Contact Us

Category: News

Hyperion Robotics to deliver 3D printed concrete sleepers for Costain’s landmark East Coast Cluster project

Posted on by Hannah

Costain, the infrastructure solutions company, and A E Yates, the civil and structural engineering delivery specialist, have brought on board Hyperion Robotics to deliver low-carbon concrete sleepers for a landmark East Coast Cluster project on Teesside.

Northern Endurance Partnership’s (NEP) onshore CO2 gathering system will provide the CO2 transportation and storage infrastructure for Teesside-based carbon capture projects. Costain is the delivery partner to NEP with A E Yates providing civil engineering services.

Costain and A E Yates will work with Hyperion to produce approximately 90 high-strength concrete pipe support bases, or sleepers, along 1.3km of onshore CO2 pipelines across Teesside using its advanced robotic manufacturing and digital technology.

Through innovative robotic 3D printing, Hyperion’s technology eliminates formwork and enables precise, repeatable production of the sleepers. This approach, when compared to traditional precast solutions, will require less soil excavation, reduce concrete and steel use by 40% and carbon emissions by up to 50%. The engineering-led solution is up to ten times stronger than traditional structures despite being up to 60% lighter thanks to a thin, reinforced base design. This will enable faster and safer installation of the sleepers, which will also be manufactured offsite to reduce on-site labour and plant.

Hyperion will oversee its role in the project from Forge I, its new UK manufacturing facility near Scunthorpe, Lincolnshire.

Mark Howard, Programme Director at Costain, said: “Our supply chain serves as a key enabler for innovation, ensuring that we continue to deliver predictable, best-in-class solutions across our projects. Hyperion’s 3D printing solution will provide a myriad of efficiency, sustainability and safety benefits this important project, while at the same time support economic growth and prosperity across the Teesside region.

Hyperion’s 3D printing solution will provide a myriad of efficiency, sustainability and safety benefits this important project, while at the same time support economic growth and prosperity across the Teesside region.

“We’re looking forward to collaborating with its team and working together with our other local supply chain partners as we continue to make strong progress in delivering a decarbonisation system that will be critical for creating a sustainable future for the UK.”

Sven Till, Chief Executive Officer at A E Yates, said: “As a business, innovation and sustainability are fundamental to how we deliver for our customers, and having the opportunity to bring this innovative solution to Teesside for NEP, in collaboration with Costain and Hyperion, demonstrates this.

“We hope that this is the first of many innovative solutions we are able to provide to Northern Endurance Partnership as we deliver the wider OSBL civil engineering works.”

Fernando De los Rios, CEO at Hyperion Robotics, said: “Working alongside Costain and the Northern Endurance Partnership on this project shows what is possible when forward-thinking organisations come together to deliver infrastructure in a different way. By combining engineering expertise, digital design and automated manufacturing, we can reduce material use and carbon emissions while meeting the highest standards of quality, performance and code compliance.

This is more than a single project milestone. It is a practical example of how the UK can build critical infrastructure faster, more efficiently and with a lower carbon footprint by bringing together strong delivery partners, advanced technology and local manufacturing capability.

This is more than a single project milestone. It is a practical example of how the UK can build critical infrastructure faster, more efficiently and with a lower carbon footprint by bringing together strong delivery partners, advanced technology and local manufacturing capability.”

Rich Denny, Managing Director at Northern Endurance Partnership, said: “By working with Costain and Hyperion Robotics to harness advanced manufacturing techniques, we are not only reducing the carbon footprint of construction itself but also supporting the development of a resilient UK supply chain. This kind of collaboration is critical to delivering a world‑class CCS network that will help decarbonise industry, protect jobs and drive long‑term economic growth in the region.”

Costain is also the delivery partner for Net Zero Teesside Power (NZT Power), which aims to be the world’s first gas-fired power station with carbon capture and storage. To date, approximately 200 people from Costain are delivering and managing the engineering, procurement and construction (EPCm) elements of the NZT NEP OSBL project, in addition to approximately 100 designers and engineers based in Manchester. Of the subcontractor contracts awarded to date, 90% are with UK-based suppliers.

