Game-Changing Sports Gear: How ITERATE Harnessed Carbon’s Design Engine

Traditional sports equipment often forces athletes to accept uncomfortable trade-offs: protection that restricts movement, durability that adds unwanted weight, or performance features that drive up costs. UK-based design consultancy ITERATE is changing this paradigm by leveraging Carbon’s Design Engine technology to develop next-generation sports equipment that delivers superior performance across multiple dimensions simultaneously.

ITERATE recognized that computational lattices offer a revolutionary alternative to conventional materials. Unlike homogeneous foam, rubber, or solid plastics, lattice structures can be precisely tuned to exhibit specific mechanical properties exactly where needed. This capability means designers can optimize for multiple performance parameters simultaneously rather than compromising between competing objectives.

The fundamental advantage of lattice structures lies in their progressive energy management. When impact occurs, lattices compress systematically, distributing force across multiple structural elements rather than transferring it directly to the athlete. This can significantly improve shock absorption while maintaining structural integrity—a combination particularly valuable in sports applications.

Carbon’s Design Engine software platform automates the creation of these performance-oriented lattice structures, enabling designers to develop innovative products more efficiently than ever before. Creating complex lattice geometries using traditional CAD systems would be virtually impossible to execute manually. However, Design Engine streamlines the process of designing multi-zone lattices with varying properties.

Traditional cricket pads are notoriously bulky and uncomfortable, limiting player mobility while adding unnecessary weight. ITERATE’s solution leveraged Carbon’s Design Engine to generate a multi-zone lattice structure that fundamentally reimagined cricket pad design.

The architecture featured a strategic gradient of mechanical properties: rigid in areas requiring maximum impact protection but flexible where player movement is essential. The design incorporated two distinct but integrated lattice layers:

• A softer outer layer engineered to absorb the initial impact of the ball, dispersing energy across the structure
• A denser inner lattice providing a more uniform contact surface with the player’s arm for additional protection

By optimizing the weight-to-protection ratio, ITERATE created cricket pads that placed structural stiffness precisely where needed rather than uniformly throughout the equipment. The lattice architecture also significantly improved airflow

The result was cricket protection that delivered measurably superior performance: lighter weight, enhanced protection, improved breathability, and better mobility. Moreover, the design enabled customization opportunities, allowing players to tailor equipment to their specific requirements—a capability previously unavailable with traditional mass-manufactured gear.

Golf performance depends substantially on the quality of connection between player and club. Traditional grips degrade over time, lack precise tuning for feel and performance, and offer minimal customization for individual preferences.

ITERATE addressed these challenges by designing a lattice-structured golf putter grip with varying compression zones for enhanced control. The team developed a grip featuring strategically positioned firm and soft areas that improved control and comfort at critical moments during the putting stroke.

By manipulating lattice parameters, ITERATE created different density zones within the grip, enabling players to fine-tune the feel to their exact requirements. This dual-texture approach provided an optimal balance between tactile feedback and comfort—a combination impossible to achieve with conventional manufacturing methods.

The resulting grip delivered a competitive advantage through its ability to adapt to individual playing styles. Carbon’s elastomeric materials, ranging from high-energy return to high-impact damping properties, provided additional performance options unavailable with traditional grip materials.

Transforming computational models into functional sports equipment requires bridging the gap between digital innovation and physical manufacturing. ITERATE’s design expertise, combined with Carbon’s Digital Light Synthesis^™ (Carbon DLS^™) printing technology, created an efficient pathway from concept to product.

The development process benefited from remarkably fast iteration cycles. ITERATE could prototype and refine designs in weeks rather than months, testing and validating performance characteristics before committing to final production. This accelerated timeline not only reduced development costs but also improved the quality of the final products through extensive real-world testing.

Perhaps most significantly, the combination of computational design and additive manufacturing unlocked customization potential previously unachievable in sports equipment. Products could be tailored to individual player preferences and performance needs, creating equipment optimized for specific playing styles and physical characteristics.

The cricket pads and golf grips developed by ITERATE represent early applications of a technology with expansive potential. As computational design and additive manufacturing continue to evolve, we’ll likely see applications expand to include more helmets with impact zones tuned to specific sports, footwear with personalized cushioning based on gait analysis, and protective gear that adapts to different playing conditions.

The prospect of mass customization represents a fundamental shift in sports equipment design. Athletes may soon have access to gear precisely tuned to their biomechanics, playing style, and performance objectives. This individualization could not only enhance performance but also potentially reduce injury by providing protection optimized for each athlete’s unique movement patterns.

ITERATE’s successful implementation of Carbon’s Design Engine demonstrates the transformative potential of computational latticing in sports equipment design. The ability to precisely tune mechanical properties throughout a structure unlocks performance optimization previously impossible with traditional materials and manufacturing methods—an approach that promises to transform athletic performance across sporting disciplines.

As computational latticing continues to redefine performance boundaries across industries, organizations face both unprecedented opportunities and technical challenges. ITERATE offers comprehensive support for businesses seeking to leverage Carbon’s Design Engine for lattice part development, bringing expertise in:

• Translating performance requirements into optimized lattice specifications
• Navigating complex multi-zone lattice design
• Ensuring the manufacturability of advanced lattice structures
• Accelerating design-to-manufacturing workflows
• Validating performance through rigorous testing methodologies

Whether you are exploring lattice structures for the first time or seeking to optimize existing applications, ITERATE’s proven expertise can significantly reduce development timelines while enhancing product performance. By partnering with ITERATE, organizations can navigate the technical complexities of computational lattice design while focusing on their core innovation objectives.

Contact ITERATE today to discuss how their specialized knowledge in lattice-based design can transform your product development process and unlock new performance paradigms that provide meaningful competitive advantages.