Mass customization provides products with high variety on demand, at a cost not significantly greater than mass production. Problem at this point is that these product variants lead to process/resource variants what has a negative impact on complexity of manufacturing complexity of such products. In this paper, we present a methodological framework for creating all possible product variants based on unlimited number of optional components while assuming with at least two constant initial components. Development of all possible product architectures is further applied for investigation the impact of product variety decisions on structural complexity of assembly processes. According to the assembly process variants created a specific complexity measure can then be assigned.