Case Study · Drinkware Lids
Designing a Lid Around the Way People Drink
Two new lids for CORKCICLE, from a rough 2D drawing to mass production
CORKCICLE wanted two new lids for its existing bottles. One became the Quick Sip Cap for the Sport Canteen. The other became the Jug Lid for the 64oz Sport Jug. From April 2020 to March 2021, we carried both from industrial design to mass production and logistics.
Overview
We started by listening
CORKCICLE came to us with a clear specification and a rough 2D drawing. We developed the drawing into detailed products, and reworked it so the design was mechanically feasible. We kept the client involved at every stage. For each problem, we brought several solutions and talked the key issues through together.
Before shaping anything, we studied the brand. We looked at benchmarks, market research and the design language of CORKCICLE's products. The lids would be used everywhere, from the sports court to the commute, home and office. Users wanted quick sips, no straw and a foldable handle, with a brand people recognize at a glance.
Key successes
- Took two lids from a rough 2D drawing to mass production in under a year
- Found the best drinking angle by testing lid base heights on mock-ups
- Balanced square and oval to find the most comfortable spout
- Kept both lids simple enough to suit every canteen style and stay on-brand
- Ran leak, pressure and durability tests before shipping
Approach
Finding the best angle to drink
Both lids had to suit every canteen in CORKCICLE's range, so we kept the forms simple and put the effort into how they work.
The real test was drinking. On the 32oz Canteen, we tried several lid base heights to find the best angle to drink. For the spout, we balanced square and oval until it sat comfortably on the lips. Our designers built many mock-ups to make sure each lid was easy to use. Then our engineers carried the chosen form into detailed mechanical design.
The solution
Quick Sip Cap · Sport Canteen
Built for quick sips on the move.
- Square-oval spout→smoother sips and fewer drips
- One-hand flip-top→opens with a single motion; the cover keeps the spout clean
- No straw→nothing extra to clean
- Large handle→easy to grab and carry
- Extra-wide mouth→room for ice cubes
- Fits 20, 32, 40 and 60oz Canteens→dishwasher safe
Jug Lid · Series A Sport Jug
Built for a 64oz bottle that has to survive the bag.
- Round spout with a twist-lock cap→seals tight against spills and leaks
- Controlled flow→even when tipped, water does not gush out
- Folding handle→carries the full jug, then folds out of the way
Finalize and realize details
In the final stage, we worked closely with our factory so production would run smoothly. We checked DFM, solved injection and material problems, then made subtle final tweaks. Before shipping, we ran durability and press tests at the client's request.
- Handle→several metal processes tested for maximum durability
- Sealing silicone→different hardnesses and shapes tried, so water does not leak
- Flip lid→pressure-tested to open with moderate force and survive repeated washing
- Screw position→studied and adjusted to fit the new lid design
- Final CMF→checked straight from the factory against the design
Impact
Two lids people reach for every day
Along the way, we worked through several technical issues and production difficulties, and brought both lids to reality. CORKCICLE built both designs into its final products. The Quick Sip Cap ships on the Series A Sport Canteen and sells on its own for US$14.95. The Jug Lid tops the 64oz Series A Sport Jug, and also sells on its own for US$14.95.
Users notice the details. On the Quick Sip Cap, they like drinking without a straw, opening it with one hand and keeping the spout covered. They say it stays sealed on its side, pours just enough, and has a handle easier to hold than the older metal one. On the Jug Lid, they like the easy twist cap and a tight seal. Even when the jug tips over, the water never gushes out.
