MEDICAL DEVICES 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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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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Sepsis Diagnosis Device

ITERATE — Sun, 15 Oct 2023 08:17:11 +0000

Sepsis
Diagnosis Device.

Design of rapid diagnostic device for maternal and neonatal patients in low income countries.

Maternal and neonatal sepsis contributes to significant morbidity and mortality globally, with an estimated 500,000 deaths each year, most of which occur in low income countries. ITERATE partnered with Seroxo as part of an InnovateUK funded competition called ‘Design Foundations’. The focus of this competition was to develop a new product that adopted a planet-centred design approach. The project followed our Rapid Product Development Pathway, walking the client through a series of considered stages. This was supplemented with specialist input by clinicians from the Department of Paediatrics and Research Centre for Maternal, Fetal, Newborn and Child Health Care Strategies, University of Pretoria, South Africa. The outcome was a demonstrable prototype that could be used to gain user insight and feedback, as well as help Seroxo raise further private investment to complete the entire design project.

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HbA1c Blood Sugar Monitor

ITERATE — Tue, 04 Mar 2025 14:29:26 +0000

HbA1c
Blood Sugar Monitor.

Empowering diabetes patients with at-home HbA1c testing – revolutionising personal health management.

Tape Specialities collaborated with ITERATE to design a groundbreaking diabetes self-management system. This device revolutionises how individuals monitor their health by enabling them to easily and regularly measure both their HbA1c and blood glucose (BG) levels anytime, anywhere.

HbA1c, a key marker in diabetes management, is essential for understanding a person’s long-term blood glucose control, as it provides an average of glucose levels over an extended period, typically 2-3 months. Traditionally, individuals with type 2 diabetes are required to visit a clinic every six months for an HbA1c test as part of their care strategy. However, having the ability to measure HbA1c at home empowers individuals to take more proactive control of their condition, offering a deeper insight into their blood glucose trends in real time.

This improved ability to independently track and manage their levels can significantly reduce the risk of developing severe complications, such as heart disease, nerve damage and kidney issues. By providing an accessible and convenient tool for regular monitoring, Tape Specialities is supporting individuals in making more informed decisions about their health, leading to better outcomes and greater confidence in managing their diabetes.

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Wearable Heart Monitor

ITERATE — Tue, 10 Oct 2023 18:19:50 +0000

Wearable
Heart Monitor.

Wrist-worn healthcare monitor aimed at tackling heart disease amongst women.

ITERATE developed a heart monitoring device, TÜLIP, as part of our FemTech initiative to address women’s heart health issues. Recognising the alarming misdiagnosis rates and symptom recognition challenges in women experiencing heart problems, the device records heart rhythm and blood oxygen levels, allowing for convenient at-home monitoring. The design process focused on user needs and aesthetics, resulting in a comfortable wrist-worn bracelet. The curvaceous and feminine design seamlessly integrates into home environments and represents empowerment in women’s health. PPG technology and an oximeter were used for heart rhythm and oxygen level monitoring, making the wrist the ideal location for data collection. The muted colours, copper accents, and the product’s sculptural shape enhance the feminine appeal and blend with the home setting. The name TÜLIP reflects the product’s shape when not in use. It offers a stylish, user-friendly, and luxury-oriented approach to FemTech, allowing women to monitor their heart health effectively and aesthetically.

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Non-Invasive Glucose Monitor

ITERATE — Sat, 14 Oct 2023 13:29:01 +0000

Non-Invasive
Glucose Monitor.

Prototyping of an ergonomic wrist worn non-invasive blood glucose monitoring device.

Afon Technology is a Welsh medical tech company, who have developed a groundbreaking device capable of non-invasively monitoring blood glucose levels in those who have diabetes. Through the Welsh Government’s SMART Productivity & Design programme, ITERATE worked closely with the company to design and develop a wrist worn prototype. A key challenge that needed to be overcome was that the monitoring technology had to be consistently placed on the wrist – from one user to another. This was achieved by the strap having a rigid half and a flexible half; enabling the user to maintain a constant position in relation to the vein. Using in-house 3D printing, the design team crafted a functional prototype featuring an Apple Watch displaying glucose data, allowing user feedback to be gained.

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Customised Mobility Support

ITERATE — Sat, 14 Oct 2023 11:03:40 +0000

Customised
Mobility Support.

Motor-driven assistive arm support system for muscular dystrophy patients.

This project represented a unique challenge for the design team, who were tasked with developing a customised arm support system for an individual experiencing severe muscular dystrophy. The aim was to increase the customer’s independence when carrying out daily activities such as eating, drinking and brushing their teeth. With support from the Assistive Technologies Innovation Centre (ATiC) based within the University of Wales Trinity St. David, ITERATE developed a motor-driven mechanism that attached to the client’s wheelchair, providing the desired movement in the upper arm. Lab-based simulation within ATiC enabled biomechanical movements to be analysed, which informed the design process. In addition, additive manufacturing was used to create a custom-fit to the body, providing the user with the greatest level of comfort. The remote controlled system is further being developed in conjunction with Cardiff & Vale University Health Board to explore its wider application across the NHS.

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Portable Urinalysis Device

ITERATE — Sat, 14 Oct 2023 12:44:32 +0000

Portable
Urinalysis Device.

Development of a urinalysis device using user-centred design techniques.

ITERATE set-about redesigning an outdated urinalysis device to demonstrate the importance of taking a user-centred approach. An observational study revealed that the usability of the diagnostic unit could be improved upon; enabling urine samples to be processed in a more streamlined way. The study also found that the time it took healthcare professionals to learn how to use the product could be drastically reduced by making the interface more intuitive. Extensive concept generation and 3D CAD modelling led to a new sleek, angular design for UriCheck, emphasising hygiene and usability. Accent colours were introduced to help highlight key user touch points such as the on/off button, graphical interface, test insertion area and printer output. A fully functional prototype was created using Stereolithography (SLA) technology and spray-painted to match the intended manufactured design.

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Cancer Diagnosis Device

ITERATE — Thu, 19 Oct 2023 16:03:28 +0000

Cancer
Diagnosis Device.

Development of in vitro medical device that utilises infra-red technology to identify early-stage lung cancer.

PulmonIR is a medical technology start-up based in Wales. The company was established in 2016 with the purpose of exploiting intellectual property that had been created as a result of research undertaken at Swansea University. The challenge involved creating a high level functional prototype that seamlessly integrated mechanical product design; electronic controls and a MEMS based infrared spectrometer to clearly demonstrate the product benefits. The device is intended for use within clinical and laboratory environments; a strong focus was placed on minimising product size so that the footprint remained limited. The functional medical device incorporates a MEMS based infrared (IR) spectrometer. This enables users to deposit a sputum sample in to a collection tray and insert it in to the unit. The IR technology can identify specific wave patterns associated with lung cancer and provide an indication of whether a patient needs to be referred for a CT scan to confirm the presence of the disease. A Selective Laser Sintered (SLS) enclosure was produced and finished using durable gloss black and satin white paint. Custom metal work enabled the touch screen display, control PCB, IR technology to be firmly held in place. Furthermore, the device demonstrates first class design practices as the product can be fully dissembled and recycled after its life.

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