Printing the future: Manchester Met and United Utilities lead the charge on 3D printing in the water sector

Water supply company United Utilities is forging ahead with its plans to adopt 3D printing methods across its delivery and daily operations thanks to a unique initiative with Manchester Metropolitan University. 

The move comes as the trailblazing ‘Water Industry Printfrastructure’ project reaches its conclusion after two successful years, during which several industry firsts have been achieved. 

Funded through Ofwat’s Innovation Fund the project was led United Utilities, in partnership with Manchester Met, tech innovators ChangeMaker3D, and Scottish Water.  

Since its launch in 2023, both concrete and polymer 3D printing have been explored in a series of studies.  

Reporting back on the results, United Utilities confirmed it has already adopted both 3D polymer printing and 3D concrete printing and is now seeking to scale up to support delivery of its AMP8 investment programme. 

AMP8 is the largest environmental programme in the North West in more than a century and aims to create cleaner rivers, more reliable water supplies and improvements to services for customers, communities and the environment. 

Lisa Mansell, Chief Engineer, Innovation and Carbon at United Utilities, said: “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 is 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.” 

Work with PrintCity, a 3D manufacturing facility based at Manchester Metropolitan University, included creating replacement parts through 3D scanning, computer aided design (CAD) and 3D polymer printing. 

As a result of the project, three printed items – a wastewater jet nozzle, CCTV skid plate and trough for water monitoring instruments – are now being used by United Utilities in everyday operations, following rigorous testing and trials.  

Laboratory equipment has also been printed and is being used by both Scottish Water and United Utilities. 

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, Manchester Met 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.” 

Another industry first saw the opening of a temporary 3D concrete printing hub at United Utilities’ Wigan Wastewater Treatment Works in June 2024.  

The hub printed a range of concrete infrastructure, including combined sewer overflow chambers and Industrial Emissions Directive (IED) containment walls. The facility was also used as a demonstration facility to showcase the technology to the water and construction sectors, along with other industries. 

Through the project, United Utilities became the first water company to install IED walls into an operational environment. They also proved the technology’s potential to extend the winter construction period when they successfully printed distribution chambers and manhole rings in cold, damp, and icy conditions – testing both the strength of the concrete, and its robot pourer/printer.  

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”