A method and device for assembling diapers of intentionally varied size. The method may comprise providing a series of waist belts having a fixed longitudinal length, and a series of chassis having a fixed longitudinal length. The waist belts may be aligned with the chassis with varying degrees of overlap, such that diapers having different lengths are manufactured by varying only the relative placement of the waist belts and chassis. The method may be used to vary diapers within a production run (e.g., to produce packs of diapers in a range of sizes) or between production runs (e.g., to produce different size diapers on the same line with reduced equipment changes or adjustments). A diaper produced according to the method is also described.
