Our First Large Scale PBR Project

In early 2025, Coastruction reached an important milestone: the successful deployment and installation of three custom-designed Purpose-Built Reefs (PBRs) to support coral and fish populations in their natural environment. This project brought together months of research, design, 3D printing, and installation, all aimed at creating new habitats to give nature a boost. In this blogpost, we share how this project unfolded and why it marks a big step forward for scalable, sustainable reef restoration.

Josine Beets and Sam van den Oever next to one of the PBRs, picture made by Eva Beets.

Building Asterix: Scaling up

As you might know, in 2023, we developed and built Asterix: our custom-made, 1-cubic-meter, powder bed 3D printer designed to scale up the production of our PBRs. Asterix came to life at the start of 2024, enabling us to complete the first prints for CREST and Reefs ‘R Us, both important early milestones for Coastruction. This project, the first large scale PBR project, marks another milestone and shows more than just our technological growth. It showed what is possible when thoughtful design, research, and collaboration meet real-world impact.

The Asterix 3D printer in action.

Designing for Biodiversity

From January through August 2024, we worked closely with marine experts to gather detailed information about the deployment site. What species of fish and coral live there? What kind of structures would support them best? Carlos Rego, our biomimicry and design expert, joined forces with artificial reef specialist David Lennon and our team to turn these insights into a set of modular PBR designs tailored for this environment.

The result? Three PBRs of 15 m² each, 1.7 meters high and weighing 1.7 tonnes, with modules ranging from 20 to 85 kg. Throughout the process, we refined how to best use Asterix: from printing the maximum number of pieces per print volume to discovering new features that helped boost our efficiency. It was a big step forward in turning PBR printing into a scalable, efficient process.

Close-ups of the design, pictures made by Eva Beets.

Transportation, Deployment and Assembly

Once the three modular PBRs were printed, they were shipped with the help of Meilink, a company specializing in international transport. Their packaging experts ensured that each PBR module was securely fitted into their crates. In the end, the three PBRs fit into a single container, ready for the journey by truck and ship.

At the end of 2024, the container left and in January, Coastruction’s Josine Beets and volunteer Lotte Fonteijne arrived on site to coordinate logistics with the local coral research team. After unpacking the crates, it was time for deployment and the modules were sorted to match the unique layout of each PBR.

Over three days, the modules were loaded onto boats and deployed overboard to settle onto the sand next to the natural reef ecosystems. Then came three days of installation: an expert dive team of six, including Josine, Lotte and the local coral experts, assembled each PBR underwater.

The PBRs getting ready for transport.

Planting for the Future

In February and March, coral fragments were outplanted on the PBRs, kicking off the long-term monitoring phase. As we write this, it is coral spawning season, a critical window for reef regeneration. We are hopeful that our PBRs will function as a hard substrate to support this natural process and help boost local coral and provide shelter for the local fish populations.

Josine, acting as the architect during assembly. Photo by Lotte Fonteijne.

Reef Realities: A Moment to Remember

During one of the deployment days, while aboard the boat, we witnessed a moment that hit home. Not far from where our PBRs were being installed, local fishermen were spear-fishing on the nearby natural reef. One would poke, with force, into the natural reef, while another waited with a net. The goal: flush fish out of hiding and catch them as they fled.

It was a sobering reminder that healthy reef systems are already under multiple threats, from warming oceans to destructive fishing practices. But rather than feel angry or defeated, we saw it as a sign that there is more work to do. Many coastal communities rely on these waters for survival, and alternatives are not always within reach. Sustainable ocean conservation must go hand-in-hand with awareness-building and community engagement. Restoration is not just about restoration, it is about bringing awareness to people, too.

Looking Ahead

The project is currently in the monitoring phase, with coral fragments already placed and fish populations being observed. Over the coming months and years, coral settlement onto the PBRs will be tracked, guided by our belief that restoration does not need to be massive to be meaningful.

Innovate, Restore and Inspire with us!

Every PBR matters. Every piece printed by our Asterix printers brings us closer to scalable, accessible coastal restoration. Every restored reef is a step towards a healthier ocean for future generations.

To the incredible team, volunteers, partners, and local experts who helped make this project possible, thank you. Here is to many more PBRs ahead!