For more information, contact us here.

Hyperion Robotics and LKAB Minerals to launch UK’s first fully digital, automated low-carbon infrastructure factory

Posted on by Hannah

Hyperion Robotics, Europe’s leading low-carbon construction technology company, has confirmed Flixborough near Scunthorpe as the location of its first UK factory, signing a strategic agreement with LKAB Minerals to establish a new advanced digital, automated and robotised manufacturing facility.

The partnership brings together Hyperion Robotics’ advanced computational design, robotics and digital manufacturing expertise with LKAB’s global leadership in low-carbon industrial minerals and materials. The new facility – known as Forge I – will be developed and operated by Hyperion Robotics, with LKAB providing both the industrial site and low-carbon material inputs that feed directly into digitally designed, robotically manufactured concrete .

Set to open before summer 2026 and produce digitally designed, robotically manufactured concrete foundation systems, the factory will become Hyperion Robotics’ primary UK manufacturing base and the first deployment of its Forge automated production platform. LKAB’s involvement ensures secure domestic material supply, enabling reduced material use and embodied carbon, faster programme delivery, and enhanced structural performance compared with conventional on-site construction.

Forge I will be the most automated concrete manufacturing facility of its kind in the UK market, initially focused on delivering high-efficiency foundation systems for the energy, water, data centre, and utilities sectors. The site will have the capacity to manufacture more than 50 large-scale, Eurocode-compliant and CE-marked foundations per week, with typical dimensions of up to 3m x 3m footprint and 2.5m height, ready for deployment nationwide.

By combining automated production with low-carbon material inputs supplied by LKAB, the facility will deliver measurable cost, programme and CO₂ savings compared with conventional construction methods. Centralised manufacturing will also reduce on-site labour requirements and significantly decrease heavy vehicle movements to and from project sites – lowering emissions across the wider value chain.

Fernando De los Rios, CEO of Hyperion Robotics, commented:

Establishing Forge I with LKAB marks a major milestone in industrialising low-carbon infrastructure delivery in the UK. This partnership brings together the material security, industrial capability and sustainability foundation needed to scale production and support the UK’s ambitious infrastructure plans and carbon reduction targets. Forge I is the first step in a new generation of manufacturing for infrastructure – helping the UK build stronger, lower-carbon assets and transforming how critical foundations are delivered at scale.

Steve Handscomb, Managing Director Cementitious, LKAB Minerals UK, said:

This partnership brings together low-carbon mineral materials and advanced digital manufacturing in a single, integrated production model. By supplying climate-efficient mineral inputs directly into Hyperion’s computational design and robotic production platform, we are helping to establish a new automated raw-materials-to-infrastructure value chain in the UK. It demonstrates how materials innovation and industrial digitalisation can work together to accelerate the transition to lower-carbon, high-performance construction.

Hyperion’s UK expansion follows increasing demand from infrastructure owners and contractors seeking proven solutions that reduce carbon without compromising structural performance or compliance. A UK manufacturing base, supported by LKAB’s materials expertise, allows earlier integration into project planning and scalable delivery across multiple sites.

The next-generation production platform in the North Lincolnshire facility will initially support around 10 skilled roles, with further growth expected as production scales. The partnership will also support workforce upskilling in advanced manufacturing, robotics and digital production systems, strengthening industrial capability in North Lincolnshire.

Hyperion has delivered projects across the UK and Europe for clients including National Grid, Yorkshire Water, Welsh Water and Mott MacDonald Bentley. The new Flixborough facility positions both companies at the forefront of scaling low-carbon, industrialised infrastructure manufacturing nationwide.

For more information, contact us here.

Hyperion Robotics and National Grid surpass strength target of UK’s first 3D-printed substation foundations

Posted on by Fernando

Hyperion Robotics, the technology company transforming how foundations are designed and delivered, has reached a major milestone in its collaboration with National Grid after completing a comprehensive series of laboratory and on-site tests validating the strength and stability of the UK’s first 3D-printed substation foundations.

