The Water Breakthrough Challenge, funded by Ofwat, has driven notable advancements in 3D printing for UK water companies. Since the 2023 launch of the Printfrastructure project, several innovation trials have been exploring the use of 3D printing with both concrete and polymer to create essential infrastructure for water management. This initiative has produced significant results for companies like United Utilities and Scottish Water, paving the way for operational improvements, increased resilience, and cost savings.

One of the standout projects from the Water Breakthrough Challenge involved PrintCity, a 3D manufacturing facility at Manchester Metropolitan University, which led the creation of replacement parts using 3D scanning, computer-aided design, and polymer printing. United Utilities has incorporated three such printed items—a wastewater jet nozzle, a CCTV skid plate, and a trough for water monitoring instruments—into its daily operations following rigorous testing and trials. Laboratory equipment printed through this technology is also now in use by both United Utilities and Scottish Water.

For water companies, the ability to print replacement parts on demand presents a valuable solution to issues around equipment availability, delivery timelines, and rising costs. The study underscores how in-house 3D printing can reduce dependence on external suppliers, improve turnaround times, and lower environmental impact. These advantages are crucial to the sector, which faces mounting operational and sustainability challenges.

In June 2024, United Utilities introduced a temporary 3D concrete printing hub at its Wigan Wastewater Treatment Works, marking a first for the industry. This hub was set up with technology provided by ChangeMaker3D, a company that began collaborating with United Utilities in 2021 through its Innovation Lab program. The Wigan facility has printed various concrete structures, including combined sewer overflow chambers and containment walls for the Industrial Emissions Directive. Beyond producing these assets for United Utilities and Scottish Water sites, the hub serves as a demonstration center to showcase 3D printing's potential to the wider water and construction sectors.

A year earlier, Yorkshire Water installed a 3D concrete-printed drawpit structure at its second-largest wastewater treatment facility near Bradford, underscoring the momentum of 3D concrete printing in the industry.

United Utilities’ chief engineer of innovation and carbon, Lisa Mansell, highlighted the transformative nature of these advancements: “The Water Industry Printfrastructure project is transforming 3D construction printing from an innovation into an accessible tool to support everyday operations, drive efficiencies and help meet environmental goals. We are seeing tangible results from the printing processes developed by the project team, which have potential for adoption at scale. The technology presents many more exciting opportunities for the sector, and we look forward to showing just what is possible.”

Nick Hurst, a technical specialist from Manchester Metropolitan University’s PrintCity, spoke to the operational value already seen from 3D printing: “This collaborative project is helping turn 3D printing into business-as-usual, an approach that will be game-changing for the sector. Some of the project’s outcomes—such as the successful printing of polymer spare parts—are already making a difference on the ground and delivering significant carbon, cost and labour savings. PrintCity has been working with the operational teams to enhance the designs, improving durability and ensuring parts can be maintained more effectively.”

Ian Watt, Scottish Water’s capital investment net zero manager, emphasized the broader impact: “The water industry is planning to spend a record amount on infrastructure during the next asset management period, with an ambitious capital programme that can only be delivered through new approaches and innovation. The Printfrastructure project has shown that 3D construction printing can deliver a 25% reduction in carbon, 20% cost saving and 55% reduction in labour, versus traditional methods. Assets can be built quickly, with a reduction in materials, creating a safer, more efficient working environment and helping meet carbon goals.”

As the Printfrastructure project approaches completion, the team plans a showcase webinar to share insights with the rest of the sector, highlighting 3D printing’s potential to reshape water infrastructure with speed, efficiency, and sustainability at scale.