The Complete Guide to Custom Shirt Sizing

The complete guide to custom shirt sizing. Getting the right shirt size is about more than just picking “small” or “large.” The right fit comes from understanding sizing charts, body measurements, shirt cuts (unisex, women’s, youth, tall), and the type of material used. At Shirt.Co, we help you match your order to real-world wearers so every shirt feels great and gets worn again and again.

Why Shirt Sizing Matters

Nothing undermines a great shirt design like a poor fit. Whether you’re outfitting a team, stocking a store, or creating event merchandise, getting the sizing right ensures:

• Comfort drives repeat wear. No one wants a shirt that feels too tight or boxy.
• Professionalism. Whether for a company, team, or fundraiser, the right size reflects attention to detail.
• Event impact. Ill-fitting shirts end up in the bottom of drawers — not proudly worn, which reduces brand visibility.
• Cost savings. Avoid wasting money on extras or reorders by ordering the right size mix the first time.

Here are the steps to follow to get the most out of custom shirt sizing:

Step 1: Understand Standard Shirt Fits

There isn’t one universal sizing method. Here’s what you’ll typically see in the custom shirt world:

• Unisex / Standard Fit — The most common, works for most body types, but may feel boxy on some.
• Women’s Fit — Tapered cut, shorter sleeves, and often shorter torso length. Runs smaller than unisex.
• Youth Sizes — Scaled-down versions for kids, typically XS-XL in youth.
• Tall Sizes — Longer torso and sleeve length for individuals over 6’.

Pro Tip: Always order a mix. For most bulk orders, mediums and larges make up the majority of requests.

Step 2: Use Sizing Charts the Right Way

Each brand essentially has its own sizing standards. At Shirt.Co, we print on popular, trusted brands like Bella+Canvas, Gildan, Next Level, and American Apparel. These manufacturers generally run true to retail sizing — but we will be sure to let you know if there are any major sizing discrepancies.

What to Look for in a Sizing Chart:

• Chest Width (armpit to armpit): Most reliable measure.
• Body Length: Especially important for tall or athletic builds.
• Sleeve Length: Can make a big difference in comfort.

Step 3: Account for Shrinkage & Materials

Shirt.Co uses the best materials and print methods. Still, some shrinkage may occur depending on care:

• 100% Cotton: Can shrink 3-5% after first wash unless pre-shrunk.
• Polyester Blends: Shrink very little and hold shape better.
• Tri-Blends: Softer, drape better, but may run slim.

Pro Tip: Wash cold, tumble dry low to minimize shrinkage.

Step 4: Build a Smart Size Breakdown

When ordering for groups, here’s a proven formula (adjust by audience):

• 10% Small
• 35% Medium
• 35% Large
• 15% XL
• 5% 2XL & above

Pro Tip: For 100 shirts at a community fundraiser, you’d want approximately 10 S, 35 M, 35 L, 15 XL, and 5 XXL.

Step 5: Special Considerations

• Youth Orders: Always size up — kids grow fast, and parents prefer “room to grow.”
• Women’s Cuts: Order one size up compared to standard unisex fits.
• Tall Sizes: Offer at least a handful if your audience includes tall/athletic builds.
• Uniforms / Workwear: Durability and consistent sizing matter more than trend fit.

Quick Summary of Custom Shirt Sizing at Shirt.Co

• Always check brand-specific sizing charts.
• Consider shrinkage based on fabric.
• Order more mediums and larges — they’re the most popular.
• Include women’s, youth, or tall fits for diverse groups.
• When in doubt, size up.

Why Choose Shirt.Co for Your Custom Shirt Sizing?

Sizing is one of the most common challenges in custom apparel, and one of the biggest sources of frustration if it’s not done right. At Shirt.Co, we’ve made sizing clarity and fit accuracy a core part of what we deliver. Here’s why we’re different:

• 1. Wide Range of Fits
  We offer unisex, men’s, women’s, youth, and tall sizes across multiple shirt brands. No matter your audience — event staff, athletic teams, corporate groups, or retail buyers — we’ve got fits that make everyone comfortable.
• 2. Consistent Brand Partnerships
  By working with industry leaders like Bella+Canvas, Gildan, Next Level, adidas, and Comfort Colors, we ensure consistent sizing standards. That means when you reorder, you can trust the fit will stay true.
• 3. Easy-to-Read Sizing Charts
  Our sizing guides break down chest width, body length, and sleeve details in plain numbers. Customers don’t have to guess, they can measure and match for confidence before ordering.
• 4. Expert Guidance
  Not sure whether to size up or down? Our team is here to advise based on the style, cut, and printing method you choose. We’ll walk you through what works best for your audience.
• 5. Options for Special Fits
  From slim cuts and women’s contour fits to youth sizes and extended-length shirts, we go beyond “one-size-fits-all.” You’ll have options that respect body diversity and style preferences.
• 6. Reduced Return Risk
  Clear sizing = fewer returns. We help you minimize wasted inventory and keep your buyers or team happy from the moment they try their shirt on.

FAQ: Common Custom Sizing Questions

Do Shirt.Co shirts run true to size?

Yes, most of our core brands run close to retail sizing. But we always provide size charts prior to your order.

What if I’m between sizes?

We recommend sizing up, slightly loose is better than too tight, especially for event wear.

Can you mix styles in one order?

Sure, you can combine unisex, women’s, youth, and tall fits to match your group.

What’s the best way to handle large groups?

Send out a sizing form ahead of time. If that’s not possible, use the size breakdown formula above.

Call Shirt.Co for Custom Shirt Sizing

Getting sizing right is one of the most important parts of ordering custom shirts — and we make it easy. At Shirt.Co, our team will walk you through sizing charts, breakdown recommendations, and brand-specific fits so your order is spot-on.

Call us today at 636-926-2777 or start a quote online to get started on your next order.