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It would be nice if there was a way for customers to leave comments while ordering a product, that would (at least temporarily) solve part of the configurable product problem by letting them specify size, color, specs by typing it in (instead of the magento running shop owner having to do hundreds of variations of 1 product)
I have been thinking quite a bit for a solution on this. One idea I had was to have a text box that the customer could fill with whatever they want. Then have a link that shows all available options in a hidden layer or something, clicking on one of the options (specifically for colors) would autofill the textbox with that colors name and SKU or whatever.
I definitely think we need something like this. Anytime you have more than one option for a configurable product the simple products start getting out of hand.