United Themes - Portfolio Management Archive - 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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Universal Suction-Cup Bike Rack

ITERATE — Tue, 19 Aug 2025 14:53:45 +0000

Universal
Suction-Cup Bike Rack.

A versatile rack engineered for safety, simplicity, and ultimate compatibility.

For many cyclists, the biggest challenge isn’t the ride itself – it’s getting the bike to the start line. Traditional roof racks can be fiddly, vehicle-specific and often limited to certain bike types.

Working side by side with the Roof Rider founders, our design team explored how to make the product safer, simpler, and universally compatible. The solution came in the form of vacuum suction cups – powerful anchors that hold the rack firmly in place, no matter the vehicle.

But the success of the design depended on more than just the technology itself. ITERATE provided guidance on the optimal placement and integration of the suction cups with the mounting bracket, ensuring the rack could withstand the demands of real-world use while remaining easy to set up and remove.

The result, a robust, versatile bike rack that gives cyclists the freedom to transport their bikes with confidence. Born from an entrepreneur’s idea, shaped by collaboration, and engineered for adventure.

And as the product evolves, a multi-bike version is already on the horizon – taking this innovation one step further.

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High-Performance Quick Release Bracket for TV & Film

ITERATE — Tue, 05 Aug 2025 13:20:03 +0000

High-Performance Quick
Release Bracket for TV & Film.

Designed to handle the pressure of the spotlight. Fast, secure, and studio-ready.

When Cotech Filters set out to reinvent how light reflectors are mounted in the TV and film industry, they turned to ITERATE for bold thinking and rapid results. The brief: develop a quick-release bracket that’s strong, versatile, and lightning-fast to attach and detach – all while handling the heavy demands of professional-grade equipment.

We kicked off by diving into the competitive landscape, identifying clear gaps and opportunities for differentiation. Our team used digital sketching and creative ideation to bring fresh concepts to life, before building a detailed 3D CAD model and a high-quality rapid prototype. This allowed Cotech to validate the design with real users, calculate production costs, and build confidence; all before committing to full-scale investment.

Backed by support from the Welsh Government’s SMART Productivity and Design programme, this project is a shining example of how speed, creativity, and strategy can come together to deliver real commercial impact.

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Carbon Fibre Tandem Bikes

ITERATE — Tue, 03 Jun 2025 10:28:57 +0000

Carbon Fibre
Tandem Bikes.

Combining ultra-lightweight performance with fully customisable geometry using precision 3D-printed connectors.

Bevelo, received funded support from the Welsh Government’s SMART programme, to develop a novel tandem frame using 3D-printed connectors and carbon fibre tubing to deliver a lighter, stronger, and more easily assembled product. While additive manufacturing (AM) has seen wide adoption in solo bicycle production, Bevelo innovate by applying AM techniques to the more complex structural challenges of tandem bikes – a largely untapped area. The bespoke connectors were designed to streamline production, reducing assembly time by around 50%, and to enhance the overall strength and aesthetics of the bike. We provided expert support over a discrete period to help refine the connector designs through advanced CAD modelling, focusing on key joint locations such as the seat tubes, head tube, and stays. This pioneering approach enables tailored geometry, lightweight performance, and a clean visual finish, positioning Bevelo’s tandem as a premium option for design-conscious cycling enthusiasts.

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Corporate Event Donut Wall

ITERATE — Tue, 13 May 2025 15:58:51 +0000

Corporate
Event Donut Wall.

Lightweight, modular donut wall for corporate events, offering easy assembly and scalable configuration to suit various event sizes.

Crosstown is known for delivering handcrafted doughnuts and specialty coffee across the UK, with a strong presence at festivals and corporate events. To support their growing event operations, the brand required a modular and durable display solution that would uphold their premium aesthetic while performing reliably in fast-paced retail environments. We were commissioned to design and manufacture a flexible stand system that balances striking visual identity with practical usability.

Engineered from aluminium, the stands are robust, lightweight and easy to clean, ideal for high-traffic food and beverage settings. Each unit can function independently or be combined to form a larger display, providing versatility across a variety of event formats. The stand, which was designed by ITERATE, supports quick assembly, efficient transport and a consistent, professional appearance that reinforces the CrossTown brand experience.

The stands have proven to be reliable and adaptable, maintaining their visual impact across numerous events. They were recently showcased during a high-profile collaboration with NYX Professional Makeup, promoting the Crosstown X NYX Cosmetics Vegan Buttermelt doughnut range.

This project is a clear example of how thoughtful design and robust engineering can elevate brand presence in any environment.

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Intelligent Solar Panel System

ITERATE — Tue, 04 Mar 2025 15:05:18 +0000

Intelligent
Solar Panel System.

Revolutionising solar energy capture on construction sites using smart technology.

Construction sites face mounting pressure to reduce carbon emissions while operating in environments with uneven terrain and constantly changing layouts. Traditional solar solutions struggle with these conditions, resulting in suboptimal energy production and complicated deployment.

Gaia Group UK has engineered the SolarWedge to address these challenges. At its core is a responsive inflatable tube mechanism that enables precise angular adjustment between 20-32 degrees, allowing solar panels to maintain optimal orientation toward the sun. This adjustability delivers a remarkable 15-20% increase in energy efficiency compared to static installations. Unlike conventional rigid mounting systems requiring time-consuming installation, the SolarWedge deploys rapidly on virtually any surface. The inflatable design conforms to uneven terrain while maintaining the ideal angle for solar collection, eliminating extensive ground preparation.

Construction companies implementing the SolarWedge report advantages beyond increased energy production. The system’s quick deployment capabilities mean renewable energy can follow construction activities as they progress across sites, ensuring continuous clean energy availability where needed most. By increasing the viability of solar energy in construction settings, the SolarWedge directly addresses one of the industry’s most persistent challenges: reducing diesel generator usage. Each installation displaces approximately 25-30% of generator requirements, substantially lowering both emissions and fuel costs.

Gaia Group UK is expanding the SolarWedge ecosystem with complementary battery storage solutions and predictive positioning software to further optimise energy capture based on weather forecasts and site-specific conditions. The SolarWedge represents more than an improvement in construction site energy solutions—it fundamentally rethinks how renewable energy technology can adapt to challenging real-world conditions rather than requiring environments to conform to technological limitations.

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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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