ADDITIVE MANUFACTURE Archives - ITERATE

Children’s Walking Aid

ITERATE — Tue, 10 Mar 2026 15:05:31 +0000

Children's Walking Aid.

Refining a bespoke walking stick through additive manufacturing to improve comfort, stability and durability.

Children who rely on walking aids often face equipment that is poorly adapted to their needs. Many conventional walking sticks are derived from adult products, resulting in uncomfortable grips, limited stability and components that wear quickly under repeated use. For children with disabilities, these limitations can affect confidence, mobility and long-term usability.

Working in collaboration with the Cerebra Innovation Centre at University of Wales Trinity Saint David, ITERATE refined an existing walking stick concept to improve ergonomics, durability and manufacturing efficiency using advanced additive manufacturing. Rather than redesigning the entire product, the focus was placed on three critical components: the handle, the feet and the structural connectors.

The handle was redesigned using Carbon’s EPU 70 Pro Expand, a tunable elastomer engineered to expand after printing. This property allowed the component to be printed at a smaller scale, improving build efficiency while enabling cost-effective small-batch production. Once expanded, the material provides a soft, resilient grip with controlled energy return, delivering greater comfort for users who depend on the walking stick throughout the day.

Stability is strongly influenced by the performance of the ground-contact features. To enhance traction and impact absorption, ITERATE developed the feet using EPU 90 Pro, a flexible elastomer with high tear strength and excellent mechanical recovery. This ensures reliable grip across a variety of indoor and outdoor surfaces while maintaining consistent performance under repeated loading.

For the structural joints connecting the walking stick to its legs, ITERATE selected RPU 130, a production-grade polyurethane that delivers the stiffness, impact resistance and dimensional stability required for load-bearing components.

The resulting design demonstrates how combining multiple materials within a single additive manufacturing platform enables a hybrid system – rigid connectors for structure, flexible elastomers for comfort and stability, and a scalable handle solution that supports both prototyping and production. The outcome is a more durable, ergonomic walking aid that improves confidence and mobility for young users.

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Liquid Medication Dispenser

ITERATE — Tue, 03 Mar 2026 11:10:43 +0000

Liquid Medication Dispenser.

A child-safe liquid medication system that combines reusable cartridges and a lockable, travel-ready case.

Administering liquid medication to children is a daily challenge for many parents. Traditional bottles, spoons and syringes often create mess, inaccurate dosing and, most critically, the risk of unsupervised access. These friction points can lead to stress at home and safety concerns when travelling.

Dose Dr. was developed to reimagine the experience through a system-led design approach focused on safety, clarity and portability. Rather than treating packaging and dosing as separate problems, the solution integrates three components: a reusable cartridge for pre-measured liquids, an ergonomic dispenser for controlled delivery, and a compact lockable storage container that keeps everything organised in one place.

The cartridge format eliminates repeated pouring and reduces contamination, while the dispenser’s form factor fits comfortably in the hand, enabling precise, one-handed administration – particularly useful with young or reluctant children. To address safe storage, squeeze-lock tabs prevent unsupervised access, giving parents peace of mind both at home and on the go.

A key innovation is the 24-hour timing dial built into the case. This simple visual tracker helps caregivers monitor when doses were last given, reducing the risk of missed or double doses; a common issue in multi-caregiver households.

The result is a portable, travel-ready medication system that transforms a stressful task into a quick, reliable routine. By combining thoughtful ergonomics with intuitive safety features, Dose Dr. improves adherence, minimises risk and delivers a calmer healthcare experience for families.

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Lone-Worker Safeguarding System

ITERATE — Sun, 08 Feb 2026 13:19:41 +0000

Lone-Worker Safeguarding System.

Balancing discretion, compliance, and accelerated production through advanced additive manufacturing.

Using our leading-edge AI capabilities, we conceptualised a purpose-built body-worn safeguarding device designed specifically for lone social workers operating in community environments. Unlike traditional body cameras adapted from law enforcement applications, this product was conceived from the outset for social care – prioritising discretion, psychological sensitivity, and professional trust.

