United Utilities is accelerating its adoption of 3D printing technologies, marking a significant shift in how the water sector approaches infrastructure and operations. This move comes as the pioneering ‘Water Industry Printfrastructure’ project concludes after two groundbreaking years, during which several industry firsts were achieved. Funded by Ofwat’s Innovation Fund and led by United Utilities in collaboration with ChangeMaker3D, Manchester Metropolitan University’s PrintCity, and Scottish Water, the project has demonstrated the potential of 3D printing to revolutionize the sector.
Since its launch in 2023, the project has explored both concrete and polymer 3D printing through a series of studies. United Utilities recently shared the results at a knowledge-sharing event attended by Ofwat, other water companies, and supply chain partners. The company confirmed that it has already integrated both 3D polymer and concrete printing into its operations and is now looking to scale up these technologies to support its AMP8 investment programme.
Lisa Mansell, Chief Engineer (Innovation and Carbon) at United Utilities, emphasized the transformative impact of the project. “We’ve all learned so much through this project, and it is no exaggeration to say it is transformative,” she said. “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.”
The collaboration with PrintCity, a 3D manufacturing facility at Manchester Metropolitan University, focused on creating replacement parts through 3D scanning, computer-aided design (CAD), and 3D polymer printing. Several printed items, including a wastewater jet nozzle and a trough for water monitoring instruments, are now in use by United Utilities following rigorous testing. Laboratory equipment printed through the project is also being utilized by both Scottish Water and United Utilities.
Alan Dempsey, Project Manager for PrintCity at Manchester Metropolitan University, highlighted the project’s impact on addressing industry challenges. “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,” he said. “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 notable industry first was the establishment of a temporary 3D concrete printing hub at United Utilities’ Wigan Wastewater Treatment Works in June 2024. The hub printed various concrete infrastructure, including combined sewer overflow chambers and Industrial Emissions Directive (IED) containment walls. The facility also served as a demonstration site to showcase the technology to the water and construction sectors, as well as other industries. United Utilities became the first water company to install IED walls into an operational environment and successfully printed distribution chambers and manhole rings in challenging winter conditions, testing both the concrete’s strength and the robot printer’s capabilities.
Natalie Wadley, CEO and Co-Founder of ChangeMaker3D, underscored the project’s significance for her company. “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 of Ofwat’s Innovation Fund, praised the project’s achievements. “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.”
This development could reshape the water, sanitation, and drainage sector by accelerating infrastructure projects, reducing costs, and minimizing environmental impact. As other water companies take notice and adopt similar technologies, the sector could see a paradigm shift towards more efficient, sustainable, and rapid construction methods. The success of the Printfrastructure project sets a precedent for future innovations, encouraging further collaboration between