Sizing a run: how many of each size to order
The order is approved, the art is perfect, and then someone asks how many larges. Here is the size curve Battle Born Clothing sees on Nevada County school, event and fundraiser orders, how to handle sign-up sheets, and why a few extras are cheaper than a second run.
A starting size curve for adults
| Size | Share | On 48 | On 96 | On 144 |
|---|---|---|---|---|
| S | 10% | 5 | 10 | 14 |
| M | 25% | 12 | 24 | 36 |
| L | 30% | 14 | 29 | 43 |
| XL | 20% | 10 | 19 | 29 |
| 2XL | 10% | 5 | 10 | 14 |
| 3XL | 5% | 2 | 4 | 8 |
This is a starting point, not a rule. A trail-running crowd skews smaller; a trades or booster crowd skews larger. Staff orders should come from a roster, not a curve.
Youth sizes
| Size | Share | On 100 youth |
|---|---|---|
| Youth XS | 15% | 15 |
| Youth S | 30% | 30 |
| Youth M | 30% | 30 |
| Youth L | 20% | 20 |
| Youth XL | 5% | 5 |
Adult and youth shirts with the same art print on the same screens and count together toward the quantity. A separate smaller print for youth XS and S is a second screen set; we tell you on the proof whether the adult print fits. The PC54 and PC54Y come in matching colors.
Sign-ups vs guesses
- For school and team orders, collect sizes with a sign-up sheet and a deadline, then add 5 to 10 percent extra in the middle sizes.
- For public events with registration, ask for size at sign-up and order on the final count plus extras for day-of registrants.
- For merch for sale, use the adult curve and lean toward M, L and XL on reorders once you see what sells.
2XL and up
Suppliers charge more for 2XL, 3XL and larger blanks, and we pass the upcharge through as published: $1 to $7 by size depending on the style. The print price is the same. On the invoice it shows as a separate blank price for those sizes.
Why extras beat a second run
A second run of 12 shirts after the event means new screens ($20 per color) and a short-run per-piece rate that is well above the 48-piece rate. Ordering 52 instead of 48 adds four shirts at the same per-piece price. Extras in M and L always get used.
Women's and fitted cuts
Most events order unisex and are fine. If you want a women's cut, the LPC54 and LPC450 exist in matching colors; they are the same art and screens and count toward the run. Fitted cuts run small; size up one on the curve.
Questions
Can I change sizes after approving the proof?
Before blanks are ordered, yes. After, a change means a blank re-order and may move the date. Finalize sizes with the proof.
Do youth and adult prices differ?
The blank prices differ (youth is quoted per job). The print rate per location is the same and they share one quantity break.
What if a size is out of stock?
We check SanMar Reno first, then the next warehouse. We tell you on the quote if a color or size is thin.