The project – a UK-first partnership between National Grid, Hyperion Robotics, and the University of Sheffield – aims to demonstrate how advanced, low-carbon foundation systems can accelerate critical infrastructure delivery and reduce environmental impact across the energy sector.

Two full scale laboratory tests – tension tests and overturning moment tests – were carried out at the University of Sheffield’s Integrated Civil and Infrastructure Research Centre (ICAIR). A third, real-world test was conducted at National Grid’s Yorkshire Green site, with support from Murphy, the site’s main contractor and operator.

The laboratory results confirmed exceptional performance across all three foundation sizes. Small foundations achieved eight times the required safety factor, while medium and large foundations achieved three times the expected capacity. These findings exceeded original estimates and demonstrate the suitability of Hyperion’s foundations for deployment in demanding, safety-critical environments.

The on-site overturning tests were carried out to provide National Grid with additional confidence in how the foundations behave across the types of ground conditions typically found at substations in England and Wales. All foundations passed the full-scale on-site overturning tests, meeting or exceeding the performance thresholds by National Grid Electricity Transmission (NGET).

Across the full testing programme, Hyperion’s 3D-printed foundations delivered an average 56% reduction in concrete volume compared with traditional foundations. This demonstrates significant material efficiency and the potential to reduce carbon emissions at scale, without compromising structural performance.

Hyperion acknowledges Murphy as a key collaborator in facilitating the on-site testing programme and enabling a robust, real-world evaluation of the foundations’ behaviour..

Fernando De los Rios, Hyperion’s CEO and founder, commented: “The successful completion of rigorous testing with National Grid confirms that our next-generation foundation system is not only strong and code-compliant, but consistent across laboratory and real-world environments. Achieving these results with significantly less material is a major step forward for smarter, greener infrastructure. Together with National Grid and the University of Sheffield, we’re proving that advanced, low-carbon construction technologies are ready to scale and ready to support the UK’s energy transition.”

Dr Muhammad Shaban, Lead Innovation Engineer at National Grid Electricity Transmission, said: “Passing these tests is a huge step forward in our commitment to leverage innovation to future-proof the network. This project has shown that 3D-printed, low-carbon alternatives to conventional concrete foundations can deliver both the structural performance and sustainability benefits we need. It’s the first trial of its kind in the UK, and the success paves the way for wider adoption across the energy sector. We’re proud to be leading the way in exploring how cutting-edge construction methods can help us meet our Net Zero commitments.”

For more information, contact us here.

Closing the carbon accountability gap in construction supply chains

Posted on by Fernando

The construction industry stands on the front lines of the climate transition. According to the International Energy Agency (IEA, 2023), the built environment accounts for nearly 40% of global CO₂ emissions, with roughly half embodied in the materials and processes that form our physical world.

For decades, the industry has focused on operational efficiency: energy use; insulation; and renewable systems; but embodied carbon now represents the next frontier. Every tonne of cement and rebar carries a carbon cost before the project even opens its doors.

As a company dedicated to delivering low-carbon infrastructure, we see this shift not only as a responsibility but as an opportunity to build smarter, faster, and greener using data and automation.

Yet, despite clear intent and growing regulation, a critical problem persists: the carbon accountability gap. The industry can estimate embodied carbon, but it cannot consistently verify it. That is where traceability, automation and digital twins come in.

1. Carbon accountability gap

Carbon accountability refers to the process of tracking and reporting a company’s greenhouse gas (GHG) emissions to measure its climate impact and take responsibility for reducing them. This is achieved through a systematic process called carbon accounting, which quantifies emissions from direct and indirect activities, converts them to a standard measurement called carbon dioxide equivalent (CO2e), and then allows for the creation of reduction targets and the tracking of progress. The goal is to provide transparency and inform strategies for mitigation.

Embodied carbon is calculated using lifecycle assessment (LCA) standards such as EN 15978 and ISO 14067, supported by Environmental Product Declarations (EPDs). While these standards have advanced the conversation, they rely on averaged and often outdated data.

