Advancing Assistive Product Design Through Material Innovation: Why ITERATE Selected Carbon’s DLS Technology
By Gethin Roberts, Managing Director, ITERATE Design and Innovation
Additive manufacturing has entered a new era – one defined not simply by geometric freedom, but by the performance of engineered materials. For assistive technology, where user safety, comfort, and reliability are non-negotiable, the capabilities of modern resin-based platforms are reshaping what is possible. As a product design consultancy specializing in medical, consumer, and industrial innovation, ITERATE has long recognized that the future of adaptive products will be driven by advances in materials science as much as by design thinking. This perspective guided our decision to adopt Carbon’s Digital Light Synthesis™ (DLS™) technology for two recent assistive products: a lightweight walking stick system and a next-generation wheelchair headrest.
Both projects reflect a broader trend: as materials become smarter, more tunable, and more resilient, assistive devices previously constrained by traditional manufacturing can now be reimagined around user-specific needs. Carbon’s platform, supported by its growing library of rigid polymers and high-performance elastomers, offers the rare combination of design freedom, mechanical reliability, and production-level repeatability needed for modern disability equipment.
Why Carbon's Materials and Process Matter for Assistive Products
At the core of Carbon’s value proposition is the Carbon Digital Light Synthesis™ (Carbon DLS) process – a photopolymer technology that produces isotropic parts with mechanical performance comparable to injection-molded components. For ITERATE, this material uniformity is critical. Assistive products endure continuous load cycles, impacts, and environmental variability. Materials must exhibit reliability not only under controlled testing but in day-to-day use by individuals whose needs and movement patterns vary widely.
Carbon’s elastomeric materials – such as EPU 46 and the EPU Pro platform – provide a unique ability to engineer product regions with different levels of softness, flexibility, or support. Meanwhile, rigid polyurethanes like RPU 130 offer durable load-bearing options appropriate for mechanical interfaces and structural components. This broad spectrum of materials enables ITERATE to design not only the shape of a product but the internal mechanical behavior of each region.
Equally important is Carbon’s support for lattice structures. These geometries enable breathability, targeted compliance, controlled rebound, and weight reduction – all of which are essential in next-generation mobility aids and seating products. Traditional manufacturing methods struggle to match this level of material control, making Carbon DLS particularly well-suited for assistive devices where personalization and comfort are core requirements.
Enhancing a Walking Stick Through Material-Led Design
The first project involved collaborating with the Cerebra Innovation Centre at the University of Wales Trinity Saint David, an organization dedicated to creating bespoke products for children with disabilities. Building upon their initial design, ITERATE refined several key components – specifically the handle, feet, and connectors – to improve durability, ergonomics, and overall performance using Carbon’s material platform.
For the handle, ITERATE selected EPU Pro to create a handle that balances comfort with long-term resilience, offering an alternative to traditional molded foam grips that degrade or compress over time.
Walking stability is heavily influenced by the ground-contact features. ITERATE chose EPU Pro 90, a flexible black elastomer, to create feet that deliver necessary traction and energy absorption. The material’s high tear strength and non-slip properties are critical for navigating varied surfaces both indoors and outdoors. Its mechanical recovery characteristics also help ensure that the feet maintain performance throughout repeated loading cycles.
The connectors linking the main body of the walking stick to its legs required a rigid, dimensionally stable material with strong load-bearing characteristics. Based on Carbon’s material library and the functional requirements, RPU 130 – a tough, production-grade polyurethane – proved the optimal candidate. It offers the stiffness, impact resistance, and durability needed for structural joints while remaining lightweight and consistent through the Carbon DLS process.
Together, these three materials form a hybrid system: rigid connectors for structure, soft elastomers for comfort and stability, and a scalable handle solution that supports both prototyping and production. This combination illustrates how material diversity within a single manufacturing platform enables more refined, user-centered engineering decisions.
A Breathable, Adaptive Wheelchair Headrest
ITERATE’s second project centered on designing a wheelchair headrest capable of fitting multiple wheelchair types while offering substantial comfort improvements over conventional foam head supports. The team selected EPU 46 as the foundational material, leveraging its elastomeric performance and compatibility with lattice structures.
Unlike dense foam, which traps heat and limits airflow, an EPU 46 lattice creates a breathable support surface. By tuning the lattice geometry, ITERATE engineered zones with varying stiffness levels to cradle the head while managing pressure distribution. This structure is designed to dissipate heat naturally, reduce discomfort during prolonged wheelchair use and improve daily quality of life for users with limited mobility or high support needs.
Some individuals naturally rest their head to one side or use asymmetric seating positions. The geometry of Carbon’s elastomeric lattice can be adapted to match these postural tendencies, offering a level of personalization typically associated with custom-fabricated medical seating systems – but without complex manufacturing setups.
EPU 46 is inherently non-absorbent and easy to clean, making the headrest significantly more hygienic than fabric-covered foam alternatives. This characteristic is especially important in clinical environments, where equipment must withstand frequent cleaning and maintain high sanitary standards.
The headrest design includes a universal attachment system compatible with a wide range of manual and powered wheelchairs. Coupled with the durability of EPU 46, this ensures that the product supports a broad user population while maintaining reliable long-term performance.
The Future of Assistive Devices: Material Science at the Core
As additive manufacturing continues to evolve, the assistive technology sector stands to benefit enormously from innovations in polymer performance, lattice engineering, and digital fabrication workflows. The Carbon platform represents a significant leap forward – not simply because it enables unique geometries, but because it introduces materials designed with durability, cleanliness, and aesthetic considerations in mind.
For ITERATE, selecting Carbon’s technology is part of a broader commitment to designing products that enhance lives and solve real-world challenges through engineering excellence. By pairing advanced materials with thoughtful, human-centered design, assistive devices can become lighter, safer, more adaptable, and significantly more comfortable.
As demand grows for personalized medical and mobility products, material-led innovation will continue to define the next generation of adaptive equipment. With platforms like Carbon’s – and the expanding portfolio of high-performance elastomers and rigid polymers – we see a future where bespoke functionality and scalable manufacturing coexist. And for users, it can support greater independence, comfort, and confidence in the products that support their daily lives.
If you’re exploring how additive manufacturing and advanced materials can elevate your medical or assistive product, ITERATE can help you move from concept to market-ready design with confidence.