In-house 3D printing technology has been introduced to manufacture customised surveying accessories for one of the largest transport infrastructure projects in Victoria, improving efficiency and reducing costs across its operations.

Sam Stevens, Survey Data Manager, highlighted the benefits of this approach.

"Not only did we realise that we could have a direct cost saving by modelling and printing ‘like-for-like’ survey accessories, but we now had the flexibility to either customise existing designs, or create our own from scratch," Mr Stevens said.

"Having these accessories available does make our surveyors much more time efficient in the field."

Survey teams play a critical role in ensuring infrastructure projects are delivered to design specifications and comply with legislative standards. Their responsibilities include structural monitoring of bridges and retaining walls, which are subject to dynamic forces such as traffic loads, temperature changes, wind and seismic activity.

To track these effects, surveyors install small monitoring prisms on structures and measure their position regularly using high-precision instruments.

Previously, these accessories were sourced from external suppliers, often requiring bulk orders and extended lead times. By adopting 3D printing, ACCIONA can now produce the components on-site at a significantly reduced cost.

Using modelling software such as AutoCAD, Civil 3D and Fusion 360, designs are created and processed through slicing software before being printed on Bambu P1S printers equipped with Automated Material Systems.

Each printer can produce up to 25 pieces in approximately nine hours.

The technology also allows for customisation to meet specific project needs. Different filaments and colours enable the production of accessories that either blend into the environment or remain highly visible for easy identification.

This flexibility improves field efficiency and supports accurate structural monitoring.

The initiative reflects ACCIONA’s commitment to innovation and sustainability by reducing material waste and transport requirements while delivering cost-effective solutions.

It also demonstrates how advanced technology can enhance precision and reliability in major infrastructure projects.

ACCIONA will continue to explore opportunities to integrate digital tools and additive manufacturing across its operations, reinforcing its focus on efficiency and technical excellence in project delivery.