A “low-carbon concrete” mix, for example, may carry a published emission factor, but the actual batch delivered to a site might have a very different footprint depending on cement source, additives, curing time, and logistics. Without a method to trace and verify that variance, sustainability reporting becomes a matter of estimation. A 2023 report by the UK Green Building Council (UKGBC) highlights that significant variation in embodied carbon assessments arises primarily from differences in data quality, modelling scope, input assumptions, and reporting practices. 

Robotic and automated construction, however, introduce a new possibility: every movement, material, and process can be measured, timestamped, and verified.

2. Traceability through automation

Each 3D-printed or robotically fabricated element carries a digital identity, in which a unique, verifiable record is linked to its source materials, production process, and embodied carbon profile. This data is automatically collected from sensors, mix systems, and machine logs in real time, forming a digital passport for every component.

This allows project managers and procurement teams to:

  • Confirm that delivered materials meet verified low-carbon specifications.
  • Track the carbon footprint of each component from factory to site.
  • Automatically update project carbon models with real, not estimated, data.

For contractors, this traceability means that carbon performance can be validated as rigorously as cost and schedule. For clients, it provides defensible evidence of genuine embodied carbon savings,  not assumptions or proxies.

3. Digital Twins for verification

Digital twins can bridge the gap between design models and real-world performance, creating a live feedback loop that continuously refines both.

Each structure is paired with a digital twin that mirrors the physical build in real time. The twin integrates verified data from the robots, materials, and sensors, forming a dynamic carbon ledger.

This system enables:

  • Real-time embodied carbon tracking during production and installation.
  • Automated reporting aligned with EN 15978 and whole-life carbon frameworks.
  • Scenario testing to optimise material selection and print strategy for minimum emissions.

Digital twins are not only visualisation tools but can be used for verification of carbon accountability.

Building infrastructure with full embodied carbon accountability

Robotic construction and 3D printing not only reduce waste and material use; they generate the granular data that makes embodied carbon truly accountable. Combined with standardised data protocols and digital twins, this creates a new infrastructure for verifiable decarbonisation.

Improving carbon accountability across construction supply chains requires coordinated effort, reliable data, and practical tools that fit into existing workflows. Automation, traceability, and digital twins offer a way to achieve this without adding complexity or burden to project teams.

Contact us to explore how our automated construction solutions can help your projects deliver low carbon infrastructure smarter, faster and with transparency.

Three groundbreaking examples of low-carbon infrastructure

Posted on by Fernando

For years, conversations about decarbonisation and automation in construction have focused mainly on residential projects – houses, schools, and low-cost housing solutions. Low-carbon infrastructure is emerging as a crucial pathway to cutting emissions at scale. 

This shift matters because infrastructure from energy networks and water systems, to roads and utilities represents one of the largest sources of embodied carbon in the built environment. Traditional construction methods depend on carbon-intensive materials, heavy labour, and long delivery times, making it difficult for asset owners to meet climate commitments. 

By enabling faster project delivery, reduced material waste, lower costs, and unprecedented design freedom, additive manufacturing is emerging as a practical solution to some of the most pressing challenges in urban development. From climate emergency and sustainable materials to the efficiency demands of rapidly growing populations, low carbon infrastructure could become a cornerstone of the future city.

Governments, engineers, and utilities are already deploying these solutions on real projects. In this article, we highlight three pioneering examples of low carbon infrastructure, powered by automation and smart design and explore its potential to form the future ecosystem we will be living in. 

What is low carbon infrastructure?

Low-carbon infrastructure refers to structures designed, engineered, and delivered to minimise embodied emissions. This can be achieved by:

  • Smart design that eliminates over-engineering and reduces unnecessary volume of material
  • Low-carbon concrete and optimised reinforcement, lowering emissions from cement and steel
  • Prefabrication and Modern Method of Construction (MMC) to cut waste, minimise transport, and reduce on-site construction activities
  • Reduced excavation and soil disturbance, lowering emissions from earthworks
  • Long-lasting, durable structures that avoid carbon-intensive maintenance or early replacement

Unlike traditional precast components, which are often over-engineered and require steel formwork, low carbon infrastructure using additive manufacturing uses only the exact amount of material needed, eliminating unnecessary waste and reducing environmental impact. This precision allows engineers to design innovative structures that would be difficult or impossible to achieve with conventional construction methods.

