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OUTCOMES.
The project established a refined direction for Pure Ella's one-size menstrual disc, developed around improved interaction, distinctive styling and eventual mass manufacture.
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Developed a one-size product architecture around defined ergonomic requirements.
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Developed grip and geometry features around insertion and removal.
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Considered folding behaviour and visual indication to support more intuitive use.
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Refined the product’s aesthetic to present a timeless look.
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Considered cleanability and durability to support repeated, long-term use.
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Multiple rounds of prototypes were created to validate the design and confirm form, geometry and material flexion.
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Developed the product around medical-grade silicone and liquid silicone injection moulding.
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Prepared production-ready CAD and technical information for professionally moulded samples.
The result was a more considered reusable menstrual-care product that brought together ergonomics, flexible material behaviour, user interaction and manufacturing requirements within a simple and distinctive design.
our approach.
Development began with analysis of the existing Pure Ella design alongside competitor products and established menstrual-disc formats.
From this, two design directions were narrowed & explored, allowing different approaches to form, grip, folding and removal to be considered before committing to detailed development.
Key areas of exploration included:
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Overall geometry - refining the shape and proportions around ergonomic requirements and intended use.
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Insertion - exploring geometry and visual cues that could make folding and positioning the disc more intuitive.
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Removal - developing gripping features and forms that could provide greater control when retrieving the product.
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Surface detailing - considering texture and grip without creating unnecessary areas that could make the product more difficult to clean.
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Flexible behaviour - considering how silicone hardness, geometry and muscular contraction could influence the way the product behaves during use.
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Brand language - introducing subtle styling that differentiated the product while remaining consistent with Pure Ella's existing range.
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Manufacturing - developing the geometry with liquid silicone injection moulding, tooling and eventual mass production in mind.
Physical prototyping formed an important part of the development process, allowing different geometries, proportions and functional details to be assessed and progressively refined. As the design developed, the CAD was adjusted around the intended liquid silicone injection moulding process, preparing the product for professionally moulded prototyping and subsequent evaluation.
KEY DEVELOPMENT CHALLENGES.
The product needed to balance a number of functional, ergonomic and manufacturing requirements:
01. Establish appropriate dimensions and proportions for a one-size product.
02. Improve grip and control during insertion and removal.
03. Explore folding features or visual indications to make insertion more intuitive.
04. Maintain smooth, easily cleaned surfaces despite the addition of functional detailing.
05. Consider how the flexible geometry behaves during use, including muscular contraction and repositioning.
06. Allow the product to support intended functions such as auto-dumping and reinsertion.
07. Develop a distinctive aesthetic consistent with the existing Pure Ella brand.
08. Design the final geometry around medical-grade liquid silicone injection moulding and mass manufacture.
The challenge was to introduce meaningful functional improvements without unnecessarily complicating a product that ultimately needed to remain simple, comfortable and easy to understand.
MENSTRUAL DISC DESIGN FOR IMPROVED EVERYDAY USE.
THE SITUATION.
the PRODUCT context.
Pure Ella approached us to develop a new and improved version of its existing menstrual disc product.
An initial design and prototype had already been created, providing a starting point for further exploration and refinement. The aim was to improve the experience of inserting and removing the disc while developing a distinctive, modern product that aligned with the existing Pure Ella brand.
The product also needed to be suitable for mass manufacture using medical-grade silicone, with tooling and manufacturing considerations incorporated throughout the development process.
Unlike menstrual cups, menstrual discs are positioned higher within the vaginal canal and rely on their geometry and flexible material behaviour to remain positioned during use. This creates a particular ergonomic challenge - the product needs sufficient flexibility to fold for insertion while maintaining the form and behaviour required once in position.
As a reusable menstrual-care product, the disc also offers an alternative to disposable pads and tampons, making durability, cleanability and long-term usability important considerations alongside comfort and performance.
Reusable one-size menstrual disc designed around intuitive insertion, removal and everyday usability.
Client: Pure Ella | 2023
Our Role: Product Strategy, Industrial Design & Engineering, Prototyping
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