In the shift toward more sustainable and efficient infrastructure, 3D concrete printing is emerging as a transformative approach. Unlike conventional construction methods that rely on moulds or subtractive cutting from solid blocks, additive manufacturing builds structures layer by layer from liquids, powders, or strands. This process eliminates the need for formwork, enabling more intricate geometries and optimized material use.
UK-based innovation specialist ChangeMaker 3D is advancing its “Printfrastructure” technology with the backing of High Speed 2 (HS2) Ltd, the organization behind Britain’s new high-speed rail line. “Printfrastructure involves using computer controlled robotic printers to extrude a rapid hardening cementitious mixture to produce concrete components,” says ChangeMaker 3D director Natalie Wadley. The precise layering allows for internal lattice structures that increase compressive strength while reducing weight, and in some cases, removes the need for carbon-intensive steel reinforcement.
Instead of rebar, the company is exploring microscopic strands of graphene, a material derived from flaked graphite and celebrated for its exceptional strength. “We aim to use microscopic strands of graphene which has shown early stage compressive benefits,” Wadley explains. This approach, supported by advanced materials specialist Versarien, could significantly lower the carbon footprint of printed components. Wadley notes, “It is apparent to us that a perfect confluence of graphene availability and development of printing capability has occurred. It adds to our feeling that Printfrastructure’s time has come.”
Dutch firm Cybe Construction, a leader in construction automation and digitalisation, is another key partner. Cybe develops hardware such as 3D printers, sustainable fast-setting materials, and software to streamline complex builds. Their machines, based on ABB Robotics platforms, are modified with specialized nozzles and digital controls for concrete extrusion. Current units weigh about 5 tonnes and have a robotic reach of 3 meters, with work underway to extend that by up to 1.5 meters. For larger components, gantry systems can position the printer beyond its standard reach.
The proprietary dry mix used in Printfrastructure arrives from Cybe in bags and is activated with water on site. Wadley is constrained in revealing details due to patent considerations but confirms, “I’ve been told there’s no ordinary Portland cement involved and assured that what we are supplied with is 30% more eco-friendly than a conventional mixture.” A “secret agent” additive enables the mix to set in just three minutes, a necessity for layer-by-layer deposition but a challenge for preventing nozzle clogs.
Material supply from continental Europe is stable for now, though scaling production in the UK may be necessary as demand grows. The technology’s credibility is bolstered by its upcoming proof-of-concept trial with HS2’s London tunnels contractor, the Skanska Costain Strabag joint venture (SCS JV). HS2 innovation manager Rob Cairns underscores the alignment: “Innovation has a crucial role to play in cutting energy consumption and carbon emissions on HS2, so we’re looking for creative and fresh thinking on how to achieve this.”
In March, SCS JV will deploy Printfrastructure to build a retaining wall that will support spoil for launching tunnel boring machines in a sensitive area. “It’s important that we give such technologies [as Printfrastructure] the opportunity to flourish because of the possibilities it offers the industry to make a step change in how projects are delivered,” says Andrew Duck, SCS JV temporary works manager.
Wadley is also contributing to the development of international standards, participating in the working group for “ISO/ASTM 52939 – additive manufacturing for construction – qualification principle – structural and infrastructure elements.” Establishing such frameworks will be essential for integrating printed concrete into mainstream engineering practice.
For HS2 and its partners, the promise of leaner, cleaner, and more adaptable construction methods extends beyond efficiency and sustainability. Cairns believes it will reshape the industry’s appeal: “I think it will inspire the next generation.”