ABB Robotics & Serendix: 3D Printing Japan’s First Railway Station

How ABB Robotics and 3D Printing are Revolutionizing Japan’s Railway Infrastructure

The construction industry is currently facing a transformative shift driven by industrial automation. In a landmark project, Serendix collaborated with ABB to construct Japan’s first 3D-printed railway station. This initiative addresses critical challenges like aging infrastructure and labor shortages while showcasing the precision of modern factory automation.

Addressing the Crisis of Aging Infrastructure

Japan Railway West (JR West) manages a vast network of 1,200 stations, many of which date back decades. The original wooden structure at Hatsushima station was built in 1948 and required urgent renewal. However, traditional construction methods are increasingly difficult to execute. Japan faces a shrinking workforce and skyrocketing material costs. Consequently, JR West sought an innovative solution to maintain its high service standards without the long lead times of conventional building.

Robotic Precision Overcomes Labor Shortages

To solve these logistical hurdles, Serendix deployed an ABB IRB 6700 robot integrated with advanced 3D printing technology. Unlike traditional onsite pouring, the robot manufactured structural elements in a factory setting. This control system allowed for extreme precision and consistency. By shifting the workload to a robotic cell, the company reduced the need for skilled manual labor. Furthermore, this approach mitigated the impact of rising wages in the construction sector.

Accelerated Timelines Through Factory Automation

The efficiency of this automated approach is staggering compared to legacy methods. A typical wooden replacement would have required two months of onsite work. In contrast, the 3D-printed station was assembled in a single night. This rapid deployment ensured zero disruption to the 1.7 million daily customers of JR West. The use of a 7-axis system—achieved by adding a travel axis to the robotic arm—provided the reach necessary for large-scale components.

Advanced Nozzle Technology and Design Freedom

A key technical breakthrough in this project is the use of Vertico’s two-component (2K) nozzle technology. Standard 1K nozzles often struggle with accuracy and material spread. However, the 2K system offers four times the precision of older models. It reduces mortar spread by 75%, allowing for intricate geometric textures. As a result, Serendix could incorporate local cultural motifs, such as a sculpted mandarin orange, into the concrete facade.

Expert Insight: The Future of Autonomous Construction

From an industry perspective, this project signals a move toward "dark factories" in construction. Mr. Sato of Serendix envisions a future where artificial intelligence (AI) handles the entire setup process. Currently, these systems require minimal human intervention during the print cycle. By integrating vision sensors and AI, the industry can achieve full automation from the initial design data to the finished product. This evolution will likely expand beyond utility buildings into high-end architecture like hotels and villas.

Cost Savings and Material Efficiency

Economic data shows that 3D printing delivers significant financial advantages. Serendix reports cost savings of 30% to 50% compared to traditional methods. Because the PLC-controlled robot deposits material only where needed, waste is virtually eliminated. Moreover, the ability to use mortar as a primary medium simplifies the supply chain. Therefore, this technology offers a robust hedge against the volatility of global material prices.

Application Scenarios for 3D Robotic Printing

• Public Infrastructure: Rapid replacement of bus shelters, railway platforms, and small utility buildings in high-traffic zones.

• Disaster Relief: Fast deployment of emergency housing or command centers following natural disasters.

• Bespoke Architecture: Creating complex, non-linear facades for luxury hotels and residential villas that are too expensive to mold traditionally.

• Industrial Enclosures: Specialized factory automation housings for sensitive DCS or PLC hardware in harsh environments.