For example, Hyperion’s robotic 3D printing system is specifically engineered for infrastructure-grade concrete, combining high performance, regulatory compliance, and sustainability. 

Three pioneering examples of low-carbon infrastructure

1. Foundations for electrical towers substation

Hyperion Robotics has partnered with National Grid in a UK-first trial to manufacture, install and test low-carbon 3D-printed substation foundations. The 3D printed foundations’ optimised design uses 70% less 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.

What makes this project groundbreaking: The UK needs a five-fold expansion of its electricity transmission infrastructure by 2035 to meet rising demand from renewables, data centers, and electrification. As part of the Great Grid Upgrade, supported by Ofgem’s £24 billion investment, over 4,400 km of overhead lines will be upgraded and 35,000 km of new circuits added, enabling up to 126 GW of clean power by 2030.

Using 3D printing for tower components can reduce emissions, minimise waste, and accelerate construction, making grid expansion faster and more sustainable.

2. Pipe support foundations for Strongford Net Zero Hub

Severn Trent Water partnered with Hyperion Robotics to design and manufacture 32 pipe support foundations, demonstrating how advanced 3D printing, material science, and Modern Methods of Construction (MMC) can transform infrastructure.

Hyperion Robotics reimagined the conventional box-shaped foundation with an optimised ribbed design engineered to Eurocode 7 standards. The hybrid structure combined 3D-printed concrete faces with a reinforced concrete core, ensuring durability and full compliance with EN1990 and EN1992 while using significantly less material.

The project achieved 50% less material usage, saving 3 cubic metres of concrete, with an optimised design that maintained full structural integrity. Cost savings reached 60% compared with traditional methods, driven by faster production, reduced installation time, material efficiency, and Hyperion Robotics’ state-of-the-art offsite automated production.

Completed in just 16 days (vs. 49 days using conventional methods), on-site work was reduced by 67%, with minimal manpower required. Foundations were installed safely and efficiently using a single 8-tonne excavator, highlighting the speed, simplicity, and safety of this innovative approach.

What makes this project groundbreaking: The Strongford Net Zero Hub set a new benchmark as the world’s first net-zero wastewater treatment facility. It is groundbreaking because it proves that critical infrastructure can operate at net zero while reliably meeting the needs of modern communities.

By deploying innovative technologies such as 3D printing to reduce, remove, and offset process emissions, the hub not only delivers immediate environmental benefits but also provides a scalable blueprint for the future of wastewater treatment operations.

3. Low-carbon foundations for Iberdrola energy plant

Iberdrola partnered with Hyperion Robotics and Peikko to design and manufacture an optimised low-carbon foundation, demonstrating how advanced automation, material efficiency, and new construction methodologies can transform energy infrastructure.

Hyperion Robotics reimagined the traditional concrete pad foundation with a fully optimised geometry engineered to withstand the structural loads of a 132 kV circuit breaker. The team developed a design-by-testing approach, combining 3D-printed concrete with precision engineering to validate strength, durability, and performance.

The project achieved 75% less material usage compared with a conventional foundation, delivering major reductions in eCO₂ while maintaining full structural integrity. After printing at Hyperion’s facility in Helsinki, the foundation was tested at Peikko’s site in Lahti, where horizontal and vertical loading tests confirmed that the element could withstand three times its design load despite using only a quarter of the material typically required.

What makes this project groundbreaking: In 2021, this low-carbon foundation became the first of its kind on the market, proving that essential energy-sector infrastructure can be manufactured with dramatically lower material consumption and environmental impact. Since this pilot project, the foundation system has continued to evolve, achieving even more advanced optimisation and performance, as demonstrated in the subsequent National Grid project.

Common questions about low-carbon infrastructure

1. Is low carbon infrastructure safe and reliable?

Yes. Properly engineered 3D printed structures are reinforced with steel or fiber additives, making them strong and resilient. In fact, Hyperion Robotics’ low-carbon foundations are up to 10 times stronger than traditional concrete. 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.

