Commercial Projects
North Lakes Design works with businesses, engineers, designers, and innovators on practical design, prototyping, and digital manufacturing projects.
Whether you’re developing a new product, improving an existing design, or solving a technical problem, we provide hands-on support to move ideas from concept to functional reality.
Commercial projects also support the development of the Community Access workshop, helping expand access to digital manufacturing capability in Carlisle.
Design & Prototyping
Turning rough ideas into functional designs. We work with clients to develop parts, components, and prototypes that solve real problems and are ready for testing or production.
Reverse Engineering
If a component is obsolete, broken, or no longer available, we can analyse the part and recreate a functional replacement using digital design and manufacturing tools.
Collaboration & Problem Solving
Many projects begin with a simple problem that needs solving.
We enjoy working with clients who need practical thinking, rapid prototyping, and an iterative approach to developing working solutions.
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Beyond the standard offerings, we tackle the projects that don't fit into neat categories — because the best engineering challenges rarely do. Our approach isn't about forcing your problem into our existing solutions; it's about crafting the right solution for your specific challenge.
We work with hybrid assemblies that combine 3D printed components with traditional hardware — heat-set inserts, threaded fasteners, springs, and electronics integration. Each project gets the full treatment: proper material selection based on load requirements, environmental conditions, and expected lifespan, not just what happens to be loaded in the printer.
From concept sketches on the back of an envelope to fully-developed CAD files ready for production, we speak your language. Whether you're working with legacy equipment that needs modern solutions, developing new products that push material limits, or solving those "impossible" problems that keep you awake at night — we're here for the interesting stuff.
Our workshop handles everything from single prototypes to short production runs, with materials ranging from flexible TPU for custom gaskets to carbon-fiber reinforced filaments for structural applications. We're constantly testing new approaches, new materials, and new ways to make additive manufacturing work harder for your business.
The only real limits? Physics, budget, and build volume. Everything else is just an engineering challenge waiting for the right approach.
Reverse Engineering
Transform existing parts into precise CAD models using advanced measurement techniques and Fusion 360. Whether you've got a broken component that's no longer manufactured, a legacy part that needs updating, or something that just needs improving, we'll recreate it digitally with meticulous accuracy.
Our process involves detailed measurement, 3D scanning where needed, and careful CAD reconstruction that captures not just the geometry, but the engineering intent behind the original design. We don't just copy — we understand what made it work in the first place, so we can make it work better.
Tooling, Jigs, and adapters
Whether you need a simple fixture to hold parts during assembly, a complex jig for repetitive manufacturing tasks, or custom adapters to make incompatible systems work together, we approach each project as a problem-solving exercise. What's slowing you down? What's causing errors? What would make your job easier?
Our tooling isn't just functional — it's designed to last. We use materials and design techniques that stand up to daily use, because the best tool is the one you can rely on day after day. From simple assembly aids to sophisticated manufacturing fixtures, we build the tools that build your business.
Prototypes & bespoke
Rapid prototyping services that bring your ideas to life with the precision and reliability your projects demand. Our FDM 3D printing capabilities handle everything from initial concept validation to functional prototypes using carefully selected materials — PLA for quick iterations, PETG for durability testing, and flexible TPU for gaskets and seals.
Whether you're validating a concept, testing fit and function, or producing short runs of specialized components, we treat each project with the same attention to detail. Because the difference between a prototype and a product is often just the confidence that comes from proper testing.