Building the future: UK’s first-of-its-kind 3D concrete printer to power sustainable construction research

Northumbria University has announced the installation of new cutting-edge 3D construction printing technology that can print concrete structures faster, cheaper and more sustainably than conventional methods. This advanced technology will enable the testing and validation of concrete elements which could be adopted by industry, positioning Northumbria as a leading hub for sustainable construction innovation in the North East.

The University has teamed up with world-leading 3D construction printer manufacturer, Luyten 3D, and UK-based, award winning sustainable technology company, ChangeMaker 3D, to establish the new capability within Northumbria’s Structures Laboratory within its Mechanical and Construction Engineering department. The addition of the new technology was supported by a Royal Society Research grant - a prestigious funding opportunity for scientists in the UK.

Transforming the way we build is a vital factor in reaching net zero commitments in the UK and around the world. According to a 2024 UN Environment Programme report, the buildings and construction sector contributes significantly to global climate change, accounting for around 21 per cent of global greenhouse gas emissions. With widespread use across the construction industry, concrete is a major source of carbon dioxide, generating around 8 per cent of all emissions globally.

3D concrete printing boasts time, energy, resource and money-saving credentials, with Luyten 3D’s projects in Australia showing it can enable up to 60 per cent reduction of construction waste, 70 per cent reduction of production time, and 80 per cent reduction of labour costs when compared to hands-on construction projects.

Northumbria’s Assistant Professor of Structural Engineering, Dr Mohammadali Rezazadeh, who is the Principal Investigator of this Royal Society Research grant, said: “At Northumbria University, our team is leading research in 3D concrete printing technology to develop sustainable infrastructure. We are developing eco-friendly concrete mixes, reinforcing them with corrosion-resistant composite materials, and optimising their designs to reduce material usage, shaping a more sustainable future in construction.”

The adoption of 3D concrete printing poses exciting opportunities, yet given the relative novelty of this construction technique, many companies have questions about how they could make best use of the technology. The installation of the ‘Platypus’ 3D concrete printer at Northumbria University will not only enable advanced research, but also opportunities for industry collaboration.

Luyten 3D’s Platypus concrete printer can produce complex geometrical structures in a short amount of time, using biomimicry to create better weight to strength ratios with less concrete. The technology will allow companies to work with Northumbria to innovate more quickly and at cheaper cost by pilot-testing smaller-scale versions of build elements for long-term performance and durability with this before investing in full-scale projects.

Scientists at the University are already exploring partnerships with leading health, water and civil engineering organisations to support the development of sustainable hospital buildings, water tanks and green infrastructure.

In addition to infrastructure applications, the printer’s abilities to print complex structures can also explore how fluid and organic structures in housing have a significantly higher energy efficiency.

Luyten 3D’s President and CEO Ahmed Mahil said, “this is among the first Luyten 3D construction 3D printers to arrive in the United Kingdom.

"Our printers are amongst the fastest selling construction robots worldwide and we look forward to seeing how they can address the challenges in the UK, especially in the housing industry,” Mahil said.

Luyten 3D’s new printing technology could also help address the low supply of housing in the market and in social housing, with the company affirming its printers can construct the majority of a three-bedroom house structure in matter of weeks rather than months.
Such solutions are welcome to the housing crisis debate, especially in North East England where social housing waiting lists are at their highest level since 2012, according to charity Shelter. The waiting list in the region hit 75,985 in 2023, which is a fifty-one per cent increase from the year prior.

Non-social housing shortages are also putting pressure on rents and housing prices. In 2022, 82 per cent of the region’s landlords reported a rise in demand for rented housing with only 5 per cent planning to increase the number of rented properties in the following year.

“Luyten3D is ready to contribute to increasing housing supply in the United Kingdom through their technology and are open to any discussions with those in the industry to help tackle the crisis at hand,” Mahil said.

ChangeMaker 3D leverage 3D concrete printing to unlock greener, faster solutions for the UK construction sector through Printfrastructure™ - their trademarked identity for 3D concrete printed infrastructure components, together with the end-to-end supply capability that supports production.

ChangeMaker 3D facilitated the selection and installation of the Luyten 3D Platypus into Northumbria University. ChangeMaker 3D’s co-founder and CEO, Natalie Wadley, will be supporting the University on the execution of civil infrastructure projects. She said: “In addition to the R&D opportunities that access to 3D concrete printing technology will provide, it will also offer students the opportunity to expand their skills and increase diversity in the construction industry.

“Working together with Northumbria University and Luyten 3D we’re supporting our mission to deliver social value through skill development and preparing our future designers and engineers to integrate 3D concrete printing into all aspects of our UK construction sector.”