2. Can low-carbon infrastructure be customised?

Yes, thanks to Modern Method of Construction like 3D printing. One of the greatest advantages of 3D-printed construction technology is the ability to deliver customised, site-specific designs. This design freedom offers optimisation, increased efficiency and reduced material waste for structures in wastewater treatment, energy, and utility projects.

3. Can low-carbon infrastructure be integrated into traditional construction workflows?

Yes. Prefabricated low-carbon structures can be designed using a Design for Manufacture and Assembly (DfMA) approach, ensuring seamless compatibility with both conventional and modern site assembly practices.

4. Is low-carbon infrastructure code-compliant?

Yes. At Hyperion Robotics, all of our low-carbon structures comply with building regulations and codes (Eurocode EN 1990, EN 1992, etc.). Moreover, all our products and materials go through a rigorous testing regime to demonstrate durability and resistance. Learn more about our code compliant low-carbon structures here.

What’s next for low-carbon infrastructure?

The future of low-carbon infrastructure is full of opportunities to transform construction, utilities, and civil engineering. From wastewater treatment facilities and substations, to renewable energy platforms and transport networks,  additive manufacturing can help deliver faster, safer, and more sustainable solutions to the current construction challenges in these sectors.

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 kind of low-carbon infrastructure can work for your projects.

Why low carbon 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, low carbon foundations are proving to be a game‑changer. At Hyperion Robotics, our mission is to make this new generation of sustainable foundations the backbone of sustainable infrastructure.

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

What are low-carbon foundations?

Low-carbon foundations are engineered concrete bases using Modern Method of Construction such as additive manufacturing to drastically reduce embodied carbon while maintaining full structural performance.

Unlike traditional precast elements, which are typically over-engineered and require steel formwork, low-carbon foundations use just the right amount of material, precisely placed, without moulds or waste. Hyperion’s approach integrates smart design, additive manufacturing and proprietary low-carbon concrete to deliver strong, compliant, and sustainable foundations fit for modern infrastructure.

The problem with traditional foundation construction

Foundations are critical to infrastructure safety and durability — but conventional construction methods are among the most carbon-intensive parts of any project. Common challenges include:

  • Excessive cement use and high CO₂ emissions
  • Over-engineering and material waste
  • Manual labour constraints, site delays, and weather risks
  • Heavy transport and logistics requirements for precast units
  • Limited flexibility to tailor design to specific soil or site conditions

For utilities and infrastructure operators managing multi-site upgrades, even small efficiency and carbon gains can scale into major system-wide benefits.

How low-carbon foundations are built

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 low-carbon 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

Research consistently highlights the carbon-saving potential of low-carbon concrete, utilising additive manufacturing:

  • 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

Low-carbon 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.

When applied across portfolios, these efficiencies can deliver millions in avoided costs — as evidenced by early results from our National Grid pilot.

Operational benefits — speed, precision, and flexibility

For asset owners and contractors working across multiple constrained sites, low-carbon foundations offer major 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

All Hyperion low-carbon foundations are fully code-compliant and structurally reinforced. 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.

Low-carbon 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 specifically on critical infrastructure — delivering code-compliant, low-carbon concrete foundations at scale.

Our integrated model combines:

  • In-house robotics and automation systems
  • Low-carbon concrete research and development
  • Structural engineering aligned with UK and EU standards
  • Digital design, QA, and delivery under one platform

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 low-carbon foundations

From substations to renewable energy sites, transport hubs, and industrial platforms, low-carbon foundations are redefining how we build sustainably — from the ground up.

The foundation of tomorrow’s infrastructure will not only support structures above ground, but also the planet beneath it.

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

Posted on by Fernando

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.

Don’t miss a thing. Sign up to our email newsletter.

Addressing 20 common myths about 3D printed structures

Posted on by Fernando

3D printing is transforming the construction industry, offering faster timelines, greater design flexibility, reduced material waste, and a more sustainable way to build. Yet despite its growing adoption worldwide, misconceptions still linger around the practicality, strength, and scalability of 3D printed structures.

