The present invention relates to a tampon applicator arrangement, having tampon, applicator unit and a film cap, attached thereto, which is at least partially uniformly shaped, typically being conforming to part or all of the tampon or applicator unit, or such that the film cap has the lowest possible surface area. The film cap is so shaped and/or generally under tension and has no rugosites, folds or even wrinkles, other than optionally tension wrinkles, and preferably also no seams or welds. The invention also relates to specific moulding processes for making the film cap and the arrangement of the invention. The arrangements of the invention provide a smoother, easier and safer insertion of a tampon in the body.