The development of the underwear industry is like a vivid history of fashion changes. For a long time in the past, the production of traditional underwear followed a standardized model and met the general needs of consumers on a batch scale. Factories carry out large-scale manufacturing according to fixed sizes, limited styles and colors, making underwear products on the market highly homogeneous.
However, with the progress of society and the significant improvement of people’s living standards, consumers’ concepts have undergone earth-shaking changes. They no longer want to be constrained by the same choice of underwear, but are eager to show their unique personality and style through underwear. In this context, custom underwear has gradually emerged as an innovative concept. Custom underwear and personalized underwear have become key words in this emerging trend.
Custom underwear gives consumers unprecedented autonomy, whether in the selection of materials, such as soft silk, breathable cotton or high-tech functional fabrics; or in style design, from exquisite lace to simple sportswear style, you can even incorporate patterns or logos with special meaning to create unique personalized underwear. It perfectly blends fashion and comfort. It not only fits the body curves and provides an excellent wearing experience, but also becomes an expression of fashion attitude. So, what are the factors that prompt more and more consumers to choose custom underwear? This is worth exploring in depth.
The rise of custom underwear: from personalization to market demand

Changes in consumer demand
In today’s era, changes in consumer demand have become a key driver of the rise of maßgeschneiderte Unterwäsche. Modern consumers’ requirements for underwear have long gone beyond basic body-covering functions. They place comfort, fit and uniqueness as extremely important. For women, custom underwear for ladies can provide just the right support and fit based on their unique body curves. Whether it is exquisite lace or soft material selection, it can satisfy women’s pursuit of beauty and The desire for comfort. Custom underwear for men pays more attention to the combination of functionality and simple fashion. For example, it uses breathable and quick-drying fabrics to stay dry and comfortable during sports or daily wear, showing men’s masculinity and ability.
Market trends
The rapid growth of the custom underwear market is an important trend in the underwear industry in recent years. According to market research reports, the global underwear market will reach US$79.5 billion in 2024, and the market share of custom underwear is expanding year by year. It is expected that the global customized underwear market will have a compound annual growth rate of 8% by 2031, especially in the Asia-Pacific region, where the demand for custom underwear has grown particularly significantly.Custom underwear manufacturers play an indispensable role in this. They continuously invest in research and development and innovation, introduce advanced production technology and processes, from accurate human body data collection to personalized design and production, ensuring that each piece of custom underwear can meet high quality standards to meet the growing market demand.
The popularity of personalized design

The popularity of personalized design has injected strong appeal into custom underwear, which is especially popular among young consumers. Custom print underwear and custom underwear with face have gradually become popular choices among young consumers. Through these designs, consumers can incorporate their own creativity into underwear to create a unique wearing experience. Consumers can choose their favorite patterns, colors and fonts, and even customize text or symbols with specific meanings. This kind of personalized design not only satisfies consumers’ pursuit of uniqueness, but also brings more market opportunities to the brand. According to market research data, in the global custom underwear market, personalized design sales will account for 25% in 2023, and this proportion will continue to grow.
Technical innovation and production process of custom underwear
In today’s rapid changes in the fashion industry, the field of custom underwear is completely reshaping the traditional production process and consumer experience with a series of eye-catching technological innovations. This change not only meets the growing personalized needs of consumers, but also injects new vitality and competitiveness into the entire underwear industry.
Technological innovation: opening a new era of custom underwear
(1) 3D scanning technology: the cornerstone of precise customization
The emergence of 3D scanning technology can be called a major revolution in the custom underwear industry. In the past, the traditional underwear size measurement method was relatively crude and could only be divided based on a few basic body dimensions, which was difficult to meet consumers’ ultimate pursuit of fit. 3D scanning technology can capture the complete three-dimensional shape of consumers’ bodies in an instant in a non-contact, high-precision manner.
Advanced 3D scanners use laser or optical imaging principles to quickly scan the human body from multiple angles. Millions of measurement points work together to build an extremely accurate digital model of the human body. This model not only covers the outer contours of the body, but also details changes in curvature, muscle texture, and subtle differences in bone structure in various parts of the body. For example, the 3D scanner launched by Japan’s Wacoal Group can complete the collection of 1.5 million data points in 5 seconds to generate an accurate human body model. For custom underwear, this rich data information is the key to achieving a perfect fit.
