Custom clothing at scale - The role of AI and 3D body scanning

In a world where personalization is king, the demand for custom-fit clothing is no longer limited to haute couture or high-end tailoring. Consumers are increasingly expecting garments that fit their unique body shapes—and they want them fast. But how can brands deliver made-to-measure clothing at scale? 

The answer lies in a powerful fusion of AI and 3D body scanning, with companies like Size Stream and their Formcut solution leading the way. 

Why Traditional Sizing No Longer Works 

Most size charts are outdated, based on narrow population samples, and simply don’t reflect the diversity of today’s consumers. The result? Poor fit, high return rates, and a growing demand for something better. 

Ill-fitting clothes are more than just an inconvenience—they’re a costly problem for brands and a sustainability concern for the planet. But that’s changing. 

Size Stream: Pioneering Precision in 3D Body Data 

Size Stream is at the forefront of advanced 3D body scanning technology. With years of research and development, they’ve built one of the most robust and accurate body data platforms on the market. Their solutions — used in retail, manufacturing, and research—can capture over 200 body measurements in seconds with incredible accuracy. 

But Size Stream isn’t just about scanning; they’re revolutionizing body data utilization. Their platform provides actionable insights for apparel design, size prediction, and digital twin generation. It’s this data-driven approach that makes them a foundational player in the push toward scalable mass customization. 

Formcut: Smart Device Scanning for the Mobile Era 

On the other side of the innovation spectrum, Formcut is making 3D body scanning accessible to every business—using only a smart device. Specializing in made-to-measure apparel, Formcut uses computer vision and AI to turn a few simple scans into incredible custom clothing, delivered right to your door. 

Formcut’s technology is particularly exciting for brands looking to tap into direct-to-consumer customization without the need for specialized hardware. Their system enables: 

• Seamless body scanning in store or at home 

• Real-time garment previews 

• On-demand manufacturing based on each individual’s exact body shape 

  
  

In short, Formcut is lowering the barrier to entry for personalized fashion, helping brands deliver premium fit with minimal overhead. 

How AI Ties It All Together 

Both Size Stream and Formcut rely on sophisticated AI to make sense of the data they collect. Here's how AI adds value: 

• Measurement interpretation: Turning scan data into usable garment specs 

• Fit prediction: Modeling how fabrics interact with body shapes 

• Style suggestions: Recommending styles based on individual morphology 

• Supply chain intelligence: Using aggregate body data to optimize sizing runs and production 

  
  

This blend of AI and body scanning is enabling a new level of personalization, while also addressing long-standing pain points in the industry. 

Challenges on the Road Ahead 

Scaling custom apparel is not without its hurdles: 

• Data privacy: Sensitive biometric data requires strict handling and storage protocols. 

• User adoption: Consumers need to trust and feel comfortable using scanning technologies. 

• Manufacturing evolution: Brands must retool traditional processes for on-demand workflows. 

• Standardization: The industry still lacks a common language for body data interoperability. 

That said, companies like Size Stream and Formcut are actively building the tools and frameworks needed to overcome these barriers. 

The Future of Fashion Is Personal 

As AI and 3D body scanning become more advanced and accessible, the future of fashion looks increasingly: 

• Sustainable: Less waste from overproduction and returns 

• Inclusive: Clothing that fits real people, not just model sizes 

• Efficient: Automated production based on real-time data 

• Personalized: Apparel that feels like it was made just for you—because it was 

With Size Stream’s precision scanning systems and Formcut’s vertically integrated made-to-measure apparel platform, we’re entering a new era where custom clothing at scale isn’t just possible—it’s already happening. 

Do you want to discuss how AI and 3D body scanning can impact the future of your business? Book time with the business development team at Formcut today.