Ordering custom apparel for a group sounds straightforward until you realize your team spans a wide range of sizes, preferences, and body types. Suddenly the order gets more complicated — and the stakes are higher, because nobody wants to end up with a shirt they won’t wear.
Planning a size run thoughtfully from the start saves time, avoids waste, and makes sure everyone ends up with something that actually fits.
Start With a Simple Size Survey
Before you place any order, collect sizing information directly from your team. A short form — even a shared spreadsheet — works well. Ask for preferred size and, if you’re ordering both unisex and fitted cuts, which style each person prefers.
Guessing sizes leads to leftovers in sizes nobody needs and shortages in the ones everyone wants. A quick survey takes a few minutes and pays off immediately.
Understand Unisex vs. Gender-Specific Cuts
Most custom apparel comes in a unisex cut and a fitted or women’s cut. These are not interchangeable — they differ in shoulder width, torso taper, and sleeve length. Some people strongly prefer one over the other.
If your team is mixed, consider offering both options in the same color and design. Most decorators can run both styles in the same order, though minimum quantities may apply to each style separately.
Know the Garment’s Size Range Before You Commit
Not every style runs the same range. Some garments top out at 2XL; others go to 5XL. If your team includes people who wear larger sizes, confirm availability before you fall in love with a specific style.
It’s also worth checking whether extended sizes are available in the same colors as the standard range. Occasionally, a colorway is discontinued at larger sizes, which can create inconsistency across your order.
Plan Your Quantities by Size Thoughtfully
A common mistake is ordering equal quantities across all sizes. In reality, most groups skew toward medium, large, and XL. A rough starting point for many teams:
- S and XS: smaller quantities unless your data says otherwise
- M, L, XL: the bulk of most orders
- 2XL and above: a few extras, based on your survey results
Your survey results should override any general guidance here. Every team is different.
Build In a Small Buffer for Common Sizes
New hires, unexpected guests, and damaged items are all reasons to order a few extras beyond what your headcount requires. Ordering an extra two or three pieces in your most common sizes is almost always cheaper than placing a second small order later.
If you’re ordering for an event, extras also help when someone’s size isn’t quite right and a swap is needed on the spot.
Ask Your Decorator What Minimums Apply Per Size
Some decorators require a minimum quantity per style or per size run — not just per order. This matters if you’re ordering only two or three pieces in a less common size. Knowing this upfront helps you decide whether to adjust quantities or choose a garment with more flexibility.
A good decorator will walk you through this before production starts rather than surprise you with it later.
Final Thoughts
Getting the sizing right on a team apparel order is mostly about preparation. A brief survey, a conversation with your decorator about cut options and minimums, and a realistic quantity breakdown by size will get you most of the way there.
The goal is simple: every person on your team ends up with something that fits well enough to actually wear — which is the only way branded apparel does its job.
