The design and manufacture of individually customised products is generally restricted to bespoke clothing or footwear for very wealthy customers. The aim of the Custom-Fit project was to develop a fast, flexible and economically viable route for the manufacture of individually customised parts. These products not only provide improved comfort levels but also provide better functional performance, including enhanced safety for the user. This 4.5 year, European Commission subsidised ?16 million project, supported by the EU, involving 30 partners across the breadth of the Europe finished in early 2009. This paper will showcase the technology developed: CAD packages which automate the design process and three new rapid manufacturing methods. It will also include case studies on a range of customised products, including customised Motorcycles helmets. The case studies not only demonstrate the performance benefits of individual customisation but also show the potential for new approaches to product design.
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