Taking custom women’s underwear as an example, women’s breast shapes are complex and diverse, and different people have significant differences in breast fullness, shape, spacing, and nipple position. Through 3D scanning technology, manufacturers can accurately obtain this personalized data to design a bra cup shape that closely fits the curves of the breasts and provides just the right support for each woman. Whether it is a round and plump hemisphere, a naturally drooping teardrop shape or a relatively flat disk-shaped breast, you can get an exclusive custom design, effectively avoiding the empty cup, strangulation or displacement caused by inappropriate sizes of traditional underwear and other questions, greatly improving the comfort and stability of wearing.
Likewise, 3D scanning technology plays an integral role when it comes to customizing men’s underwear. Men’s anatomy has large individual differences in the shape and size of waist, hip, thigh, and private parts. Custom men’s underwear manufacturers can use 3D scanning data to accurately design underwear styles that fit the curves of the male body, such as custom sports shorts with good elasticity and support designed for sports enthusiasts, or custom sports shorts for business people. Slim-fitting and comfortable custom-made boxer briefs can show off a man’s figure advantages and elegance while ensuring freedom of movement.
For some special styles of custom underwear, such as custom thongs, the advantages of 3D scanning technology are even more prominent. The design characteristics of the thong determine that it needs to fit the private parts of the human body more accurately to avoid discomfort or embarrassment when wearing it. 3D scanning can capture the special curves of the hips and crotch in detail, providing millimeter-accurate dimensional reference for the design of thongs to ensure smooth lines and tight fit. Material selection and sewing processes can also be based on these data. Optimize so that consumers feel unprecedented comfort and confidence when wearing them.
(2) AI design technology: the engine of personalized creativity

After obtaining accurate human body data, AI design technology has become a powerful engine for transforming consumers’ personalized needs into actual underwear design solutions. With its powerful data analysis capabilities and deep learning algorithms, the AI system can deeply understand consumer preference information and quickly generate creative design solutions that meet actual production needs. For example, the AI design tool developed by ChimerAI can generate 200 different underwear designs in a few seconds. Consumers only need to input key information, and AI can automatically refine inspiration and generate concrete design drawings. This technology not only improves design efficiency, but also provides consumers with more choices and satisfies their pursuit of personalization and uniqueness.
AI technology can also be applied to underwear size recommendations. For example, the AI measurement tool developed by ThirdLove can analyze a consumer’s bust through a mobile phone camera and recommend the most suitable cup size, with an accuracy that can even reach half size. This intelligent measurement and recommendation method greatly simplifies the consumer purchasing process and improves the user experience.
Production process: from design blueprint to exquisite finished product
(1) Design link: the integration of creativity and data
The design phase is the starting point of the custom underwear production process and is one of the most creative and challenging stages of the entire process. At this stage, designers need to organically integrate consumers’ individual needs, 3D scanning data and AI design-generated solutions, and use professional design software and rich design experience to draw a detailed design blueprint for custom underwear.
First, the designer will accurately design the underwear pattern based on the human body data obtained from 3D scanning. This includes determining the shape, measurements and proportion of the various components of the underwear, such as the cup shape, sides, strap width and length of the bra, the waist circumference, hip circumference, crotch depth and the shape of the leg openings of the underwear. During the design process, designers will fully consider the principles of human body motion mechanics to ensure that the underwear can naturally stretch and fit with the body’s activities when worn, without causing a sense of restraint or discomfort.
At the same time, designers will skillfully integrate these design elements into the overall design of underwear based on the colors, patterns and decorative elements selected by consumers. They will carefully select suitable fabrics and determine the best printing or embroidery process based on the characteristics of the fabric and the style of the pattern. For example, for soft and thin silk fabrics, delicate digital printing technology may be used to present exquisite floral patterns to fully demonstrate the luster and texture of silk; while for cotton fabrics, embroidery technology may be chosen to add some three-dimensional decoration elements such as lace, bows or metallic accessories to add layering and fashion to the underwear.
During the design process, designers will also communicate closely with consumers and repeatedly modify and improve the design plan based on consumers’ feedback until consumers are completely satisfied. This interactive design process not only ensures that custom underwear can fully meet the individual needs of consumers, but also allows consumers to participate in the design and creation process of underwear, enhancing their sense of identity and belonging to custom underwear.
(2) Cutting process: guarantee of accuracy and efficiency

Once the design plan is determined, the next step is the cutting process. At this stage, advanced CNC cutting equipment has become a key tool to achieve precise cutting. These devices can read the cutting data generated by the design software and automatically adjust the position and movement trajectory of the tool based on these data to accurately cut the selected fabric.
