Fernando
24 Feb 2026
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.”
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