Carbon-Enhanced Design.
We push the boundaries of product design, leveraging Carbon’s revolutionary Digital Light Synthesis™ (DLS)
technology and Design Engine software to create high-performance, customized sporting equipment.
For decades, traditional manufacturing has dictated the limits of product innovation. The process is often rigid, costly, and slow, requiring expensive molds and tooling that make customization nearly impossible. Athletes, designers, and engineers have had to work within these constraints, sacrificing optimal performance and personalization for the sake of feasibility.
With Carbon, we are no longer bound by the constraints of traditional methods. The old ways of designing, prototyping, and producing equipment have given way to a new era of mass customization, performance optimization, and rapid iteration. Carbon’s Design Engine software and DLS printing technology allow us to refine and personalize each piece of equipment in ways never before possible.
Case Study.
Our cricket arm guard utilizes multi-layer lattice structures. The design strategically blends a softer outer layer to absorb initial impact with a denser inner lattice for reinforced protection. This dynamic energy absorption mechanism ensures players are protected without compromising mobility. Unlike traditional foam-based guards, the use of optimized lattice structures results in superior energy damping, reducing stress and risk of injury.
Performance Benefits.
Carbon’s technology allows us to revolutionize sporting equipment by offering tailored precision for every athlete. No two players are the same, and with our advanced design capabilities, we create protective gear and performance equipment that fit each individual’s exact needs. By using engineered material properties, we achieve lighter yet stronger products that enhance endurance and reduce fatigue without compromising durability.
Unlike traditional manufacturing, which demands costly tooling and large minimum orders, Carbon’s DLS technology removes these barriers, making custom, one-off, and small-batch production entirely viable. The power of computational design and lattice optimization means designs can be constantly refined and improved, allowing for rapid innovation and adaptation to performance insights – all without the delays of traditional manufacturing constraints.
Case Study.
Using Carbon’s Design Engine, this golf putter grip demonstrates how multi-zonal lattices, allow players to customize the softness, texture, and responsiveness of their grip. Due to the high level of customisation, this handle adapts perfectly to your playing style, providing a true competitive edge on the course. Traditional grip manufacturing cannot achieve this type of fine-tuned performance, but with Carbon’s DLS technology, ITERATE brings your ideal grip to life with precision and efficiency.
Our Work.
We are a product design, research, development and prototyping consultancy who work with
private companies and public sector organisations in the medical, consumer and industrial markets.
Sepsis Diagnosis Device
MEDICAL DEVICES, SUSTAINABLE DESIGN-
Dynamic Energy Absorption Arm Guard
ADDITIVE MANUFACTURE, CONSUMER PRODUCTS -
Sustainable Home Office Footrest
CONSUMER PRODUCTS, SUSTAINABLE DESIGN -
HbA1c Blood Sugar Monitor
CONSUMER PRODUCTS, MEDICAL DEVICES -
CNC Control Panel
CONSUMER PRODUCTS, INDUSTRIAL EQUIPMENT -
Eco Shower Head
CONSUMER PRODUCTS, SUSTAINABLE DESIGN -
AI-Powered Dance Training Projector
CONSUMER PRODUCTS -
Office Wellbeing Monitor
CONSUMER PRODUCTS -
Custom Fitted Golf Putter Grip
ADDITIVE MANUFACTURE, CONSUMER PRODUCTS -
Wearable Heart Monitor
CONSUMER PRODUCTS, MEDICAL DEVICES -
Diamond Brilliance Analyser
CONSUMER PRODUCTS, INDUSTRIAL EQUIPMENT -
Bathroom Air Purifier
CONSUMER PRODUCTS -
Sock Laundry Clip
CONSUMER PRODUCTS -
Automatic Soap Dispenser
CONSUMER PRODUCTS -
Wired Headphone Converter
CONSUMER PRODUCTS, SUSTAINABLE DESIGN -
Seated VR Controller
CONSUMER PRODUCTS -
InkJet Bio Printer
INDUSTRIAL EQUIPMENT, MEDICAL DEVICES -
Non-Invasive Glucose Monitor
ADDITIVE MANUFACTURE, MEDICAL DEVICES -
Customised Mobility Support
ADDITIVE MANUFACTURE, MEDICAL DEVICES -
Portable Urinalysis Device
MEDICAL DEVICES -
Cancer Diagnosis Device
MEDICAL DEVICES -
Oral Device Packaging
MEDICAL DEVICES, SUSTAINABLE DESIGN -
3D Printing Conductive Tracks
ADDITIVE MANUFACTURE, CONSUMER PRODUCTS
FAQs.
