National Grid has announced a groundbreaking collaboration with Hyperion Robotics and the University of Sheffield to trial the UK's first 3D-printed substation foundations.

The initiative aims to reduce construction-related carbon emissions and cut network infrastructure costs, aligning with National Grid’s broader mission to leverage innovation to future-proof the electricity transmission network.

The pilot project, funded by Ofgem's Network Innovation Allowance, is exploring the viability of using low-carbon, 3D-printed concrete structures as an alternative to traditional substation foundations. If adopted across all National Grid substations, the technology could save up to 705 tons of concrete, reduce CO₂ emissions by 323 tons, and deliver £1.7 million in consumer savings over the next decade.

Significant environmental and operational benefits are projected, including:

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• 70% reduction in concrete usage

• 80% less soil displacement

• 65% cut in embodied carbon emissions

• 70% weight reduction

• 50% fewer site operative hours

The substation foundations will be designed and manufactured by Hyperion Robotics in Finland. Full-scale testing will be conducted by the University of Sheffield, with additional field trials set for late 2025 at National Grid’s Deeside Centre for Innovation in North Wales.

Dr Muhammad Shaban, Lead Innovation Engineer at National Grid Electricity Transmission, commented: "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."

Hyperion Robotics CEO and founder Fernando De los Rios added: "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."