The Indian Army Combat uniform, then, was being procured from Ordnance Factory Boards in four/five sizes from small to extra large wherein the shirt and trouser were given as separate unit. This created mismatch to the final users in terms of size and colour. To address this problem, the main requirement of this sizing survey was to provide them the combat uniform in a set with shirt and trouser as one unit. DIPAS acquired a state of art facility, 3D Human Body Scanner to carry out 3D anthropometric survey in different phases in different units to study the size rolls of troops of the Indian army by using 3d human body scanner with primary objective of improvement of army combat uniform. Methods: SYMCAD human whole body scanner was utilized to garner the anthropometric scans of 7956 Indian male personnel’s as the anthropometric dimensions of other countries populace cannot be transferred to Indian population for the design and sizing of an any personal protective gear or combat uniform because the population is made up of diffeent ethnic composition. Result: For Indian army combat uniform, thirteen (13) sizes were recommended and implemented by the Indian army. For developing the desired combinations chest girth and navel waist girth were taken up as critical variables. Data analysis was performed by a statistical package, SPSS (20.0v). Bi-variate analysis was done by taking up the critical variables and frequency tables were obtained in the form of cross tabs. It helped in making size classes based on the two critical parameters i.e. chest girth and navel waist girth. The present paper also shows the development of a new sizing software (Defence Size India or DSI), which was based on 7,956 Indian soldiers’ anthropometric data. DSI is designed to maintain the combat uniform details of all the army units at central place. This will reduce human error in making reports and generating demands for uniform. DSI will save many man hours and reports can be generated in a few seconds. Using this DSI, by entering only two major parameters i.e., chest girth and navel girth, all the other seven parameters are calculated and stored in the database automatically, thus efficiently reducing and saving time.