At Hyperion Robotics, we know that these myths often hold contractor, developers, and clients back from embracing the full potential of 3D printing in construction. In this post, we’re diving into 20 common myths about 3D printing, and setting the record straight once and for all.

Myth 1: 3D printing can only be used to print houses

While residential buildings have been among the first 3D printed structures due to demand and practicality, the technology is far more versatile. It’s being used for everything from electrical transmission tower foundations to wastewater treatment plants and other infrastructure. Hyperion Robotics has been leading the way in large-scale, civil infrastructure applications, proving that 3D printing can handle projects of any type or size. 

Myth 2: 3D printed structures aren’t strong enough

Many people mistakenly believe 3D printed structures lack strength. This couldn’t be further from the truth. 

Our structures meet local codes and standards (Eurocode EN 1990, EN 1992, etc.) Moreover, all our products and materials undergo rigorous testing to guarantee long-lasting performance. Learn more about our code compliant 3D printed structures here.

Myth 3: 3D printing is more expensive than traditional construction

While upfront costs for 3D printing may seem high, the overall long-term cost savings are significant. Minimal labour on site, less material waste, faster construction timelines, and minimised site disruptions all contribute to lower total project costs. 

Take our partnership with National Grid as an example. We’re working together on a UK-first trial to manufacture, install, and test low-carbon, 3D-printed substation foundations that use 70% less material and have been proven to be four times stronger than those built using traditional methods.

Even better, Hyperion Robotics offers prefabricated 3D printed components, so clients don’t need to invest in printers themselves. These components are delivered and installed on-site, making the technology accessible without requiring additional infrastructure. 

Myth 4: 3D printing is just a trend, not a long-term solution

3D printing is far from a fleeting trend. It’s backed by decades of research, increasing investment, and successful real-world projects worldwide. As technologies mature and regulations adapt, 3D printing is becoming an essential tool in modern construction practices. At Hyperion Robotics, we’re focused on delivering scalable, long-term solutions that meet the evolving needs of the industry.

Myth 5: 3D printing is a new technology

Although it’s gaining popularity now, 3D printing was actually developed in the 1980s. Its application in construction has evolved over the last decade, leveraging advancements in robotics, materials science, and computer-aided design, to produce complex, high-performance structures.

Myth 6: All 3D printed parts are made of plastic

In construction, plastics are rarely used structurally. Instead, we use concrete, mortar, geopolymer, and composite materials that offer durability, fire resistance, and load-bearing properties necessary for building safe, long-lasting structures.

Myth 7: 3D printed structures are weak

Properly engineered 3D printed structures are reinforced with steel or fiber additives, making them strong and resilient. In fact, Hyperion Robotics’ 3D printed foundations are up to 10 times stronger than traditional concrete. 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.

Myth 8: 3D printing will replace all construction jobs

Far from eliminating jobs, 3D printing changes the nature of work. It reduces labour-intensive tasks, improves worker safety, and opens new roles in machine operation, digital design, and quality control.

Myth 9: 3D printing is only suitable for small-scale projects

3D printing is highly scalable, making it perfect for both large-scale projects and custom, one-off components. In fact, at Hyperion Robotics, we’ve successfully delivered hundreds of 3D reinforced concrete foundations, demonstrating how the technology can support real-world, high-volume construction needs with consistent performance and reduced material use.

Myth 10: 3D printing is extremely slow and inefficient

Advanced 3D printing technology can operate continuously and complete projects faster than traditional construction methods. Take our Killinghall case study: we completed the chambers in just one day, instead of three weeks. Minimal manpower and a small HIAB ensured safer, simpler assembly, cutting labour and disruption time drastically.

Myth 11: 3D printing is only useful for creating prototypes

While prototyping remains valuable, many 3D printed elements are finalised components designed for actual use. These components often require fewer adjustments and rework due to the precision of digital manufacturing.

Myth 12: 3D printed structures are heavy

3D printing in construction allows for the creation of highly optimised, lightweight structures. By precisely controlling material placement, we use only what is structurally necessary and nothing more. Unlike traditional methods, which often rely on overbuilt elements and excess material to ensure strength, 3D printing leverages design algorithms and advanced robotics to minimise volume without compromising integrity.

