How many of each size? A size-run guide for bulk apparel orders

The hardest part of a bulk apparel order usually isn’t choosing the garment or the decoration — it’s the size breakdown. You have to commit to an exact count for every size before a single person has tried one on. Order too many smalls and you’re left with a box nobody wants; order too few larges and half your team is wearing something too tight. This guide is the math and the judgment calls we walk organizers through every week.

The short version: collect real sizes when you can, and fall back to a proven size curve when you can’t. Below is the curve we start from, why it’s shaped the way it is, and the adjustments that matter for your specific crowd.

The standard size curve

When you have no other information, the most widely used adult unisex split across the custom-apparel industry is roughly 10% Small, 25% Medium, 35% Large, 20% XL, 10% 2XL. Industry guides converge on this shape because it tracks the typical North American adult body distribution, and several decorators report it covers the majority of general-public groups reasonably well. Treat the percentages below as an illustrative starting point, not a guarantee — your group will vary.

Adjust the curve for your crowd

The standard curve is an average. The fastest way to waste shirts is to apply it to a group it doesn’t describe. A few adjustments we make depending on who’s wearing the gear:

Athletic teams and run crews

Sports and fitness groups skew larger and more uniform than the general public — a common rule of thumb among decorators is a 1–3–5–3 split across S/M/L/XL, weighting the middle heavily. Hockey, rugby, and football rosters push further into XL and 2XL. Cheer, dance, and youth-adjacent teams pull the other way, toward S and M.

Women’s and fitted cuts

If you’re ordering a women’s or fitted style, the whole curve shifts down roughly one size versus the unisex chart, and you’ll want more S and M. Many organizers order a split run — unisex tees plus a smaller block of women’s-cut tees — rather than forcing one cut on everyone. Decide this early; it changes your per-size counts.

Youth and family events

Charity walks, school events, and community days need a youth block (YS–YL) on top of the adult curve. We usually suggest starting youth at 15–20% of total volume for an all-ages event and adjusting from the first year’s actuals.

Corporate and trade-event giveaways

Booth giveaways and swag handed to strangers can’t be collected size-by-size, so the standard curve is your best tool — but add a little extra L and XL. People self-select a roomier fit on free apparel, and an unworn shirt that’s too small is a wasted impression.

Better than any curve: collect real sizes

Every percentage above is a fallback. If you can get actual sizes from the people who’ll wear the shirt, do it — it’s the difference between a 5% mis-order and a 25% one. Practical ways we’ve seen organizers do this well:

• Put size as a required field on the signup, registration, or RSVP form — not an optional one.
• Share the garment’s measurement chart (chest width and body length), not just letter sizes. “Large” means different things across brands, and a flat-measurement chart removes the guesswork.
• Order one physical sample set early so a few people can try the actual blank before the group commits.
• Close the size count a week before you need to go to production, then add a small buffer (see below) rather than chasing late responses.

The pre-order sizing checklist

Run through this before you submit final quantities:

• Cut confirmed — unisex, women’s, youth, or a mix? This decides everything downstream.
• Real sizes collected where possible; standard curve applied only to the unknown remainder.
• Crowd adjustment applied — athletic, women’s-heavy, youth, or giveaway.
• Extended sizes checked — confirm 2XL/3XL pricing and availability for your blank; larger sizes often carry a small upcharge.
• Buffer added — 5–10% over headcount, weighted toward L and XL.
• Minimums met per size if your decoration method has a per-size minimum.
• Reorder window understood — know the lead time before you cut it close.

When you’re still not sure

If you genuinely can’t collect sizes and your group doesn’t fit a clean profile, send us your headcount, who’s wearing the gear, and the garment you’re leaning toward. We’ll suggest a size run based on what comparable Montreal orders have actually needed, flag any sizes that carry an upcharge on that blank, and quote it. You can browse blanks first in our catalog, or skip straight to a quote and we’ll handle the breakdown with you.