We deal in t-shirts and custom apparel every day, so we're pretty familiar with sizing trends. Here's what 15,000 orders taught us about splitting up a size run — plus a calculator that does the math for you, whether you're ordering for a kindergarten class or a company picnic.

Avoid Guesswork

When it's time to place an order with an array of different sized t-shirts, it's sometimes tempting to say: "let's just do 50 of each size." The problem with that is that you're pretty likely to end up with inventory you don't need or worse: running out of the sizes you actually need.

What Are the Most Common Shirt Sizes Sold?

Below is a chart showing the average distribution of sizes purchased, based on a sample of 15,000 orders collected from around the United States.

You can tell that the majority of the sizes are medium and large. Because shirt sizing can vary by brand, we do recommend the following breakdown that skews a little more toward the XL size. Remember, you can still wear a shirt that's too big but a shirt that's too small usually ends up in the donation pile.

Our Recommended Size Breakdown

That's the split we'd put on a general adult order: a little heavier on L and XL than the raw data, because a shirt that runs big still gets worn and a shirt that runs small ends up in the donation pile.

If you want a version you can do in your head, round it off to a total of 10:

S - M - L - XL - 2XL = 1 - 2 - 3 - 3 - 1

On 1,000 shirts that's 100 (S) - 200 (M) - 300 (L) - 300 (XL) - 100 (2XL) = 1,000 shirts.

It's close enough for a quick gut check, but it is a rounding — it evens out L and XL, and it drops the handful of XS and 3XL you should still order at either end. The chart is the more accurate version, and it's what our calculator uses.

Who Are You Ordering For?

Everything above assumes a room full of adults. The moment you're ordering for a school, the curve moves — sometimes all the way into youth sizes. Here's how we'd start each group:

Elementary (PK–5th)

Almost entirely youth sizes. Pre-K and kindergarten sit at Youth XS and Youth S; by 4th and 5th grade the bulk has moved to Youth L and Youth XL. Order a small handful of Adult S for the tall kids and you're covered.

Middle School (6th–8th)

The hardest group to size, and the one people get wrong most often. Youth XL and Adult S are the bridge sizes — together they're about half the order. Some 8th graders are fully adult-sized, so carry Adult M and a few Adult L.

High School (9th–12th)

Adult sizes throughout, but with more smalls than a general adult order and a real tail at 2XL. Don't under-order the big end — it's the most common miss on a school order.

College

Skews smaller than a general adult order, especially for women-heavy groups. Worth noting: the oversized fit is in, and plenty of people who'd normally wear an S will ask for an L on purpose. If you're printing for a student org, ask before you assume.

Adults

The chart above. Mixed staff, employees, event giveaways, family reunions — L is the single most common size, and M through XL covers about three quarters of the order.

Punch your total into the calculator at the top of this page, pick the group, and it'll split it out for you.

Other Considerations

Keep in mind that shrinkage is a factor as well. If your shirts are all 100% cotton, you may want to encourage sizing up. If your shirts are 50/50 cotton/poly you don't have to worry as much, and if your shirts are 100% polyester, shrinkage isn't a concern.

Another thing to consider is that many "fashion fit" styles run slightly smaller than their standard counterparts. On certain styles from Bella + Canvas and Next Level, for example, the cut may be tapered for a slimmer fit. Check with your sales rep if you are unsure about the cut of the particular shirt you are ordering.

If your order spans youth and adult sizes, the print has to work on both. A design sized for an adult chest will swallow a Youth S, so we'll usually either scale the art down for the youth run or pick one size around 10" wide that sits well on everything. Worth a conversation with your rep before we burn screens.

Finally, think about your audience or demographic. Is it a local barbecue all-you-can-eat contest? You might want to go a bit larger. Is it a yoga retreat? Maybe tend on the smaller side. Is it band merch for fans in their 20's? Go with the fashion fit.

Take all these things into consideration and you will make your customers, employees, family, and fans very happy.