UK water utility United Utilities has explored the potential of 3D printing technologies in the water industry as part of the “Water Industry Printfrastructure” project and is now beginning to gradually integrate these methods into regular operations. The focus was on both polymer-based and concrete-based additive manufacturing processes, which were tested under real-world conditions over a two-year project period. The initiative was funded by the Innovation Fund of the regulatory authority Ofwat.
In collaboration with start-up ChangeMaker3D, the PrintCity 3D printing center at Manchester Metropolitan University, and Scottish Water, the project investigated the suitability of various printing techniques for producing components and infrastructure elements. Items printed included wastewater components such as jet nozzles and measurement troughs, as well as load-bearing structures like distribution chambers, overflow systems, and IED (Infrastructure Explosive Device) protection walls made of concrete.
Chief Engineer (Innovation and Carbon) Lisa Mansell explained: “We’ve all learned so much through this project and it is no exaggeration to say it is transformative. We’ve seen tangible results using both techniques and it’s clear that 3D printing will play an important role in driving efficiency in construction and daily operations. As well as being able to print assets in a matter of hours rather than days or weeks, the techniques have proven to be financially and environmentally efficient with carbon savings of up to 50% possible. We’ve already seen a lot of interest from other water companies, and it is encouraging to see that some are already adopting these techniques.”
Alan Dempsey, Project Manager for PrintCity at Manchester Metropolitan University, said: “This project enabled us to address a range of challenges faced by water companies around the availability of replacement parts when managing their infrastructure, as well as lead times and excessive costs. Alongside ChangeMaker3D, MMU has empowered United Utilities to 3D print concrete and polymer parts when they are required. This is helping them to reduce the reliance on the delivery of new equipment, improve the turnaround times for project delivery and take major steps forward in reducing costs, resources and impact on the environment.”
A temporary print center located at the Wigan wastewater treatment plant served as the central hub for technology testing and knowledge transfer within the industry.
Natalie Wadley, CEO and Co-Founder of ChangeMaker3D added: “This project has been game changing for our business. We are a self-funded UK start up with an unwavering belief in our vision to print like our planet depends on it. The time is now. AMP8 won’t wait, our climate crisis won’t wait. Printfrastructure has a vital role to play in creating a water legacy that everyone is proud of, and we are ready to scale, integrate and deliver impact.”
Marc Hannis, Principal, Ofwat Innovation Fund, said: “The Ofwat Innovation Fund was launched to encourage industry-wide collaboration to tackle the major challenges facing the sector. Water Industry Printfrastructure is a perfect example of what can be achieved when the sector works closely with innovative start-ups like ChangeMaker3D, leading universities and partners outside of England and Wales. 3D printing provides enormous opportunities for the water sector to build and upgrade infrastructure rapidly, with a lower cost to both bill payers and the environment. In just two years, WIP has demonstrated its effectiveness and value; we want technology like this to be used at scale in the coming years across England and Wales”.
Looking ahead to the upcoming AMP8 investment cycle, United Utilities plans to further expand the use of 3D printing. The goal is to establish additive manufacturing not just for individual applications, but as an integral part of infrastructure maintenance and new construction.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
