Pillowflow
Consumer Product
PillowFlow is a therapeutic foam pillow designed to support the driver’s leg in a more natural, relaxed position. By subtly adjusting leg alignment, PillowFlow helps reduce tension, improve circulation, and support quicker, more controlled braking response. Formed in a modern, sculptural profile and anchored discreetly to the seatbelt buckle, PillowFlow integrates seamlessly into the driving environment enhancing comfort, safety, and long-distance driving performance without distraction.
Project Overview
PillowFlow began as a clients outdated existing concept, presenting an opportunity to rethink the product from the ground up. DBS was engaged to redesign the product with a focus on form differentiation, improved ergonomics, and manufacturability, transforming a dated concept into a modern, scalable consumer product.
Our goal was to elevate the product beyond its original function, creating a therapeutic foam pillow that improves driver comfort, circulation, and reaction time, while integrating seamlessly into the driving environment.
The Challenge
The original product concept lacked both visual distinction and manufacturing efficiency. Key challenges included:
- Outdated form language that did not align with modern automotive interiors
- Limited ergonomic refinement despite therapeutic intent
- Inefficient geometry for scalable foam manufacturing
- No clear system for secure, repeatable in-seat positioning
The redesign needed to respect the functional intent of the original idea while clearly establishing a new design identity and production-ready solution.
Our Approach
DBS approached PillowFlow as both a design and engineering challenge.
We began by analyzing the original design and identifying where innovation could occur without constraint. From there, we focused on three core pillars:
1. Form Development as Differentiation
The pillow’s geometry was completely reimagined to feel intentional, modern, and purpose-built—balancing softness with structure.
2. Ergonomic Performance
Subtle changes in angle, height, and curvature were used to adjust leg position, supporting improved blood flow and faster braking response without restricting movement.
3. Design for Manufacturability
Every surface, radius, and transition was evaluated for foam molding efficiency, repeatability, and cost control at scale.
Design & Development
Through iterative sketching, CAD modeling, and physical prototyping, the PillowFlow form evolved into a sculptural yet restrained object that integrates naturally into the vehicle interior.
A key design decision was the seatbelt-buckle connection, which anchors the pillow in a consistent position while remaining intuitive and unobtrusive for the driver. This solution eliminated sliding, improved safety, and reinforced the product’s system-level thinking.
Material selection and internal geometry were refined to ensure consistent compression, durability, and comfort over extended use.
Manufacturing Strategy
DBS prepared PillowFlow for scalable production by optimizing the form for injection or compression-molded foam manufacturing. Design decisions prioritized:
- Reduced tooling complexity
- Efficient material usage
- Consistent part geometry
- Repeatable quality a cross production runs
Manufacturing files, tolerances, and production considerations were finalized to support smooth supplier onboarding and pilot runs.
Outcome
The result is a modern, therapeutic driving accessory that clearly differentiates itself through form, function, and manufacturability. PillowFlow successfully transformed an expired-patent concept into a product positioned for contemporary e-commerce and consumer markets—ready for production, branding, and scale.
