On-demand manufacturing is integral to sustainable practices, but product returns must be avoided to reduce waste and maximize revenue streams. With garment fit being a driving cause of returns, concerted technological engagement has been directed at acquisition of data defining apparel fit. (e.g., radial ease, compression ease, fit preference, body-shape, fit mapping, etc.) Such data has somewhat improved size selection algorithms but shed little insight on quantifying fit at the garment pattern level. For example, while a flattened 3D body mesh effectively reveals the body as 2D geometry, it offers little toward the developable garment pattern as it lacks relevance to established principles of dart manipulation and pattern-making theory. This paper discusses how a 'block comparison' approach to fit assessment better translates body data to linear dimensions suitable for both changing fit at the pattern level and improving fit prediction algorithms. Discussion will elaborate how body-blocks define 3D human morphology at the garment pattern level to establish practice for quantified fit theory while supporting traditional apparel pattern practice. The change management required for fit validation (the digital asset as tech pack) lays the foundation for automated mass customization, not as the once considered singular solution, but as a scope of solutions ranging from ready-to-wear (RTW) to bespoke. Not as the once considered singular solution, but as a scope of solutions ranging from ready-to-wear (RTW), to bespoke. With sustainable garment production being a key factor in mitigating climate change, fit validation to reduce garment returns (increasing the profitability of on-demand manufacturing) is a logical next step. In this environment, both customer and brand fit preference may align or differ without imposing on the other. From here we must consider that perhaps Industry 4.0 is better embraced with a full suite of fit intent offerings, where the change management required for RTW fit validation (digital tech packs) sets the foundation for automated mass customization, not as the once considered singular solution, but as a scope of solutions ranging from ready-to-wear (RTW), to bespoke. In this environment, both customer and brand fit preference may align or differ without imposing on the other.