Garment “fitting” from tailor-made to ready-to-wear clothing, has evolved over time. Ready to-wear and standardized sizes appeared in the middle 19th century. Today garment fitting is one of the most important criteria in the consumer buying decision making process. This is particularly so with “body hugging” garments, such as intimate apparel; or the bra that moulds the form of the wearer to produce “smooth” outer garment silhouettes. The South African bra retailer and manufacturers sizing charts are generally based upon body dimension data collected using traditional anthropometric methods. Professional measurers are not able to capture the hidden areas of the breast such as the inframmatory fold line, the volume, shape and contour of the breast using tape measures, calipers and other measuring devices. Traditional anthropometry also does not have the ability to systemically observe the bottom line of the breast base and extract accurate data on breast volume which are key factors in designing underwire bras and in the pattern making of the bra cup panels. Exploratory retail and consumer studies have indicated that consumers, notably plus size women, experience considerable problems and dissatisfaction with poorly fitting bras. There is therefore clearly a need in South Africa to conduct a 3D anthropometric study, focusing especially on the plus-sized women’s bra market segment, as there is very little or limited studies, to date, conduct for this market segment of the population. This pilot study collected 3D torso body measurement data from a convenient sample of 176 plus sized women, recruited from Playtex (Pty) Ltd. situated in Durban, KwaZulu Natal, South Africa. The study evaluates the 3D breast volume measurement data extraction process, using an expert system developed by [TC]2 integrated into the propriety NX12-3D full body scanner software and that taken using the traditional dress-makers tape-measure. The objective is to establish the relationship between the 3D torso and breast volume data measurement output as extracted by the expert system when compared to the South African bra manufacturers sizing chart, for use in pattern making for bra cup panel designs and in the designing of underwire bras for large breasted or plus size women. The results contained in this dissertation cannot be extrapolated to the larger population of South Africa and is limited to the 176 plus size women selected by Body Mass Index; recruited from KwaZulu Natal, South Africa.