CNC cutting equipment has extremely high cutting accuracy and can cut fabrics into individual parts with extremely small errors, ensuring that each piece of cut fabric is completely consistent with the design requirements. This is crucial when it comes to custom-made bras, as even small errors in tailoring can result in inappropriate sizes, uneven seams, or cosmetic imperfections after the bra is sewn. For example, when cutting the cup shape of a bra, CNC cutting equipment can accurately determine the curve shape of the cup shape based on 3D scan data, and cut the fabric into a shape that perfectly matches it, ensuring the symmetry and fit of the left and right cup shapes.
At the same time, CNC cutting equipment also has efficient cutting speed, which can greatly shorten cutting time and improve production efficiency. This advantage is particularly obvious in mass customization production. Through the automated cutting process, manufacturers can complete a large number of custom underwear cutting tasks in a short period of time, providing sufficient parts supply for subsequent sewing links, thereby ensuring the smooth progress of the entire production process.
In addition, in order to improve fabric utilization and reduce waste, some advanced CNC cutting equipment is also equipped with intelligent typesetting software. These software can automatically calculate the optimal layout plan based on the the fabric width, the repetition pattern, and the shape and size of the cutting parts, so that the fabric can be utilized to the maximum extent during the cutting process. For example, for fabrics with patterns, the software can ensure the integrity and beauty of the patterns on each cutting part through precise calculations and adjustments, while avoiding fabric waste caused by improper pattern splicing.
(3) Sewing process: carving out craftsmanship and quality
The sewing process is a key step in assembling the cut fabric parts into complete custom underwear. It is also an important link that reflects the quality of underwear craftsmanship and detail processing. In this link, experienced tailors and advanced automated sewing robots work together to ensure that every piece of custom underwear meets high quality standards.
For some complex processes, such as the cup-shaped sewing of bras, the splicing of lace, and the hemming of underwear edges, it is often necessary to rely on the exquisite manual skills of tailors. With years of accumulated experience and a keen sense of touch, they are able to skillfully operate sewing machines and use a variety of different stitches and sewing techniques to delicately sew fabric components together. For example, when sewing the cup shape of a bra, the tailor will use a special three-dimensional sewing process to give the cup shape a good three-dimensional feel and support, and can naturally fit the breast curve; when splicing lace, a fine The invisible stitching method ensures the seamless connection between the lace and the main body of the underwear, making the entire underwear look more refined and beautiful.
At the same time, with the continuous development of automation technology, automated sewing robots have also been widely used in the production of custom underwear. These robots can quickly and accurately complete some highly repetitive sewing tasks, such as straight-line stitching, hemming, buttoning, etc., according to preset programs and process parameters. Automated sewing robots have extremely high work efficiency and stability, and can greatly increase production speed while ensuring sewing quality. For example, when sewing the waistline and leg openings of underwear, automated sewing robots can quickly complete the sewing and hemming of elastic bands to ensure that the tension of the elastic bands is even, the stitching is firm, and the appearance is smooth and beautiful.
In the sewing process, quality control is also a crucial link. After each sewing process is completed, professional quality inspectors will strictly inspect the sewing quality. They will check the evenness of the stitches, the density of the stitches, the firmness of the stitches, and whether there are skipped threads, broken threads, etc. Any quality problems discovered will be reworked in a timely manner to ensure that every piece of custom underwear can be delivered to consumers with perfect quality.
(4) Quality inspection and packaging: final check and presentation

After the custom underwear is sewn, it needs to go through strict quality inspection to ensure that the product quality meets relevant standards and consumer expectations. The quality inspection process covers multiple aspects of inspection, including dimensional accuracy inspection, fabric quality inspection, sewing quality inspection, appearance defect inspection, functional inspection, etc.
In terms of dimensional accuracy testing, professional measuring tools will be used to measure the measurements of each part of the custom underwear and compare it with the measurements required by the design to ensure that the error is within the allowable range. Fabric quality testing will check whether the color fastness, breathability, elasticity, softness and other performance indicators of the fabric meet the requirements to avoid fabric quality questions that affect the wearing comfort and service life of underwear. Sewing quality inspection mainly checks the previously mentioned issues such as sutures, stitches, and suture firmness to ensure that the underwear will not open or come off during the wearing process. Appearance defect detection will carefully check whether there are stains, color differences, damage, wrinkles and other questions that affect the appearance of the underwear surface. Any defects found will be repaired or eliminated in a timely manner. Functional testing conducts corresponding tests based on the different types and functional requirements of custom underwear, such as support testing of bras, shock-absorbing testing of sports bras, thermal performance testing of thermal underwear, etc., to ensure that the underwear can meet the actual needs of consumers.
