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This seems like something you could throw a Kinect at. Get a few images at the right angles, build a crude 3D model, and measure that in software instead of wasting resources shipping shirts around. It wouldn't account for preference, but surely it's as accurate as someone guessing at their own adjustments.

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Thanks pwf, we have been considering this avenue. Especially to help with the first step of size selection optimization, but through a variety of tests and interviews we conducted, there was something about people actually touching fabric and trying on the garments that could not be replaced with digital images and 3D modeling. But, we will certainly be giving more thought and research into this area!

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