-changer for Utilities

Utilities operate in some of the most complex and constrained environments, often working below ground, in congested corridors, or in ecologically sensitive areas. Traditional construction methods, which rely heavily on manual labour, formwork, and long lead times, can be slow, disruptive, and expensive.

That’s where energy infrastructure digital construction can transform outcomes.

Digitally enabled methods like 3D printing offer utilities a way to:

  • Automate and accelerate prefabrication of reinforced concrete structures
  • Standardise and customise components through parametric design
  • Reduce on-site labour and disruption with off-site production and plug-and-play installation
  • Improve traceability and quality control through data-rich digital workflows

By integrating 3D printing into infrastructure programmes, utilities gain more control over time, cost, and carbon – key priorities as the sector modernises.

Concrete 3D Printing in action: real-world applications

The Strongford Wastewater Hub

At Severn Trent’s Strongford Wastewater Treatment Works, Hyperion Robotics delivered 3D printed concrete chambers and drawpits designed for underground utility infrastructure as part of the UK’s first Net Zero Hub for wastewater treatment. By reimagining foundation design, Hyperion achieved a 32% reduction in embodied carbon – saving 608 kilograms of CO₂ per foundation – through optimised 3D printing that reduced concrete use by 50%, resulting in cost savings of 60%.

Efficient offsite production enabled all 32 foundations to be printed in just two days, with each unit taking only 15 minutes. On-site installation was fast and required minimal manpower, cutting project time by 67% to just 16 days. The durable, Eurocode-compliant hybrid structures demonstrate Hyperion’s ability to deliver sustainable, high-quality, and cost-effective infrastructure solutions for UK utilities.

Read more about the Strongford project.

National Grid’s 3D-Printed Substation Foundations

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

Hyperion Robotics has partnered with National Grid and the University of Sheffield to trial low-carbon 3D-printed concrete foundations for electrical substations – a UK-first initiative aimed at reducing carbon emissions, material use, and costs. The project is part of National Grid’s commitment to leverage innovation to future-proof the network.

Our 3D-printed foundations offer multiple efficiency improvements over conventional designs. As conservative figures, these include a 70% reduction in concrete usage, 80% less soil displacement, and a 65% decrease in carbon emissions. The new foundations are also 70% lighter than typical foundations and require 50% fewer site operative hours.

Learn more about the National Grid project.

Yorkshire Water – Esholt Wastewater Treatment Works

At Yorkshire Water’s Esholt Wastewater Treatment Works near Leeds, Hyperion Robotics collaborated with Mott MacDonald Bentley and Tarmac to deliver four 3D-printed drawpits for electrical cabling. These bespoke structures replaced traditional 5.2m² concrete pits with 2.2m diameter circular designs, reducing material use by 50% and achieving a 40% reduction in embodied carbon.

Each drawpit was printed in approximately two hours, incorporating pipes and reinforcement. The units were then delivered from Finland to the UK, where they were successfully installed at the newly refurbished pumping station.

This project exemplifies how 3D printing can facilitate faster, more sustainable infrastructure delivery, aligning with Yorkshire Water’s commitment to reducing its carbon footprint and exploring innovative construction methods.

Learn more about this Esholt project.

Quantifiable benefits for utilities

Transitioning to 3D printed infrastructure isn’t just about innovation; it’s about delivering tangible business and project outcomes. Here are some of the key benefits that matter most to utility stakeholders:

Carbon savings

Hyperion’s concrete formulations are low-carbon, cutting embodied CO₂ by up to 75% compared to conventional concrete. With sustainable infrastructure construction UK targets becoming more stringent, this offers a credible pathway to reduce Scope 3 emissions.

Time savings

3D printed components can be produced in days, not weeks. No time is spent building and dismantling formwork, waiting for curing, or transporting large raw materials to site.

Fewer man hours and lower site risk

Automation reduces dependency on skilled on-site labour – a major advantage amid industry-wide labour shortages. Fewer personnel on-site also means lower health and safety risks, fewer vehicle movements, and reduced need for site accommodation or welfare facilities.

