<p>This study introduces a novel approach for producing zero-waste dress shirts (ZWSs) through size development by proposing a method that transforms a base pattern into a rectangle, effectively reducing fabric waste while maintaining garment functionality. To minimize fabric waste, we developed ZWSs by marking a graded conventional shirt pattern within a rectangle that has a large seam allowance. Moreover, we proposed a sewing method for handling the large seam allowance. The produced ZWSs were evaluated against conventional shirts for appearance, comfort, satisfaction, and purchase intention. In addition, we investigated the difference between consumer evaluations before and after explaining zero-waste fashion design. Although the ZWSs were slightly more wrinkled than the conventional shirts, their overall appearance was comparable. At the same time, the method successfully achieved zero waste. In terms of comfort, ZWSs required more ease allowance around curved areas like the neck and armholes owing to the stiffness of the seam allowance. This could be addressed using thin fabric. Although the ZWSs initially scored lower in comfort and satisfaction, their overall satisfaction and purchase intention improved when participants were informed about their zero-waste design. This highlights the importance of consumer awareness of sustainable practices in increasing the acceptance and appeal of zero-waste fashion design.</p>