The paper presents the virtual prototyping of protective clothing for oversized female and male subjects, highlighting the importance of personalization and its competitive advantages. Customisation of protective clothing for oversized subjects offered the possibility to individualise the products to each wearer with different conformation and specific work activities. Customized protective clothing involves the dimensional and conformational aspects of the body, respectively the product size as well as the quality-linked functionality criterion, aspects regarding its wearability and protection tested in accredited laboratories, the effects over the individual comfort. The research implementation involved 3D body scanning for analysis and determination of anthropometric measurements and conformation, 3D CAD technology for automatic rapid design of patterns in Made to measure system, modeling and simulation of product in the virtual environment on customized mannequin, highlighting the body-product correspondence. New technologies in the context of Industry 4.0 are the seeds for disruptive innovation in the clothing industry, by increasing the digital capacity and flexibility to satisfy the customer requests and implement more dedicated services.