Apparel · 5 min read
How to collect sizes for a team apparel order
Guessing sizes is the fastest way to waste a merch budget. Here's a simple system for getting an accurate size breakdown across your team — without the endless back-and-forth.
You've picked the garment, nailed the artwork, and approved the mockup. Then comes the part that quietly makes or breaks the whole order: getting sizes right. A shirt that doesn't fit never gets worn — and a pile of unworn custom t-shirts wastes the whole gesture, no matter how good they look on the rack. The good news is that collecting accurate sizes is mostly a matter of having a system instead of a group chat.
Why guessing fails
The temptation is always there: order a stack of mediums, a handful of larges, and call it done. It almost never works. Real teams skew in directions you can't predict from a headcount — fit preferences vary, body types vary, and what someone wears day to day is personal. Order on a guess and you end up with sizes nobody claims and people quietly left out. Since you can mix sizes in a single run at no extra cost, there's no reason to gamble. The only thing standing between you and a clean breakdown is asking.
Decide unisex vs fitted first
Before you collect a single response, settle one question: are you running a single unisex cut, or offering men's and women's fits? A single unisex run keeps the ask simple — one size scale, one chart, fewer columns to track. Offering separate cuts is more inclusive and tends to get worn more, at the cost of a slightly more detailed survey. Either way, plan to offer the full XS–2XL range so nobody has to size out of the order. Mixing those sizes in one run costs you nothing extra, so the only real decision here is unisex versus fitted — not which sizes to leave off.
Collect sizes in one place
The single biggest upgrade you can make is to stop collecting sizes in conversation and start collecting them in a form. A simple Google Form or a shared spreadsheet with two columns — name and size — beats a hundred Slack replies every time. Better yet, fold the size question into something people already fill out: the onboarding paperwork for new hires, or the RSVP for an event. Our onboarding kits work well precisely because the size lands during day-one paperwork, when people are already answering questions about themselves. Always ask for the name alongside the size — it lets you chase down the handful who haven't replied without re-surveying everyone.
Tips for accurate counts
- Share a size chart. Sizing varies between garments, so link the chart for the exact piece you're ordering. People who can check measurements pick far more accurately than people guessing from memory.
- Set a clear deadline. An open form sits ignored; a deadline gets answers. Give it a week and send one reminder a day or two before it closes.
- Add a small buffer. Order a few extra in the most common sizes — typically medium and large — to cover new arrivals, replacements, and the occasional spare.
- Account for no-responses. Someone always misses the form. For the holdouts, default them to a common size rather than dropping them, and lean on that buffer.
Hand us the breakdown
Once you have your counts, you don't need a polished spreadsheet to get started — a rough split is plenty. Tell us something like “ten smalls, twenty mediums, fifteen larges, five XL,” and we'll plan the run around it. Because mixing sizes from XS through 2XL in a single order costs nothing extra, your breakdown can be as varied as your team actually is. Most orders start around a 25–50 piece minimum, we turn a free mockup around in roughly 24 hours, and production runs about two weeks once artwork is approved — so a little lead time on the size survey keeps the whole timeline comfortable. Still settling on the garment? Our guide to choosing the right blank is the natural next step.
Get the system right and sizing stops being the stressful part of a merch order. Collect once, in one place, with a deadline and a chart — then hand us the numbers. When you're ready, send us your breakdown for a free quote and we'll plan the run, mock it up, and get your team into apparel that actually fits. Questions on minimums or timelines? Our FAQ covers the details, or call us at (737) 253-8727.
