Product Design Flaws
Low-height or stiff leak-guard edges fail to conform to a baby’s leg contours, causing gaps.
– Fix: Use elastic materials (e.g., Lycra) and 3D tailoring for dynamic fit.
– Uneven Absorbent Core Distribution:
– Superabsorbent polymer (SAP) concentrated in the center leads to lateral leakage when lying sideways.
– Fix: Reinforce side absorbency with layered cores or dual-channel wicking.
Incorrect Sizing
– Mismatched Size/Weight:
– Too loose (gaps at legs) or too tight (compression leaks).
– Fix: Provide detailed size charts and sample packs.
– Unisex Designs:
– Generic diapers may not account for gender-based wetting patterns.
– Fix: Gender-specific designs (e.g., front-heavy for boys, wider middle for girls).
User Errors
– Improper Wear:
– Un-tucked leak guards, asymmetrical fastening, or incorrect waist tightness.
– Fix: Add visual guides/QR codes linking to tutorial videos.
– Delayed Changes:
– Over-saturation reduces absorption capacity.
– Fix: Highlight wetness indicators and recommend 2–3 hour changes.
Material & Manufacturing Issues
– Breathability vs. Absorption Trade-off:
– Overly breathable topsheets may slow liquid diffusion.
– Fix: Use textured surfaces (e.g., 3D embossing) for rapid liquid intake.
– Quality Control Lapses:
– Misaligned cores or weak seam adhesions in production.
– Fix: Implement pressure tests and batch tracking.
Unaddressed Usage Scenarios
– Nighttime/Active Use:
– Frequent movement (rolling/crawling) increases lateral pressure.
– Fix: Launch “overnight” or “active-fit” variants with enhanced waistbands.
