Fernando
09 Jun 2025
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.
The 3D printed foundation’s optimised design saves 70% of the material, resulting in 80% less soil displacement and reduced weight for easier transportation. Throughout the lifecycle from design to installation, 65% less CO2 is produced.
Despite using fewer materials, Hyperion Robotics’ foundations have been proven four times stronger than traditional methods. Previous on-site structural tests of printed specimens have demonstrated significantly higher resistance compared to conventional foundations, ensuring enhanced durability and long-term reliability. Hyperion Robotics’ approach to Design for Manufacture and Assembly (DfMA) reduces site operative hours by 50%, streamlining production and minimising the risks associated with manual labour.
Fernando De los Rios, Hyperion’s CEO and founder, commented, “Collaborating with National Grid, one of the world’s largest utility companies, marks a pivotal moment for Hyperion Robotics as we advance our mission to help the industry build smarter and greener. This partnership accelerates our efforts to decarbonise the construction sector through cutting-edge engineering and low carbon 3D-printed concrete structures. Through this collaboration, National Grid is setting an inspiring global benchmark for innovation and sustainability in the energy sector.”
Dr Muhammad Shaban, Lead Innovation Engineer at National Grid Electricity Transmission, said: “Our collaboration with Hyperion Robotics is a real step forward in achieving more innovative construction practices which align with our bold and ambitious commitments on sustainability. This trial of low-carbon 3D printed alternatives to concrete for substation foundations is the first of its kind in the UK, and has the potential to transform construction activities across the industry. The project has been funded by Ofgem’s Network Innovation Allowance, which provides an allowance to energy network licensees to fund innovation projects that have the potential to deliver longer term financial and environmental benefits for consumers.”
Dr. Behzad Nematollahi, Lecturer in Concrete Technology at the University of Sheffield at the University of Sheffield, said: “We are delighted to be collaborating with Hyperion Robotics and National Grid on this innovative project. To ascertain the load-bearing capacity of the 3D-printed concrete foundations, we will conduct full-scale testing using state-of-the-art engineering testing facilities at the Intelligent Infrastructure Laboratory located at ICAIR, the Integrated Civil and Infrastructure Research Centre at the University of Sheffield.”
The project has been funded by Ofgem’s Network Innovation Allowance, which provides an allowance to energy network licensees to fund innovation projects that have the potential to deliver longer term financial and environmental benefits for consumers.
For more information or to explore potential partnerships, contact contact@hyperionrobotics.com.
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