Less site disruption

Off-site prefabrication and just-in-time delivery are particularly beneficial in dense urban environments, rural locations, or ecologically sensitive zones. With energy infrastructure digital construction, you avoid the noise, dust, and traffic disruption of traditional site works.

Cost efficiency

3D printed components require less raw material, less transport, and less installation time. Combined, this results in reduced total installed cost for utilities and contractors, especially when scaled across multiple standardised assets.

Learn more about how our technology delivers these results on the Hyperion Robotics homepage.

Built for compliance: meeting industry standards

Innovative construction methods must still meet the rigorous technical and regulatory requirements of the utilities sector. At Hyperion, we design every solution with compliance and safety at the core.

  • Our components follow British Standards (BS) and Eurocode guidelines for reinforced concrete structures
  • All designs are structurally validated through finite element analysis and digital simulation
  • Hyperion is actively pursuing CE marking and other certification pathways for widespread infrastructure use
  • We collaborate with our partners to co-develop specifications, ensuring all outputs meet utility performance criteria

Whether you’re installing a foundation or a drawpit, you can trust that every Hyperion product is engineered for the demands of UK infrastructure environments.

What’s next: the future of Utilities Construction

As asset owners look to decarbonise their portfolios, streamline delivery, and build more resilient infrastructure, 3D printing offers a unique opportunity to reset expectations.

We’re seeing growing interest from UK utilities in using 3D printing to:

  • Standardise repetitive infrastructure assets
  • Prototype and test modular systems in energy transition projects
  • Reduce embodied carbon across major capital programmes
  • Deploy prefabricated solutions at pace for maintenance and emergency repairs

By embracing sustainable infrastructure construction UK methods now, utilities can unlock long-term cost savings, risk reduction, and carbon reduction – all while staying ahead of regulatory and public expectations.

Let’s build the future – together

Hyperion Robotics is ready to help you explore what 3D printing can do for your utilities project. Whether you’re focused on water, gas, or energy, our team of engineers, designers, and project delivery experts can help you identify the right pilot opportunity, align with your internal standards, and demonstrate impact quickly.

Get in touch to explore a pilot project and start building smarter with Hyperion Robotics.

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50+ Essential Terms of Modern Construction for Civil Engineers

Posted on by Phuong Ngo Pitkänen

Welcome to the Hyperion Robotics Glossary, your comprehensive resource for exploring the cutting-edge world of sustainable construction. 

This glossary is designed to demystify the terminology surrounding advanced technologies like 3D printing, robotics, intelligent automation, and low-carbon concrete. It also serves as a guide to the innovative structures and solutions we offer, including chambers, drawpits, and foundations.

 At Hyperion Robotics, our mission is to revolutionise the construction industry by blending sustainability with precision and efficiency, and this glossary will help you better understand the tools, materials, and techniques that power this transformation. Whether you’re a civil engineer, contractor, investor, or curious learner, this glossary has something for everyone.

A | B | C | D | E | F | G | H | I | J | K | L | M | N | O | P | Q | R | S | T | U | V | W | X | Y | Z

A

What is 3D Printing in construction?

3D printing in construction is a manufacturing process that creates three-dimensional objects by layering materials based on digital designs. Used in construction to produce optimised, customised concrete structures with reduced material waste. Example: Entire homes can now be 3D printed in under 24 hours.

What are 3D printed foundations?

3D printed foundations are concrete bases built layer by layer using automated additive manufacturing instead of traditional poured or precast methods. A robotic arm extrudes concrete from a digital model, enabling complex shapes and efficient material use.

What is Additive Manufacturing?

Additive Manufacturing is a process of creating objects by layering material, typically used interchangeably with 3D printing. It offers high customisation and reduced material waste.

What is Admixture?

Admixtures are substances added to concrete or mortar—typically in small quantities—before or during mixing to modify properties such as workability, setting time, durability, or strength

What is Advanced Manufacturing?