What makes Carbon’s technology different?
Carbon’s DLS technology is a revolutionary approach to manufacturing, leveraging light and programmable resins to produce parts with unmatched precision, strength, and flexibility. Unlike traditional injection molding or CNC machining, DLS allows for:
- Complex geometries and lattice structures that enhance performance and comfort.
- No tooling or setup costs, making it cost-effective for both one-off and mass production.
- Faster iteration cycles, allowing for rapid design modifications without expensive retooling.
- Enhanced material properties, such as high energy return, durability, and lightweighting.
With DLS, designs that were once impossible to produce are now reality—from custom-fit sports gear to medical-grade wearables.
Can I fully customize my sporting gear?
Yes! Customization is one of the biggest advantages of using Carbon’s Design Engine and DLS printing technology. Unlike mass-produced equipment that takes a one-size-fits-all approach, our method enables:
- Athlete-specific designs—your equipment can be tailored to your exact measurements and playing style.
- Material customization—we fine-tune lattice structures for impact absorption, flexibility, or energy return.
- Personalized aesthetics—custom colors, branding, and textures to match your preferences.
Whether you need a cricket arm guard shaped perfectly to your arm or a putter grip engineered for your unique putting style, our technology ensures that your equipment is optimized for peak performance.
What are the benefits of using lattice structures?
Lattice structures unlock a new level of performance and comfort that traditional solid materials simply cannot achieve. With Carbon’s Design Engine, we can precisely control:
- Impact absorption—Lattices disperse force upon impact, reducing injury risk.
- Energy return—Flexible lattice zones can improve movement efficiency and responsiveness.
- Breathability & comfort—Open-cell lattice designs improve airflow, keeping athletes cool.
- Lightweighting—By using lattice patterns, we maintain structural integrity while significantly reducing weight.
For example, our Cricket Arm Guard features a dual-density lattice structure, where a softer outer layer absorbs initial impact while a denser inner layer distributes force evenly, providing maximum protection with minimal bulk.
How does Carbon’s technology contribute to sustainability?
Unlike traditional manufacturing, which often produces excess waste due to material trimming, mold creation, and mass production inefficiencies, Carbon’s DLS technology is inherently sustainable. We use only the exact amount of material needed, reducing waste. No tooling or molds are required; traditional injection molding requires expensive, wasteful tooling that becomes obsolete. DLS eliminates this need entirely. Instead of overproducing and storing excess inventory, we can print products only when they’re needed, reducing excess stock and waste. Carbon’s elastomeric and high-performance materials last longer, meaning fewer replacements and less environmental impact. By choosing ITERATE’s lattice-reinforced products, athletes and brands can invest in sustainable performance gear without compromising on quality or durability.
How does ITERATE use Carbon’s Design Engine?
At ITERATE, we harness the power of Carbon’s Design Engine to create high-performance, custom sporting equipment with precise mechanical properties. This cutting-edge computational design software allows us to generate and fine-tune multi-zonal lattice structures, optimizing factors like impact absorption, flexibility, and energy return. By starting with a characterized unit cell, we can tailor the lattice density and geometry to achieve the exact performance requirements needed for each product. Whether it’s a protective cricket arm guard or a customized golf putter grip, Design Engine enables us to engineer products that deliver superior comfort, durability, and responsiveness, ensuring that every design is fine-tuned for peak performance.
Can ITERATE help me design my custom product?
Absolutely! At ITERATE, we specialize in end-to-end product development, guiding you from initial concept through to prototyping and final production using Carbon’s DLS technology. Whether you have a rough idea or a fully formed concept, our team of expert designers and engineers will work with you to refine your vision, optimize performance, and create a one-of-a-kind product tailored to your specific needs. Through advanced computational design, we can fine-tune material properties, lattice structures, and mechanical performance, ensuring that your product is engineered for excellence. Whether it’s sports equipment, protective gear, or a specialized application, we help bring innovative, high-performance products to life with no tooling costs and unmatched design flexibility.