The process of bra design in the underwear industry is studied. Several important aspects of the process were identified: sizing, fabric selection, pattern development and grading, the use of CAD system, fitting and wear trials. Although the design process relies heavily on the expertise and experience of designers, the modern technology such as CAD can facilitate and optimize the design process, and the fitting process on life models is essential for the underwear design. The differences between domestic underwear companies and foreign major ones mainly lie at the lack of dress form specially used for underwear design, lack of CAD/CAM or not making full use of them, and most of all, lack of the professional bra designers or even skillful pattern designers. The prospects and future model of bra design process were also elaborated in this paper.