Advanced Manufacturing is the use of innovative technologies and processes—including robotics, automation, and digital tools—to improve the efficiency, precision, and sustainability of manufacturing operations.

What are Anchor Bars used for?

Anchor Bars are steel rods with threaded ends embedded in cast concrete elements to securely anchor steel connection plates, ensuring structural stability and load transfer.

What is Automation Workflow?

Automation Workflow is a sequence of automated tasks or processes that improve efficiency, reduce human error, and accelerate construction timelines.

What is Autonomous Construction?

Autonomous Construction is the use of self-operating machinery and robotics to perform construction tasks with minimal human intervention, improving safety, speed, and precision.

Back to A–Z

B

What is BIM in Construction?

BIM (Building Information Modelling) is a collaborative digital process involving 3D modeling to plan, design, manage, and construct infrastructure projects. Hyperion Robotics integrates seamlessly into BIM environments. 

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C

What is Carbon Footprint?

Carbon Footprint is the total greenhouse gas emissions caused by a process, product, or activity. Reducing the carbon footprint is a core goal in sustainable construction.

What is Carbon-negative Construction?

Carbon-negative Construction refers to building practices that remove more carbon dioxide from the atmosphere than they emit over the entire lifecycle of the structure.

What is Circular Economy?

Circular Economy is a model focused on reusing, recycling, and regenerating materials to minimise waste and create sustainable, closed-loop systems in construction.

What is Computational Design?

Computational Design is a process that uses algorithms and computational logic to generate and evaluate complex design options, enabling highly optimised structures tailored to performance and sustainability goals.

What is Concrete made of?

Concrete is a composite construction material made from a mixture of cement, water, aggregates (such as sand and gravel or crushed stone), and sometimes admixtures, which hardens over time to form a strong, durable building material.

What is Concrete Curing?

Concrete Curing is the process of maintaining adequate moisture, temperature, and time to allow concrete to achieve its desired strength and durability.

What is Concrete Extrusion?

Concrete Extrusion a 3D printing technique where layers of concrete are deposited through a nozzle to build structures. This method enables intricate shapes and material efficiency.

What are the application of Robotics in Construction?

Construction Robotics are automated systems designed specifically for construction tasks, such as bricklaying, concrete printing, or site surveying, to enhance productivity and reduce human risk.

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D

What is Design for Manufacturing and Assembly?

Design for Manufacturing and Assembly? (DfMA) is an approach that simplifies product designs to make manufacturing and assembly more efficient and cost-effective, often used in prefabrication and modular construction.

What is Digital Fabrication?

Digital Fabrication is the process of creating physical objects directly from digital models using automated methods like 3D printing, CNC machining, or robotic arms, allowing for high accuracy and reduced waste.

What is Digital Twin in Construction?

Digital Twin is a virtual replica of a physical asset or system that allows for real-time monitoring, simulation, and optimisation throughout its lifecycle.

What is a Drawpit?

Drawpits are specialised concrete structures designed for underground networks, providing robust and efficient solutions for housing electrical and utility connections.

What is Durability Optimisation?

Durability Optimisation  is a process that enhances the strength and lifespan of structures by placing concrete only where it is needed, reducing material use while maintaining performance. 

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E

What are Embedded Sensors in Construction?

Embedded Sensors are sensors integrated into structures during manufacturing to monitor variables like temperature, stress, and movement in real-time, enabling predictive maintenance and quality control. In 3D printing systems for construction, embedded sensors can measure the temperature, consistency, and flow dynamics of the material being extruded by the robotic system.

What is embodied carbon?

Embodied carbon is the total CO₂ emissions generated during the production, transport, construction, and disposal of building materials and products.

What is Environmental Product Declaration?

Environmental Product Declaration (EPD) is a standardised, third-party verified document that transparently reports the environmental impacts of a product throughout its lifecycle, based on a Life Cycle Assessment (LCA).