Lone social workers face unpredictable situations during home visits, yet existing solutions often create tension or fail to provide adequate documentation when incidents occur. The objective was to create a discreet, lanyard-worn device that remains unobtrusive during routine interactions but can be activated instantly when required. The design language deliberately avoids tactical cues, instead adopting softened geometry, neutral tones, and a non-confrontational aesthetic suited to sensitive environments.

Given the emerging nature of the category and uncertainty around production volumes, traditional injection moulding was ruled out early. High tooling costs and long lead times would have delayed market entry and locked the design before real-world validation. Instead, the enclosure was engineered specifically for Multi Jet Fusion (MJF) additive manufacturing.

This approach enabled rapid transition from concept to pilot production, allowing early deployment, revenue generation, and real-world feedback from frontline professionals. The enclosure was optimised for durability and repeatable batch manufacture, while retaining the flexibility to evolve as internal electronics and safeguarding requirements develop.

The result is a production-ready, scalable safeguarding device built on a design philosophy of agility and continuous refinement – enabling faster deployment today while supporting long-term evolution in a rapidly changing technological and regulatory landscape.

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Advanced Wheelchair Headrest

ITERATE — Tue, 11 Nov 2025 17:30:31 +0000

Advanced Wheelchair Headrest.

3D-printed wheelchair headrest delivering targeted support, improved breathability, and enhanced hygiene for long-term user comfort.

In collaboration with Carbon, we designed an advanced wheelchair headrest that addresses the comfort, hygiene, and usability limitations of traditional solutions.

Conventional wheelchair headrests are typically made from rigid plastics or foam wrapped in vinyl. While functional, these designs often provide uniform support that fails to accommodate individual anatomy, leading to pressure points, poor posture, and discomfort during prolonged use. Additionally, non-breathable surfaces can trap heat and moisture, raising hygiene concerns – particularly in clinical or long-term care environments.

To overcome these challenges, the headrest was developed using Carbon’s EPU 45 elastomer. This material enabled the creation of a lattice-based structure that delivers targeted support in key areas such as the occipital region and upper cervical spine, while remaining compliant where flexibility is required. The result is a headrest that better distributes pressure and improves overall user comfort.

EPU 45 also offers significant hygiene and durability benefits. Its open lattice structure promotes airflow, improving breathability and reducing heat buildup during extended use. Unlike traditional foam, EPU 45 is resilient, tear-resistant, and easy to clean, making it well-suited for medical and assistive applications where cleanliness and longevity are critical.

By combining ergonomic design principles with advanced additive manufacturing materials, ITERATE and Carbon demonstrated how EPU 45 can redefine comfort, performance, and hygiene in wheelchair support systems.

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Dynamic Energy Absorption Arm Guard

ITERATE — Thu, 27 Feb 2025 14:29:24 +0000

Dynamic Energy
Absorption Arm Guard

Protective 3D printed arm guards – lightweight, breathable, and custom-built for every player.

In an exciting collaboration with Carbon, we have redefined the way protective equipment is designed and manufactured for one of the most popular sports in the world – cricket. Our arm guard presents a groundbreaking new direction that allows players to directly input into every stage of the design process, allowing them to tailor protective equipment to their exact needs. By utilising Carbon’s DLS printing technology, the arm guard is not only lightweight, durable and flexible, essential qualities for any effective protection, but also offers exceptional breathability and customisation opportunities. The ability to refine lattice properties in the design process mean the arm guard can be optimised to absorb any level of impact, as well as be uniquely formed to the player themself.

Carbon’s Design Engine software utilises physical simulation and optimisation techniques to fine tune lattice patterns, helping to further manage impact energies. This particular design features two blended layers of lattice, a softer outer layer to absorb the initial impact of the ball, which is combined with a denser lattice structure to provide a more uniform surface for contact with the batter’s arm, absorbing any additional level of high impact, results in an optimised protective guard. This cannot be achieved through any other method than that of using Carbons DLS printing technology.

