Every shirt order has the same two ways to go wrong. You end up with a box of smalls nobody can wear, or you’re three XLs short the morning of the 5K. Both come from the same mistake, which is guessing the sizes instead of planning them.
So how many, and in what sizes? Start with a headcount. Then ask people what they wear, as many as you can reach. The ones you can’t ask, you estimate with a size chart. Toss in a few extras and you’re done. A 12-person office is easy. A 150-kid league takes a form. A walk-up crowd at a charity run? That one’s mostly educated guessing.
Two real-world size curves, side by side
When you have to guess, a size curve is the starting point. But even printers don’t agree on one. Here’s what two of them report from their own customer orders.
Branded Shirts to Promote Your Business
| Size | Real Thread (US) | Clothes2Order (UK) |
| Small | About 20% | 10% |
| Medium | About 28% | 28% |
| Large | About 27% | 32% |
| XL | About 16% | 19% |
| 2XL | About 5% | 8% |
| 3XL and up | Not listed | 3% |
Medium and large lead in both. After that, they split. That difference is exactly why a generic chart should be your last resort, not your first.
How do you plan sizes for staff shirts?
Ask. It’s the easiest group to plan because you know every person on the list.
Send a quick form or pass around a sheet with name, size and fit. Collect it before you order, not after. And if someone isn’t sure, have a sample in each size on hand to try on. A shirt that’s a size too small sits in a drawer, and a uniform nobody wears does nothing for your brand. We go into why that matters in The Importance of Work Uniforms.
Plan for turnover, too. A couple of extras in your most common sizes means the new hire next month isn’t waiting on a reorder.
How do you plan for a team or league?
Get sizes from parents or players at registration. Put it right on the sign-up form.
Kids are the tricky part, since they can grow between registration and opening day. If a player is between sizes, size up. Real Thread also points out that teams can skew one way or the other, a wrestling team might run larger, a cheer squad smaller, so don’t plug a whole roster into a generic curve.
And count the coaches and volunteers. They need shirts too.
What if you don’t know anyone’s size?
That’s the event problem. A fundraiser walk, a festival, a company picnic with plus-ones.
This is where a size curve earns its keep. Start with the table above and adjust for your crowd. A youth sports fundraiser needs more youth sizes and smalls. An adult crowd may need more XL and 2XL. If you ran a similar event last year, last year’s leftovers are your best data. Whatever was left in the box, order less of it.
There’s another option worth knowing about. Our Custom Design Studio lets people order online, with drop shipping or local pickup. Instead of guessing for everyone, each person picks their own size.
How many extra shirts should you order?
Some. Not a lot.
There’s no official number here, but a small cushion in your two most common sizes covers the late sign-up and the person who changes their mind. Real Thread makes a practical point too. Sometimes adding two shirts pushes your order into the next price tier, and the bigger order costs less in total. Ask about that when you get a quote.
Leftovers aren’t wasted, either. They become new-hire shirts, prizes or giveaways at the next event.
Does the decoration method change how many you should order?
It changes the cost math.
With screen printing, price depends on the number of colors in your design and the quantity. More shirts usually means a better price per piece. Embroidery is priced by stitch count, design size and quantity, and we have no minimum. An embroidery order can be as small as one piece. That makes embroidery handy for small staff runs and one-off replacements. If you’re weighing the two, read Embroidered vs Screen Printed Logos On Business Shirts.
Reorders are easier than first orders. There’s a one-time setup fee for your logo, and once we have it on file, there are no more setup fees.
When should you place the order?
Pick the day the shirts have to be in people’s hands, then count back from there.
Once you approve the art, we usually need about a week. But the clock doesn’t start at your first email. Before we print anything, you get a computer mockup to look over, and if you want the logo bigger or the color changed, that’s another round. So get your sizes in first. Sign off on the proof second. Leave yourself a few spare days on top. Running late anyway? Ask about rush service.
Frequently asked questions
What size do most people wear in a branded t-shirt order?
Medium and large are the most common in printer data, followed by XL and small. Exact splits vary by crowd.
How do I order shirts when I don’t know everyone’s size?
Start with a standard size curve, adjust for your audience, and use past events as your guide.
Is there a minimum order for embroidered shirts?
Not with us. Embroidery orders can be as small as one piece.
Do I pay setup fees again when I reorder?
No. After the one-time logo setup, there are no more setup fees once your logo is on file.
Planning shirts for your staff, team, or next event? Coby Graphics is family-owned at 65 Wilson Ave. in Manalapan. Call 732-446-4448 for a free estimate, see our Screen Printing and Custom Embroidery services, read Custom Printed T-Shirts in Manalapan, NJ: Apparel for Business and Events, or contact us.