What are Eurocodes used for?

Eurocodes are European standards for structural design, ensuring that concrete structures meet safety, reliability, and compliance requirements during construction. All Hyperion structures comply with EN206, EN1990, EN1992, EN1997 among other relevant standards.

What is Extrusion-based Printing?

Extrusion-based printing is a 3D printing technique that involves pushing material through a nozzle to deposit it layer by layer. Each layer bonds to the previous one, forming a three-dimensional object composed of successive two-dimensional cross-sections.

Back to A–Z

F

What is Finite Element Analysis (FEA)?

Finite Element Analysis (FEA) is a computational technique used to simulate how materials and structures respond to forces, stress, and other physical effects, aiding in the optimisation of structural designs.

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G

What is Geopolymer Concrete?

Geopolymer Concrete is an eco-friendly alternative to traditional Portland cement concrete, made from industrial by-products like fly ash or slag. It significantly reduces carbon emissions and offers equivalent durability and strength as traditional concrete.

What are Green Building Standards?

Green Building Standards are guidelines and certifications (such as LEED or BREEAM) that promote environmentally responsible and resource-efficient building practices.

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H

What is Hybrid Manufacturing?

Hybrid Manufacturing is a method combining additive manufacturing (3D printing) with traditional techniques (like casting or milling) to leverage the benefits of both approaches.

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I

What is Intelligent Automation?

Intelligent Automation is the integration of smart technologies, such as robotics and data-driven systems, into manufacturing workflows to enhance productivity, accuracy, and consistency. 

What are ISO Standards?

ISO Standards are internationally recognised guidelines and specifications that ensure quality, safety, and environmental efficiency in materials, products, and systems used in construction.

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L

What is Lifecycle Assessment Analysis (LCA)?

Lifecycle Assessment Analysis (LCA) is a comprehensive analysis of the environmental impacts associated with all stages of a product’s life – from raw material extraction to end-of-life disposal.

What is Load Path Analysis?

Load Path Analysis is the process of identifying how loads (forces) travel through a structure to the foundation. Essential in ensuring that structures are safe, stable, and efficiently designed.

What is Load-Bearing Capacity?

Load-Bearing Capacity is the maximum load a structure or component can safely support without risk of collapse or failure.

What is Low-Carbon Concrete?

Low-Carbon Concrete is a sustainable concrete variant made using traditional concrete ingredients in an innovative way to significantly reduce CO₂ emissions while maintaining strength and durability according to building codes (EN 206). 

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M

What is Material Consumption Reduction?

Material Consumption Reduction is a key benefit of 3D printing in construction, achieved by using only the precise amount of material required placed in the right location. This approach is used when printing the optimised formwork of our structures, or when placing the reinforcement bars

What are Microfactories?

Microfactories are small, localised production facilities near project sites that streamline logistics, reduce transportation costs, and speed up construction timelines. 

What are Modern Methods of Construction?

Modern Methods of Construction (MMC) refers to innovative building techniques that improve efficiency, quality, and sustainability by using off-site fabrication, advanced materials, and streamlined on-site assembly processes compared to traditional construction methods.

What is Modular Construction?

Modular Construction is a technique that involves producing sections (modules) of a building off-site and assembling them on location. It speeds up construction and enhances quality control.

What is Mortar made of?

Mortar is a workable paste made from a mixture of cement (or lime), sand, and water, typically used to bond bricks, stones, or other masonry units together.

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N

What is Net-Zero Construction?

Net-Zero Construction is a building approach aimed at achieving zero net energy consumption and minimal environmental impact through energy-efficient design and the use of renewable energy sources.

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P

What are Pad foundations?

Pad Foundations are shallow concrete foundations used to support individual point loads, such as columns, by spreading the load over a broad area of soil to prevent excessive settlement

What is Parametric Design?

Parametric Design is data-driven design method using algorithmic processes to efficiently generate precise, flexible, and optimised 3D models. This is crucial for customising concrete elements to meet specific project needs and allow maximum flexibility over geometry. 

