3D printing optimised structures using less concrete

Optimising waste recycling into sustainable, 3D-printed concrete. 
Climate Change Mitigation Resource Use Advancing Net Zero

Problem Addressed

In the built environment, cement use is the cause of 8% of global CO2 emissions every year, according to the BBC. Construction companies face the challenge of virgin material over-consumption, whilst industrial companies endure high storage costs and high risk environments from the generation of large quantities of waste.

Solution Overview

Hyperion Robotics combines large-scale, 3D printing with low-carbon concrete made of industrial waste materials such as mining tailings, ashes, slags and demolition waste. Their variety of sustainable infrastructure products include foundations, water tanks, trenches and buildings. They have developed a special construction material based mainly of mining tailings that uses zero cement. Accompanying this, their software enables optimized structural designs for 3D printing, resulting in minimal material usage. Clients can choose to use traditional cement-based concrete with the technology or low-carbon concrete made from local recycled materials.

The system has low power requirements at approximately 15kw/hr, though it may vary per project. Due to the decreased use of cement and virgin aggregates, embodied carbon is reduced, lead time is reduced by 50%, and the need for tailing storage facilities is lessened, limiting health and safety risks. Accompanying this, Hyperion Robotics also provides training, support and maintenance services.

Hyperion Robotics provides different options to allow customers to more easily adopt their technology – either an initial investment (£150k to £500k depending on the complexity of the systems) or through leasing it for a project / a certain period of time. Clients can expect an ROI in 12 months or less when Hyperion Robotics’ micro-factories are at full production, with 30% in financial savings due to the decreased use of cement and virgin aggregates. Their models and technology allow clients to easily scale up their production and execute projects that otherwise they would have not been able to deliver with traditional technology.

Company name

Hyperion Robotics Oy

UK availability

Yes

Solution launch date

2021

Links

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Case Study

Hyperion Robotics designed and produced 2 x 2 m water tanks for the mining industry made with almost 99% recycled mining tailings and zero cement.

Metso Outotec develops mineral processing plants for mining and industrial companies that allow the drying of mining tailings on a very large scale. Once the tailings are processed, Hyperion Robotics’ solution is used to complement Metso’s technology, allowing the use of a high percentage of this waste as a component in their concrete. The concrete has been used to produce sustainable infrastructure products for the mining company itself, but also for the surrounding communities. They are currently looking into building similar tanks with 10 x 10 m dimensions.

Facts and Figures

12 Months

Return on investment.

50 %

Reduction in lead time.

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