Studies have confirmed that many women, particularly larger busted women, experience breast discomfort while exercising, causing some to avoid exercise all together. The purpose of this study was to use a systematic design process that incorporated conducting several research studies as input to the development of a prototype sports bra for large-busted women. The resulting prototype sports bra, developed by draping and flat pattern, was designed to resolve specific comfort, support, and aesthetic issues reported by large-busted women. Fabric choices, design modifications, and fabric layering were used to accommodate these specific issues. A performance evaluation wear study of the prototype bra and two other sports bras was completed in July 2002.