Beyond the pilot: How Encirc and i3D Robotics turned Tenfold NetZero’s proof-of-concept into real-world impact

Since completing the Tenfold NetZero Accelerator Pilot Programme in November 2024, i3D robotics is demonstrating how a well-structured innovation challenge can lead to meaningful industrial progress. What began as a short-term proof of concept on the Digital Catapult-led programme has evolved into a live production trial at Encirc, a major UK glass manufacturer based in Northern Ireland, with the potential to revolutionise defect detection in one of the most energy-intensive industries.

Funded by the Department of Agriculture, Environment and Rural Affairs (DAERA) and delivered by Digital Catapult,

Tenfold NetZero supported three industry partners in Northern Ireland to tackle industrial decarbonisation challenges using advanced technologies. By connecting innovative deep tech SMEs with large industrial partners, Digital Catapult supported developing, testing and validating solutions that could help accelerate decarbonisation in the glass industry. For i3D robotics, it offered a rare opportunity to apply its inspection technology directly to the sustainability challenges of glass manufacturing.

Digital Catapult’s structured innovation model – a tight timescale, a clear brief, and direct engagement with the industry challenge owner – created conditions that encouraged rapid progress. Rather than building something entirely new, i3D was able to adapt its existing software platform, avoiding the risk and cost of new hardware development.

“What surprised us was the short duration of the project,” Richard explained. “It really focused our minds to come up with a simple, low-cost solution.”

Crucially, the partnership with Encirc gave the team a deeper understanding of real-world factory environments and a rare opportunity to access a global supply chain. Combined with Digital Catapult’s technical expertise and industry insight, i3D was able to align its innovation not just with technical goals, but with operational needs and broader commercial priorities.

This experience proved transformative. It helped the company fine-tune a prototype that could provide digitised, reliable defect data from live production lines—something that had not been possible before.

The proof of concept developed during the Tenfold NetZero programme presents a significant advancement for the glass industry, particularly in addressing long-standing challenges related to quality assurance in dark glass production. By leveraging cutting-edge automation and machine learning, it enhances the accuracy of defect detection—something previously hindered by the opacity and colour of dark glass containers.

As a result, manufacturers can drastically reduce waste, lower production costs, and streamline efficiency. These improvements not only drive economic benefits but also contribute to greater consistency and quality across production lines.

Barry King, Engineering Manager at Encirc said: “In the long term, the technology could enable manufacturers to innovate further, particularly in producing lighter containers without compromising quality.

“This opens the door to additional energy savings and a smaller environmental footprint, aligning with broader industry goals around sustainability. The collaboration between public and private sectors exemplified in this initiative showcases how technology can support more sustainable, cost-effective practices across heavy manufacturing.”

Participation in the Tenfold NetZero programme didn’t change i3D’s fundamental innovation strategy, but it did influence how the company evaluates opportunities. The experience with Digital Catapult and Encirc showed the value of focused, well-framed challenges and how powerful collaboration with industry partners can be.

Richard reflected: “We have become more selective in what we do as our business, our technology, and our experience mature.

“The programme also demonstrated that speed doesn’t have to compromise substance. The combination of a well-defined problem, a committed industry partner and small but targeted funding helped accelerate development that might otherwise have taken years.”

With a live trial underway and a strong technology platform in place, i3D robotics is now focused on a steady rollout of inspection technologies across other UK industrial sectors. The company has built on the insights and relationships forged through Tenfold NetZero, continuing to apply deep tech to practical industrial problems to shape products that improve quality, minimise waste, and support sustainable manufacturing.

The journey beyond the Digital Catapult programme has proven that with the right conditions and the right partners, deep tech solutions can move quickly from concept to impactful deployment – helping to advance decarbonisation, supply chain resilience and data-driven innovation across UK industry.