This reduction in material volume directly translates into lighter components, which means fewer trucks are needed for transport, less fuel consumption, and lower emissions. On dense urban sites or remote projects, the logistical advantages are even more significant, reducing congestion, cutting delivery costs, and enabling faster on-site assembly.

Myth 13: 3D printing doesn’t offer any real sustainability benefits

3D printing significantly reduces construction waste by using only the material needed. Additionally, it allows for topological optimisation, designing structures that are strong yet lightweight, saving materials and energy. Many projects also incorporate recycled materials, enhancing environmental credentials.

Myth 14: 3D printed structures require expensive, specialised materials

While some high-end and innovative materials exist, many 3D printing processes can use standard, locally sourced materials like concrete and sand mixtures. This makes 3D printing an affordable solution for a wide range of projects. 

Myth 15: 3D printing can’t comply with building codes

At Hyperion Roboticss, all of our 3D printed products comply with building regulations and codes (Eurocode EN 1990, EN 1992, etc.). Moreover, all our products and materials go through a rigorous testing regime to demonstrate durability and resistance. Learn more about our code compliant 3D printed structures here.

Myth 16: 3D printing makes repairs and maintenance difficult

The modular nature of 3D printed components actually simplifies repairs. With digital models, parts can be quickly reproduced, reducing downtime and maintenance costs. 

Myth 17: 3D printing requires large, expensive, immobile equipment

Mobile and modular 3D printers have been developed to facilitate on-site printing in remote or constrained locations, making the technology accessible beyond large factory settings. For example, by applying DfMA principles and 3D printing technology, Hyperion Robotics delivers foundations, split flow chambers and draw pits that can be transported by truck to the site and installed in the same day by their client’s own excavator without any special tools or equipment.

Myth 18: 3D printing is only suitable for niche or experimental projects; not mainstream construction

3D printing is rapidly moving into the mainstream, with successful applications in housing, infrastructure, and commercial buildings. Hyperion Robotics is leading this charge by demonstrating how 3D printing can meet the demands of large, complex construction projects.  

Myth 19: 3D printing complicates project management and coordination

Integrating 3D printing with digital workflows and Building Information Modeling (BIM) significantly streamlines project management by enhancing communication, minimising errors, and enabling precise planning before construction begins. In our recent project with MMB, this integration even accommodated last-minute design changes without disrupting the project timeline or progress.

Myth 20: 3D printing limits design flexibility and customisation for clients

3D printing offers exceptional design freedom, enabling the creation of complex geometries, curved surfaces, and customised architectural details without the cost and time constraints of traditional fabrication methods. Hyperion Robotics’ products feature unique geometries that optimise material usage while meeting the diverse needs of clients across various sectors.

It’s time to move beyond the myths and embrace 3D printing

3D printing in construction is far beyond reach; it’s a practical, proven technology transforming how we build. By understanding and debunking these common myths, we hope you have a clearer understanding of how 3D printing can benefit your next project.

Now is the time to move beyond the myths and embrace what’s possible. Explore how advanced 3D printing is addressing today’s construction challenges—and how it can be strategically adopted for your next project. Get in touch to learn more.

Don’t miss a thing. Sign up to our email newsletter.

50+ Essential Terms of Modern Construction for Civil Engineers

Posted on by Fernando

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. 

Back to A–Z

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.

Back to A–Z

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 a Digital Product Passport?

A Digital Product Passport (DPP) is a secure digital record that stores and shares key information about a product’s materials, origin, environmental impact, and lifecycle to improve transparency, traceability, and sustainability across the supply chain.

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. 

Back to A–Z

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.

Back to A–Z

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.

Back to A–Z

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.

Back to A–Z

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.

Back to A–Z

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). 

Back to A–Z

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.

Back to A–Z

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.

Back to A–Z

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.

Back to A–Z

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.

Back to A–Z

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. 

Back to A–Z

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.

Back to A–Z

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.

Don’t miss a thing. Sign up to our email newsletter. 

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.

Don’t miss a thing. Sign up to our email newsletter.