Ordering custom apparel sounds straightforward until you have to figure out sizes. How many smalls? How many extra-large? Do you stock 4XL? The sizing conversation is where most apparel orders go wrong, and it’s worth talking through before you place the order. Here’s what we’ve learned.
Brand-specific sizing
The first thing that surprises people: an “Adult Large” in one apparel brand isn’t the same as an “Adult Large” in another. Some brands run small (especially fashion-forward brands); some run generously (older workwear brands); some run truly to size. Before you commit to a brand for a large order, get sample sizes in your hands. We have samples for the brands we recommend.
The size curve for general audiences
If you’re ordering for a broad general audience without knowing specific sizes (event giveaways, customer apparel, charity walk shirts), the rough distribution most stockists recommend is approximately: 10% Small, 25% Medium, 30% Large, 25% XL, 10% 2XL+. Adjust if your audience skews younger (more S and M) or older (more L and XL).
Team uniforms: collect actual sizes
For staff or team apparel, don’t guess. Send a one-time email asking everyone for their preferred size in the specific brand. Yes, it’s mildly tedious. It saves you from ordering 4 mediums when 7 staff members wanted them and only 1 large nobody needs. We can provide a size chart to share with your team.
Don’t forget plus sizes
Most apparel brands now offer extended sizing up to 4XL or 5XL. If you’re stocking shirts for staff or events, including extended sizes signals inclusion in a way that matters. The per-shirt cost on larger sizes is usually a small upcharge — worth it.
Women’s cut vs unisex
“Unisex” sizing is essentially men’s sizing relabeled. For women’s apparel, an actual women’s-cut polo, t-shirt, or jacket fits and looks dramatically better. If your team includes women or your audience is mixed, offer both cuts. The difference in fit is large.
Youth sizes
For school-related or family-event apparel, youth sizing matters. Kids sizes run different from adult — most run XS-XL with youth size charts.
Reorder leftovers strategically
After the first order, you’ll have leftover shirts in some sizes. Take notes. Your next order should adjust based on what actually moved. After two or three orders, you’ll have a real picture of your specific size distribution.
We help every apparel client think through sizing before they order. Bring us your project and we’ll walk through it together.
Let’s bring your project to life.
Choice1Graphics can help with this — every job we mentioned here, we do in-house at our Webster shop. Have a project in mind? Reach out for a free quote or stop by 505 S Main St, Webster.