UK’s first 3D concrete printer to tackle sustainability challenges

Northumbria University has installed the UK’s first advanced 3D concrete printer, aiming to revolutionise sustainable construction through research and collaboration. The cutting-edge printer, developed by Luyten 3D, is now operational in the university’s structures laboratory within the mechanical and construction engineering department.

The technology, known as the Platypus 3D concrete printer, uses advanced biomimicry to create lightweight structures with better strength-to-weight ratios. It can produce complex geometrical designs quickly, reducing material use and optimising performance. According to Luyten 3D, the printer reduces construction waste by 60%, production time by 70%, and labour costs by 80% compared to traditional methods.

Dr Mohammadali Rezazadeh, assistant professor of structural engineering and principal investigator of the project, says the printer enables researchers to test eco-friendly concrete mixes and innovative designs: “We are developing sustainable infrastructure by reinforcing concrete with corrosion-resistant materials and reducing overall material usage,” he says.

The project is a collaboration between Northumbria, Luyten 3D, and UK-based sustainable technology company Changemaker 3D. The installation was funded by a Royal Society research grant. Highlighting the project’s broader impact, Changemaker 3D co-founder Natalie Wadley, said: “This technology not only enables advanced research but also equips students with skills to integrate 3D concrete printing into the UK construction sector.”

The printer has the potential to address critical challenges in the industry. Concrete is a significant source of carbon dioxide, contributing 8% of global emissions. According to the UN, the construction sector accounts for 21% of global greenhouse gas emissions. Luyten 3D’s printer aims to tackle these issues by reducing waste and energy use.

Beyond sustainability, the printer offers solutions to the UK’s housing shortages. Luyten 3D claims it can construct most of a three-bedroom house in just weeks. The North East has been particularly affected, with a 51% increase in social housing waitlists between 2022 and 2023, according to charity Shelter.

The Platypus printer also allows businesses to pilot smaller-scale designs before committing to full-scale projects, saving costs and resources. It is already being used to explore applications such as sustainable hospital buildings, water tanks, and green infrastructure.

“This printer represents a step forward in creating a sustainable construction sector that meets the challenges of our time. It will also help build collaborations with industry to innovate more effectively,” added Dr Rezazadeh.