The paper describes how creative processes were applied to developing a new product range, to enhance performance, streamline production, reduce costs and open up new markets for body armour solutions. It describes how a company with a proven track record in manufacturing, had lost market share during the first Gulf war due to supply chain issues and had found it difficult to regain share, as the market place had shifted in terms of design. The paper details internal and external challenges in bringing creative processes to the company, to enhance personal protection, improve performance and deliver on aesthetics. Social contexts and physiological issues brought additional challenges. From a business operations perspective, valuing and solving design problems had to be cost effective to manufacture using existing technology. The paper outlines how an academic in fashion and textiles used anthropometrics to research and develop creative solutions for soft body armour. The innovative, new products are now used by security forces globally.