As the arm guard is 3D printed, only the necessary material is used, significantly reducing waste and offering a clear sustainability advantage over current protective equipment seen on the market. This method also enables a more precise fit, enhancing comfort and mobility, as well as allowing players to reflect their personality within the design. Carbon offers a range of impact-absorbing and energy-damping materials, which will easily withstand any level of impact a player will potentially endure on the cricket field. Additionally, in contrast to current products which use just a single layer of foam for protection, utilising a non-uniform lattice structure significantly improves the damping effect of the guard upon impact – minimising stress and pain on the player.

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Custom Fitted Golf Putter Grip

ITERATE — Thu, 27 Feb 2025 15:00:46 +0000

Custom Fitted
Golf Putter Grip

3D printed putter grip – customised for ultimate control, comfort, and performance on the green.

Your choice of grip can make the difference between a good round of golf and an exceptional one. By utilising Carbon’s groundbreaking technology, our design team developed an innovative putter grip that enables you to compete at the highest level. The grip is flexible, comfortable and lightweight, but most importantly; by utilising Carbons DLS printing technology, the grip can be custom designed and made to the exact specification of any player – giving them a unique edge.

Our expert team have developed a grip that features a combination of firm and soft areas which help improve control and comfort at the most critical of moments. To achieve this winning combination, ITERATE leveraged the power of Carbon’s Design Engine to optimise the grip and create different density zones within the design. The software platform allows parameters of the lattice structure to be tailored to the specific requirements of the player. The density of each lattice zone can be specified, depending on the players preferences, allowing them to finely tune the softness and feel of the grip to their exact requirements. The dual texture, also enables golfers to find the perfect balance between responsiveness, feel and comfort.

Traditional methods of manufacturing and designing grips can simply not produce such an optimised and customisable design. The flexibility Carbons printing technology offers, is unmatched within this field. As the grip is 3D printed, only the necessary material is used, significantly reducing waste and offering a clear sustainability advantage over current grips seen on the market today. Carbon produces a wide range of elastomeric materials, that offer a number of different properties, ranging from high-energy return to high-impact damping. This unique selection of materials, combined with a custom optimised design, results in a grip that is like no other.

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3D Printed Superhero Mask

ITERATE — Sat, 14 Oct 2023 18:42:26 +0000

3D Printed
Superhero Mask.

Additively manufactured master part to streamline the creation of latex masks.

Ministry of Masks produce collector quality latex masks for an array of purposes. We were approached to assist with the use of new manufacturing technologies to streamline their creation process. The aim was to 3D print a Batman mask that the client could use as a master to create a mould from. A true-to-size mask was so large for our FDM printer that had to be split into multiple bodies which were precisely bonded together to achieve minimal visibility of the split lines. A hauntingly realistic Batman mask was successfully produced, with a seamless and detailed finish. FDM technology presented a more efficient solution for the client than a traditional process without compromising the high-quality of the product. The success of this FDM printed Batman mask showcases how additive manufacturing technology can be used in novel outlets to maximise the efficiency of production process.

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3D Printed Razor

ITERATE — Sat, 14 Oct 2023 12:27:37 +0000

3D
Printed Razor.

Compostable razor produced using the latest additive manufacturing technologies.

Mutiny Shaving is a sustainable personal grooming product supplier, who partnered with ITERATE through the Welsh Government’s SMART Productivity & Design program. The challenge was to design an eco-friendly razor using 3D printing technology that was safe to use and performed in the same way as a traditional razor. After rigorous prototyping and testing, ITERATE created a v-shaped neck with a pin and collar locking mechanism for precise and repeatable blade attachment. Careful material selection led to three eco-conscious 3D printing options, including 70% recycled polymer, wood concentrate and beer waste filaments. The result is a unique razor designed for Fuse Deposition Modelling (FDM) technology, which is fully compostable after its life-in-service. This razor stands out as a sustainable alternative to non-recyclable razors in the market, reflecting Mutiny Shaving’s commitment to becoming carbon neutral.

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