What is a good size breakdown for 50 shirts?

For a general adult group in the US, a safe split is roughly S 7, M 14, L 14, XL 10, 2XL 5, about 15% S, 27% M, 27% L, 20% XL, and 10% 2XL. Round toward M and L when in doubt; middle sizes always move first.

Should I order extra shirts beyond my headcount?

For events and giveaways, yes: 5-10% extra, weighted toward M and L, covers walk-ups, swaps, and the occasional misprint replacement. For a known team with collected sizes, ordering exact counts plus one or two spares in middle sizes is usually enough.

What if the garment runs oversized?

Fit changes the math. Oversized and drop-shoulder blanks are cut a size or more roomier than a classic fit, so many people size down. Before locking a split, compare the flat garment measurements on the size guide to a shirt people already own rather than assuming letter sizes match.

Can you help us pick a size split?

Yes. Tell us who the order is for (team, event, resale) and any sizes you have collected in the quote form, and we will sanity-check the curve on your written quote before production.

How many of each size to order

July 1, 2026 · 5 min read

A practical size curve for bulk apparel orders: typical S-2XL splits for teams and events, when to collect real sizes instead, and how to avoid leftover boxes.

The problem with guessing

Size splits are where first-time orders quietly go wrong. Guess flat, ten of every size, and you run out of L while a box of XS gathers dust. The fix isn't complicated: either use a proven curve, or collect real sizes when the group is small enough to ask.

The standard curve

For a general adult group in the US, unisex sizing distributes remarkably consistently:

S: 10-15%
M: 25-30%
L: 25-30%
XL: 15-20%
2XL: ~10%
XS and 3XL: a few of each once the run passes ~50 pieces, or on request.

On 50 shirts that lands around S 7, M 14, L 14, XL 10, 2XL 5. M and L always sell out first, so when the math doesn't divide evenly, round toward the middle.

When to bend the curve

Student groups skew smaller: shift a step toward S and M.
Oversized and drop-shoulder blanks are cut a size or more roomier, so many people size down. Check the flat measurements before locking counts.
Mixed-audience events (conferences, launches) are the strongest case for the standard curve plus a 5-10% buffer in M and L.
Resale drops should follow your audience data if you have any; if not, the curve above is the standard starting point.

Under ~30 people? Just ask

For a team, club, or onboarding kit, collecting real sizes beats any curve. A one-question form gets it done, but send the size guide along with it: letter sizes vary between styles, and flat garment measurements compared against a shirt someone already owns is the only reliable check. This matters double for oversized fits, where the style guide explains how each cut runs.

Lock it in on the quote

Size splits are part of every written quote, so you don't have to get this perfect alone: send your headcount or collected sizes with the quote request and we sanity-check the curve before production. Ordering for a club or class? The club merch playbook covers the whole flow from size collection to delivery.

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