At present, the manufacturing of musical instruments still strongly relies on the tacit knowledge of experienced handcrafts while is commonly based on standard machining or casting techniques. This limits the musician-tailoredness to a small group of players, while others take compromises by employing stock parts. The present article describes a new methodology for the design and production of woodwind instruments mouthpieces. By embracing digital modeling and manufacturing, this methodology encompasses four phases, which can be cut short when necessary. The aim of the presented methodology is to link the geometry of the mouthpiece to tone properties. Based on 3D printing, the inside geometry can be altered to complex and reproducible detail to obtain the desired acoustic features - eventually leading to mouthpiece geometries tailored to the player’s sound and playability requirements. The results of aerodynamic investigations together with the subjective experience of saxophone players have been used to design mouthpieces with modified inside geometries of both baffle and chamber. Prototypes have been produced at the Delft University of Technology (TU Delft) using several 3D printing technologies and different materials. Both professional and amateur saxophone players tested these at the Royal Conservatoire of The Hague and at the North Sea Jazz festival (Rotterdam 2012). Based on the judgment of the players, specific geometrical features were revealed to emphasize specific tone characteristics. A number of professional players are actively performing with our mouthpieces. The application and further development of the methodology will lead to a better empirical basis to reason about acoustics and playability, and can be applied to other instruments as well. Future work includes additional measurements and developing a parameterized datdatabase of 3D models