Blank apparel sizing and fit: how to size a group order

Sizing a bulk order comes down to two calls: which cut each person wears, and how many of each size to buy. This guide covers how unisex, women's, youth, relaxed and oversized cuts differ, which size runs common blanks offer, and how to split a mixed group. When you're unsure of a size, order samples first.

The shortlist

These cover the main cuts and size runs, and several come in matching unisex, women's and youth versions.

• Gildan 5000 Heavy Cotton T-Shirt: unisex, classic fit, 5.3 oz, S to 5XL. Best for one style across a mixed adult group.
• Gildan 5000L Women's Heavy Cotton T-Shirt: semi-fitted with cap sleeves and side seams, S to 3XL. Best for a women's cut that matches a 5000 order.
• Gildan 5000B Youth Heavy Cotton T-Shirt: classic fit, youth XS to XL. Best for putting kids in the same shirt as the adults.
• Tultex 202 Fine Jersey T-Shirt: unisex, pre-shrunk ringspun cotton (heathers are blends), XS to 5XL. Best for a pre-shrunk tee across a wide adult run.
• Tultex 235 Youth Fine Jersey T-Shirt: pre-shrunk ringspun cotton (heathers are blends), youth XS to XL. Best for the youth match to the 202.
• Tultex 602W Women's Combed Cotton T-Shirt: retail fit, 4.2 oz combed ringspun cotton, S to 2XL. Best for a lighter, closer-fitting women's tee.
• Next Level 3600 Unisex Cotton Tee: regular fit, 4.3 oz combed ringspun cotton, XS to 6XL. Best for groups that need the biggest sizes.
• Next Level 7200 Heavyweight Tee: oversized fit with a dropped shoulder, 6.8 oz cotton, XS to 3XL. Best for a loose streetwear look.
• Comfort Colors 1717 Garment-Dyed Heavyweight T-Shirt: relaxed fit, 6.1 oz ringspun cotton, garment-dyed, S to 4XL. Best for a roomy retail tee.
• Rabbit Skins 3321 Toddler Fine Jersey Tee: toddler sizes 2T, 3T, 4T, 5/6 and 7. Best for the littlest kids on a family or school order.

Which cut does each person need?

Cut is the shape of the shirt, and it's a separate choice from size.

Unisex is the default for teams, staff and events, because one style covers the whole group. Brands use their own fit words. Gildan calls the 5000 a classic fit, and Next Level calls the 3600 a regular fit.

Women's cuts are shaped closer to the body. The Gildan 5000L is semi-fitted with cap sleeves, and the Tultex 602W is a retail fit. A women's cut is sized on its own, so a unisex size doesn't carry over. A sample in the size someone expects settles it. For more women's styles, see the women's-cut blanks guide.

Youth sizes are a separate system, so don't map them to adult sizes in your head. Toddler sizes are separate again, and the Rabbit Skins 3321 runs 2T through 7. For baby sizes, see the infant and baby buyer's guide.

Relaxed and oversized cuts are meant to wear loose. Comfort Colors calls the 1717 a relaxed fit. Next Level calls the 7200 an oversized fit with a dropped shoulder, so the shoulder seam sits down the arm. A sample laid next to a shirt the wearer already likes loose shows which size gives the look. The streetwear and oversized guide covers more boxy cuts.

Does the size run cover everyone?

Check where each run starts and stops before you quote a group:

• Up to 6XL: Next Level 3600
• Up to 5XL: Tultex 202 (from XS) and Gildan 5000 (from S)
• Up to 4XL: Comfort Colors 1717
• Up to 3XL: Next Level 7200 and Gildan 5000L
• Up to 2XL: Tultex 602W
• Youth XS to XL: Gildan 5000B and Tultex 235

If your group needs 4XL and a style stops at 3XL, some people are left out. Check the price for each size on the product page too, since larger sizes can price differently.

How do you size a mixed group?

Collect real sizes from each person on the sign-up form.

A common approach is to add a few spares in the middle sizes for people who join late.

Keep a mixed group in one family where you can. The Gildan 5000, 5000L and 5000B let adults, women and kids wear a matching shirt. The Tultex 202 and 235 match adults and kids. Check that your color is offered in each style before you promise a match.

Will it shrink after the first wash?

Cotton that isn't pre-shrunk can move in the first wash. Before you lock the size breakdown, wash and dry one sample the way the wearer will, then measure it.

The Tultex 202 and 235 are pre-shrunk, so they're the picks when the fit needs to stay put. The Comfort Colors 1717 is garment-dyed, which Comfort Colors says gives minimal shrinkage. The sample wash above still applies.

How do you check a size before the full order?

Order one sample in each size you're unsure of, or a full size run for a big order. Sizing differs by brand and cut, so lay each sample flat next to a shirt the wearer already likes and compare length and width. Then pick the size that matches.

Which blank fits a mixed group best?

For a group that spans adults and kids, our pick is the Tultex 202 with the Tultex 235 for youth. Both are pre-shrunk ringspun cotton in the solid colors, and the 202 runs XS to 5XL, so one family covers nearly everyone. Here's where the rest fit:

• Adult, women's and youth in one look: Gildan 5000, 5000L and 5000B
• Big-and-tall sizes: Next Level 3600
• Loose streetwear fit: Next Level 7200
• Relaxed retail tee: Comfort Colors 1717
• Toddlers: Rabbit Skins 3321

For everyday tees compared on fabric, see the core t-shirts guide.