Accurate block pattern generation is critical for improving garment fit and production efficiency, particularly in bespoke garment production. This study introduces an innovative method for generating bodice and skirt block patterns through body surface flattening using Computer-Aided Design (CAD) and 3D body scanning technologies. The proposed approach minimises distortion by flattening body curves and incorporates subdividing lines to define curved body regions. These lines align with contour guidelines established in Helen Joseph Armstrong’s (2014) study on pattern drafting, applying dart manipulation techniques for improved accuracy. A quantitative comparison was conducted to assess pattern measurement proximity between two flat block methods: traditional draping and the proposed body surface flattening technique. Eight primary circumferential body measurements were collected and analysed. Results revealed that the Draped Block Pattern consistently produced larger measurements across all parameters compared to the Flatted Block Pattern. The mid-thigh exhibited the most significant discrepancy (12.97%), while the Hip demonstrated the smallest variation (0.16%). These results highlight the effectiveness of the proposed method in achieving measurements closer to the body surface.