Not yet. I'm thinking of reinforcing the cups with rigilene and ironing them into a rounded shape. But I'm not sure.

Hey, what is there to lose? Give it a shot. It's not like there's even all that much fabric involved, and you can salvage the wires and strap findings.

Yes very true. I've already been eyeing up the underwires to bras I've almost worn out that will still fit since I've gone down in band size. I've also been keeping an eye on large band average cup sized bras due to the fact that a 50DD shrinks down to approximately my current bra size depending on the brand. The bonus with these is they're usually designed for plus sizes so the straps are wider and usually more comfortable. If all else fails I can just cut up the band and make it smaller without losing the style.

Indeed. If any of those are fitting particularly well, it wouldn't be a bad idea to chop them up for patterns, either.

Hi ceciled,
Sorry for not getting back to you sooner, as usual I have 100 and 1 things on the go.
I have been meaning to cover this subject in an article for ages, as it is a fitting issue that the industry is still falling to address.
Yes, the old usual solution to a bra not sitting on the chest at centre front was to go up a cup size BUT women’s breasts are getting bigger and the shape is changing from a conical to a more rounded spheroid form. The industries main problem is that when they increase the cup size / volume the wire size also goes up, so the cup contains the volume of the breast but the underwire do’s not sit in the breast root to give support. It’s all to do with how they “mechanically” Grade bras.
Believe it or not you were thinking along the right lines when you talked about “The only solution I can see is to make cups that are shaped like torpedoes” it’s not a torpedo shape but a spherical shape cup that has a perimeter equal to a correct breast root fitting underwire, but the spheroid must be “asymmetrically” shaped.
If you would allow me some time as I have two more soft bra articles to finish, I will work up an article to explain how to draft the cup shape and you can be my “guinea-pig” for fitting.
Corset Hugs
Mark.

Thank you for your response Mark. I understand you are busy and I look forward to reading those other soft bra articles. So it seems like this is an increasing problem since women's chests are getting bigger. Especially with plastic surgery where implants are a very unnatural shape.
I've also found that even though I've found my correct size, underwires are very uncomfortable due to the cup increase and I run into the problem of them being too close to my armpit and rubbing. A Demi cup would solve this problem but would not provide the needed coverage to keep things under control.
You almost need an engineering degree for these things lol.