Only custom underwear that has passed all quality inspection items will enter the final packaging process. In the packaging process, appropriate packaging materials and packaging methods will be selected based on the style, size and customer requirements of the underwear. Generally speaking, custom underwear will be packaged in exquisite, environmentally friendly packaging boxes or polybags to protect the integrity and beauty of the underwear during transportation and storage. At the same time, product descriptions, maintenance guides, brand promotional materials and other related items will also be included in the packaging to provide consumers with comprehensive product information and after-sales service guarantees. After packaging, the custom underwear can be quickly delivered to consumers through express delivery or logistics, completing the entire custom underwear production process.
Environmental protection and sustainability: equal emphasis on fashion and responsibility
In today’s context of increasing global environmental awareness, the custom underwear industry has also actively responded to the call for sustainable development and integrated environmental protection concepts into the production process of products through various methods, making custom underwear an important practitioner of sustainable fashion. .
(1) Selection of environmentally friendly materials: the choice between natural and recycled materials
Custom underwear manufacturers are increasingly turning to eco-friendly materials for their products. Among them, natural materials such as organic cotton, bamboo fiber, modal fiber, etc. have become popular choices. Organic cotton does not use chemical pesticides and fertilizers during the planting process, reducing pollution to soil and water sources. At the same time, its softness, comfort, and good breathability are also very suitable for making underwear. Bamboo fiber has natural antibacterial and antibacterial properties, which can effectively inhibit the growth of bacteria and keep underwear clean and hygienic. The production process of bamboo fiber is relatively environmentally friendly. Bamboo grows rapidly and is a renewable resource. Modal fiber has good hygroscopicity and breathability, is cool and comfortable to wear, and its processing process is relatively simple and energy consumption is low.
In addition to natural materials, recycled materials are also widely used in the production of custom underwear. Recycled polyester fiber is a typical representative. It is made by recycling discarded polyester bottles, polyester fiber products, etc., and then remaking the fiber after a series of processing. Using recycled polyester fiber to make custom underwear can not only reduce environmental pollution from waste, but also reduce dependence on non-renewable resources such as petroleum and achieve resource recycling. For example, some brands have launched “custom printed underwear” using recycled polyester fiber fabrics and printing environmentally-themed patterns on the fabrics, which not only shows fashion personality but also conveys environmental protection concepts and is deeply loved by consumers with strong environmental awareness.
(2) Measures to reduce waste: lean production and resource optimization
In the production process of custom underwear, manufacturers strive to reduce waste by implementing lean production concepts and using advanced resource optimization technology. In the cutting process, as mentioned above, intelligent typesetting software is used to achieve efficient use of fabrics and reduce the generation of cutting waste. In terms of production planning, precise production is carried out according to order requirements to avoid inventory backlog and waste caused by over-production. At the same time, some companies are also actively exploring ways to recycle the scraps generated during the production process, such as processing them into fiber fillers for making pillows, toys and other products to realize the reuse value of the scraps.
In addition, in the packaging process, custom underwear manufacturers also focus on using environmentally friendly packaging materials, such as paper packaging boxes, degradable plastic bags, etc., to reduce environmental pollution caused by plastic packaging waste. Some brands are also innovating in packaging design, adopting simple and lightweight packaging styles, which not only reduces packaging costs but also reduces the use of packaging materials, further embodying the concepts of environmental protection and sustainability.
Technological innovation and changes in the production process of custom underwear not only bring more personalized, comfortable and fashionable underwear products to consumers, but also open up a new path for the sustainable development of the industry. With the continuous advancement of technology and the continuous enhancement of environmental awareness, it is believed that the custom underwear industry will continue to show unlimited innovation vitality and development potential in the future, becoming a bright green star in the fashion industry.
Custom underwear brand case analysis

In the booming development of custom underwear, many internationally renowned brands have actively participated in it and launched distinctive custom underwear services. For example, Italy’s La Perla, as a leader in the field of high-end underwear, its customized services are eye-catching. In terms of custom print underwear, it provides a rich library of printing materials, covering classic Italian patterns, fashionable geometric patterns and artistic master painting elements. Consumers can also upload their own designs, and brands can use exquisite printing technology perfectly integrates these patterns into underwear, making each piece of custom underwear a unique work of art. Not to be outdone, Victoria’s Secret in the United States launched the custom underwear with face series, which uses advanced image printing technology to clearly present consumers’ photos or favorite celebrity photos on underwear. This creative design It has attracted many young fashion enthusiasts and satisfied their ultimate pursuit of personalization.