What are Pile Cap Foundations?

Pile Cap Foundations are thick concrete mats that rest on top of a group of piles, tying them together and distributing the structural load from columns or walls evenly across the piles to transfer it deep into the ground.

What is Predictive Maintenance?

Predictive Maintenance is using real-time data from sensors and analytics to anticipate and address maintenance needs before failures occur, reducing downtime and extending equipment lifespan.

What is Prefabrication?

Prefabrication is the practice of manufacturing building components off-site in a controlled environment, then assembling them on-site. It improves quality control and shortens construction time.

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R

What are Reinforcement Bars?

Reinforcement Bars is a steel lattice structure embedded in concrete to provide structural strength and resist tensile forces, crucial in ensuring load-bearing capacity and ductility of the concrete elements.

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S

What is Smart Infrastructure?

Smart Infrastructure is infrastructure embedded with digital technologies and sensors that collect data to improve operation, maintenance, and decision-making processes.

What is Structural Integrity?

Structural Integrity is the ability of a structure to withstand its intended load without failing due to fracture, deformation, or fatigue over time.

What are Sustainability Practices? 

Sustainability Practices are methods and technologies aimed at minimising environmental and societal impact, including the use of low-carbon materials, waste reduction, and energy efficiency during construction. 

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T

What is Topology Optimisation?

Topology Optimisation is a computational technique that optimises material layout within a given design space, resulting in lightweight and high-performance structural components.

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W

What are Water Chambers? 

Water Chambers are reinforced concrete structures manufactured using 3D printing for the treatment of waste water, ensuring sustainable and resource-efficient alternatives to traditional cast in situ methods

 

Missing something? Let us know!

Whether you’re exploring technical terms or curious about our innovative structures – like 3D-printed chambers, drawpits, and foundations – our glossary is packed with insights to guide your journey in sustainable construction.

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Why contractors choose 3D Concrete Printing for UK Infrastructure Projects

Posted on by Fernando

Anyone in the UK construction industry knows the intense pressures all around them: rising costs; strict timelines; and the growing importance of Environmental, Social, and Governance (ESG) goals; are just a few.

How do they succeed? By embracing innovation. One of the most groundbreaking advancements transforming the sector is 3D concrete printing.

By harnessing infrastructure 3D printing solutions, contractors can realise faster project handovers, reduce waste, and meet evolving ESG standards.

Today, we’ll explore why so many UK contractors are adopting 3D concrete printing to reshape rail, power, and water infrastructure projects.

Top 5 benefits of 3D Concrete Printing

1. Faster site handovers

It’s a fact that traditional building methods often incur delays thanks to the unpredictability of adverse weather or on-site material shortages.

But, by moving production off-site, 3D concrete printing shortens project schedules significantly. In this way, components are built in controlled environments via off-site digital manufacturing, ensuring consistency and speed.

This means that contractors can meet their deadlines more reliably, which in turn improves client trust and satisfaction.

How does this work in practice? Let’s take a water infrastructure project as an example. Prefabricated 3D printed civil engineering components, such as pipe segments and chamber linings, can be delivered to the site and installed quickly, cutting on-site labour time. Hyperion Robotics offers innovative solutions like chambers, which include integrated pipe inserts and support various pipe layouts, reinforced with high-strength steel for exceptional durability. They typically deliver up to 50% material savings compared to traditional box structures.

2. The delivery of repeatable, precision components

Infrastructure projects often require multiples of the same component. For example, tunnel linings or bridge supports. As these must all be identical, the production can be laborious. With 3D printing, however, contractors achieve extraordinary accuracy and repeatability easily.

Why? The digital design ensures that each piece meets exact specifications, eliminating inconsistencies common in manual processes. This precise approach of engineering components enhances infrastructure durability, minimising future repair costs. For underground networks, Hyperion’s drawpits provide tailored, robust, and cost-efficient solutions. Learn more about drawpits.

