Sizing a run: how many of each size to order
Nobody has a size list when they order event shirts, and crew rosters change. Here is the split Battle Born Clothing suggests when you do not have real counts, and what to do when you do.
The default adult split
| Size | Share | Per 48 |
|---|---|---|
| S | 8% | 4 |
| M | 23% | 11 |
| L | 31% | 15 |
| XL | 23% | 11 |
| 2XL | 10% | 5 |
| 3XL | 4% | 2 |
This is a general starting point, not a survey. Crews skew larger (more L, XL and 2XL); running events skew smaller (more S and M); mixed public events are close to the table. Adjust and send us the list.
Youth sizes
Youth XS-XL on the PC54Y matches adult PC54 colors. For schools and leagues a common split is YS 20%, YM 35%, YL 30%, YXL 15%. Youth and adult shirts with the same art count together toward the 48-piece rate.
2XL and up
Blanks in 2XL and larger carry the supplier's size upcharge, usually $1 to a few dollars per shirt depending on the style. The print rate does not change. We list the upcharge on the quote so there is no surprise.
Why 10% extra is cheaper
| Option | Math | Total |
|---|---|---|
| Order exactly 48 | 48 x $10.38 + $20 | $518.24 |
| Order 53 (10% extra) | 48 at $10.38 + 5 quoted per job (+ ~$52) + $20 | about $570 |
| Order 48, then 5 more later | $518.24 + 5 quoted per job + $20 new screen | more, and 28 more days |
The second run costs a new screen, a new setup and another turnaround. Five extra shirts in the first run cost about the per-shirt price. Order the buffer.
Fit differences between shirts
- PC61, PC54, PC55: classic, roomy. Most people take their usual size.
- Gildan 64000, Next Level 3600: slim retail fit. Size up for a crew.
- Comfort Colors 1717: relaxed and boxy; runs big.
- Hoodies: order the usual tee size; the PC78H and 18500 are roomy.
What to send
- Artwork (vector preferred: AI, EPS, PDF, SVG; a 300 dpi PNG is fine)
- Quantity and a size breakdown (S-XL, 2XL and up carry the supplier upcharge)
- Shirt style and color, or tell us the budget and we will suggest one
- Print locations and ink colors per location
- Need-by date. Standard is 28 days from proof approval; rush is quoted per job
Questions
Can we change sizes after the proof?
Sizes can change until blanks are ordered, usually within a day or two of approval. Art cannot change without a new proof.
Do you keep leftover blanks?
No. Every blank is ordered for your job. Extras you order are yours.