In Australia, there are also many brands that have successfully broken through in the custom underwear market. Like the Bonds brand, its “custom underwear for ladies” series fully considers women’s needs in different life scenarios. Through accurate human body data collection, they can create underwear styles that fit women’s body curves. Whether it is simple daily styles or gorgeous designs required for special occasions, they can achieve the ultimate in comfort. In terms of material selection, high-quality cotton and elastic fiber blends are used to ensure softness, skin-friendly and elasticity. For men, the aussieBum brand’s “custom underwear men” performs well. Inspired by Australians’ love for outdoor life and sports culture, it designs customized men’s underwear that is both fashionable and functional. It uses breathable and quick-drying high-tech fabrics to meet men’s needs in sports, fitness or daily activities. At the same time, it incorporates Australian characteristic elements into the design, such as unique coastline patterns, native animal images, etc., and successfully open the door to the market with personalized customized services.
Consumers also speak highly of custom underwear. A female consumer said after experiencing La Perla’s custom-printed underwear: “The printing of this underwear is exquisite, and it is as comfortable as a second skin. It perfectly shows my personality.” A male customer Comments on aussieBum’s custom underwear: “The fit is beyond imagination, and there is no sense of restriction when exercising. The unique design makes me stand out among my friends, and I truly feel the charm of customization.” This feedback strongly proves the significant advantages of custom underwear in terms of comfort and uniqueness, and also lays a solid foundation for its continued development in the market.
Schlussfolgerung
Custom underwear is profoundly reshaping the future landscape of the underwear industry with its personalized design, technological innovation and accurate grasp of market demand. Through personalized design, consumers can freely choose the style, color, pattern and even material of underwear based on their own aesthetic preferences, physical characteristics and life scenes, whether it is “custom print underwear” to show unique artistic taste, or “custom underwear with face” ” showcasing personal emotions and identity, making underwear a unique form of self-expression. Technological innovations such as 3D scanning and AI design make the customization process more scientific, precise and efficient, ensuring a perfect fit between underwear and the body, greatly improving comfort. Driven by market demand, custom underwear has gradually moved from being exclusive to a few people to the masses, satisfying people’s pursuit of quality life and individuality expression.
Custom underwear is not just a piece of clothing, it has evolved into a symbol of lifestyle. It represents the deep understanding and acceptance of oneself, and the ultimate attention and carving to the details of life. It breaks the monotony of traditional underwear and gives consumers more autonomy and confidence. Here, we sincerely encourage readers to bravely try custom underwear, experience for themselves the unparalleled comfort experience and inner self-confidence brought by personalization, and start their own journey of fashionable and personalized underwear. In the pursuit of uniqueness and beauty on the road, showing a different kind of charm and style.
FAQs
What is custom underwear?
Custom underwear refers to personalized or made-to-order underwear that caters to individual preferences in terms of fabric, style, fit, and design. This allows customers to express their unique style and ensure maximum comfort, as the items are tailored specifically for their body dimensions and personal taste.
How can I design my own underwear?
Designing your own underwear typically involves choosing the style (such as briefs, boxers, or thongs), selecting fabric, and personalizing colors and patterns. Many custom underwear brands offer online design tools where you can mix and match these options to create the perfect piece that meets your specific needs.
What materials are commonly used in custom underwear?
Common materials for custom underwear include organic cotton, bamboo fiber, modal, polyester, and so on. Each material offers different benefits, such as breathability, stretchability, and comfort. It’s important to consider fabric type based on personal preferences for warmth, moisture-wicking capabilities, and overall wearability.
Is custom underwear more expensive than regular underwear?
Yes, custom underwear can often be more expensive than regular, off-the-shelf options due to the personalization involved and the quality of materials used. However, many find the investment worthwhile for the comfort and unique design tailored to their preferences.
How long does it take to receive custom underwear?
The bulk lead time for custom underwear can vary depending on the manufacturer and the complexity of the design. Typically, it can take anywhere from a few days up to several weeks. It’s always advisable to check the estimated shipping timelines provided by the supplier before placing an order.
Can I return custom underwear if it doesn’t fit?
Return policies for custom underwear typically differ from standard products, as they are often made to individual specifications. Most suppliers do not accept returns for custom underwear. Some companies may offer a limited return policy, usually only for defects or if the item was incorrectly made. It’s essential to review the specific return policy of the brand before purchasing.