And it can be done incredibly quickly. For example, on a recent project for Severn Trent, Hyperion Robotics was able to manufacture all 32 of the required foundations in just two days.

3. Flexible design capabilities

Complex forms that were once challenging or even impossible to create with traditional methods are now possible with 3D concrete printing. The technology can apply intricate geometries and custom designs without any additional time or cost.

Say your goal is to design a durable, space-efficient pedestrian overpass. With the advanced 3D printing technology, you can create sleek, aesthetically-pleasing, lightweight structures tailored to your site’s specific requirements.

4. Safer off-site production

Construction sites remain hazardous environments despite everyone’s best efforts.

But, moving manufacturing to controlled settings via off-site digital manufacturing reduces both the risk to workers and the costs associated with on-site safety management. Workers interact with robotics and automated systems, thereby minimising physical strain and exposure to unsafe conditions. This not only protects valuable teams but also supports compliance with UK workplace health and safety regulations.

One key advancement in safer and sustainable off-site production comes from Hyperion Robotics’ localised microfactories. These innovative facilities not only facilitate our cutting-edge 3D printing technology but they’re also transportable so that they can be set up close to project sites. This therefore reduces the need for material transportation, cutting both costs and carbon emissions.

5. Lower material waste and higher sustainability

Sustainability is no longer optional in infrastructure development. The high precision of 3D printing eliminates unnecessary waste, as materials are deposited layer by layer, using only what’s required.

Not only that but many infrastructure 3D printing solutions use recycled aggregates or green concrete mixes to reduce the carbon footprint even further. This is a point that you would certainly benefit from highlighting in bids, or in company reports to showcase your ESG efforts.

Hyperion Robotics takes sustainability a step further with their foundations, achieving peak performance with up to 75% less material than traditional pad foundations. Learn more about foundations.

How it works: From design to print

At its core, the process of 3D concrete printing while innovative is also fairly simple. Here’s how it works:

  1. Digital design: Our engineers design the components using advanced CAD software, ensuring they meet your technical and regulatory requirements.
  2. Onboarding to printer: The digital file is uploaded to our state-of-the-art 3D printers.
  3. Printing process: Concrete is applied layer by layer in a controlled environment, ensuring precise material application for strength and consistency.
  4. Testing process: Before components are finalised for use, full-scale testing is conducted using our specialist engineering testing facilities. Our testing process ensures the printed structures meet all necessary safety, durability, and performance standards, providing confidence in the reliability of the final product.
  5. Delivery to site: Once ready, printed components are transported to the construction site for installation.

Exploring our work

At Hyperion Robotics, we take pride in the part we play in helping utility providers and infrastructure companies build smarter, faster and greener. To see examples of where our advanced technology has been successfully applied to solve critical challenges in water treatment and the energy sector, visit our case studies page.

If you’re interested in learning more about how we can bring value to your sector, please get in touch with our team.

Your next steps

Are you ready to build smarter, faster and greener? Partnering with Hyperion Robotics unlocks the potential of 3D concrete printing to enhance both cost-efficiency and project timelines.

To help you explore the benefits for your next project, we’re offering complimentary feasibility reviews. This includes evaluating ROI, sustainability outcomes, and production timelines based on your specific needs.

Get in touch to find out more.

FAQs

1. What materials are used in 3D concrete printing?

Most systems use a combination of specialty concrete mixes, often incorporating recycled materials to meet sustainability goals.

2. Is 3D concrete printing more expensive than traditional methods?

While upfront costs for equipment can be higher, savings on labour, material waste, and time often lead to a lower total cost of ownership.

3. What kinds of projects are best suited to 3D concrete printing?

Projects requiring custom components, intricate designs, or fast turnarounds benefit most. Common applications include bridges, retaining walls, and utility infrastructure.

4. How durable are 3D printed structures?

Concrete components created with 3D printing meet or exceed the same durability standards as traditionally cast elements, making them long-lasting and reliable.

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