Hyperion Robotics to open Forge I concrete 3D printing factory in Flixborough by summer 2026

Finnish additive manufacturing specialist Hyperion Robotics has signed an agreement with LKAB Minerals to establish Forge I, a prefabricated concrete production plant in North Lincolnshire, UK. The facility will utilize robotic and automated manufacturing systems to produce pre-cast concrete foundation units with footprints up to 3m x 3m and heights of 2.5m. LKAB Minerals will provide the industrial site and mineral inputs, while Hyperion Robotics manages the computational design and robotic production operations. The factory aims to produce over 50 foundation units per week for clients in the energy, water, data center, and utilities sectors.

This expansion addresses the high labor costs and carbon intensity of traditional on-site concrete construction by moving production to a controlled factory environment. Hyperion's approach follows successful trials with National Grid and the University of Sheffield, which demonstrated a 70% reduction in concrete volume and a 65% reduction in embodied carbon for electricity substation foundations. By integrating mineral supply chains directly with automated additive manufacturing, the company is positioning itself as a vertically integrated provider of low-carbon infrastructure components. This model competes with traditional pre-cast concrete manufacturers by offering higher geometric complexity and material efficiency through digital design.

Hyperion Robotics must now prove that the Forge I facility can maintain consistent production rates of 50 units per week while meeting Eurocode and CE compliance standards. The success of this scale-up depends on the seamless integration of LKAB's mineral supply with the proprietary robotic deposition systems to ensure repeatable structural integrity across large-scale infrastructure deployments.