http://ijaers.com/ Open Access international Journal to publish research paper en-us With millions of tons of materials discarded annually during production, the fashion sector is one of the largest contributors to textile waste worldwide. Zero-waste fashion design (ZWFD) aims to eliminate waste at every stage of clothing production. This study explores ZWFD concepts and methods, focusing on reducing material waste during production. The research examines design approaches including zero-waste patterns, fabric optimization, and upcycled materials. It also analyzes technical breakthroughs such as digital pattern-making and automated production. Using a mixed-methods approach (consumer survey, n=280; designer interviews, n=15; expert interviews, n=10; case studies, n=5), this study assesses environmental, economic, and social dimensions of ZWFD. Results show that while consumer awareness of ZWFD is moderate (57.9%), willingness to pay a premium remains low (27.9%). High prices (70.7%) and limited design variety (40%) are the primary adoption barriers. Scenario-based environmental indicators suggest ZWFD could reduce textile waste by 66.7% and carbon emissions by 37.5% compared to conventional production. The study contributes to sustainable fashion literature by providing empirical data on consumer perceptions alongside technical environmental estimates. http://ijaers.com/detail/zero-waste-fashion-design-minimizing-material-waste-in-the-production-process/ Md Kowsar Alam Sarker, Liu Lixian, Md Yousof Talukdar http://ijaers.com/uploads/issue_files/1IJAERS-04202612-Zero-Waste.pdf