3 Smart Moves to Make Fashion Production More Profitable and Sustainable

In today’s uncertain economy, fashion production costs are rising while customer expectations remain higher than ever.
To stay profitable, fashion brands must rethink the way they design, produce, and sell their garments.

Here are three smart moves that can help your brand cut costs, reduce waste, and survive the recession:

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1️⃣ Get Sizing and Fit Right

Inaccurate sizing is one of the biggest hidden costs in fashion production. When your size chart doesn’t reflect your customers’ real measurements, you create waste before the first item is even shipped.

With SizeSense.ai, you can collect real data about your customers’ bodies – not just their sizes.

Once the SizeSense.ai recommender is active on your store, you’ll receive analytics about your shoppers’ body measurements and recommended sizes. You’ll see which sizes are searched most often and where the demand truly lies.

When I ran my own brand (XS–4XL), I discovered something surprising: we almost never received orders for 3XL, but 4XL was one of our best sellers.
So, we stopped producing 3XL and focused on 4XL – reducing dead stock and improving sell-through rates.

That’s what happens when you use data to guide fashion production decisions:
✅ Less overstock
✅ Smarter production planning
✅ Higher profitability

2️⃣ Design for Your Customers’ Real Body Types

Another costly mistake in fashion production is designing for a generic fit model instead of your actual customers.

With SizeSense.ai analytics, you can see your shoppers’ body shapes – whether they’re apple, pear, or hourglass.

If most of your audience is pear-shaped but your designs follow a straight silhouette, you’re creating returns before garments even leave the warehouse.

When you design based on real proportions, your customers will:
✔ Look better
✔ Feel better
✔ Keep their clothes longer

Designing for your customers’ real body types – not a generic chart – is how you make your fashion production both sustainable and profitable.

3️⃣ Check Your Sizing Before You Produce – Not After

Most brands only realize a sizing issue after the first sample arrives. By then, fabric, time, and budget are already wasted.

With SizeSense.ai, you can test your sizing before starting fashion production.

Simply input your garment measurements from your tech pack into SizeSense.ai. If your fabric stretches, measure how much it extends per 10 cm. For example:

If 10 cm of fabric stretches 0.4 cm, that’s 3.76 cm of stretch over a 94 cm bust.
This data – combined with garment measurements and fabric elasticity – allows SizeSense.ai to calculate how each size fits real customer bodies.

Example:
Your Size Small is designed for:

• Bust: 90 cm
• Waist: 70 cm
• Hips: 94 cm

If SizeSense.ai shows that the Small feels too tight, you’ll know before sampling begins – saving material and time.

By checking sizing early, you can:
✅ Reduce the number of samples
✅ Avoid fit-related returns
✅ Prevent customer frustration

The Profitability of Getting Fit Right

Getting sizing right isn’t just about comfort – it’s about profitability and smarter fashion production.

That’s why we built SizeSense.ai – a tool that delivers tailor-level accuracy straight from your tech pack:

• 94% size recommendation accuracy
• Matches body measurements with garment design
• Factors in body shape, fit preference, garment ease, and fabric elasticity
• Calculates elasticity impact with unmatched precision

And we’re just getting started.
🚀 Coming soon: body scan, virtual try-on, and AI styling assistant – to make the future of fashion production data-driven, efficient, and sustainable.

When fit stops being a barrier, it doesn’t just reduce returns – it becomes your most powerful growth driver.

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Accurate sizing starts before production – not after.
With SizeSense.ai, your brand can produce smarter, waste less, and grow stronger – even in a recession.