First Apparel Run Sizing: The Size Ladder
Most first-time founders guess at sizing or copy a random distribution they found online. Here is the math that holds across hundreds of launches, with real unit counts for 50 and 100-unit runs.
Why Sizing Decisions Happen Before You Order Blanks
Ordering blanks in the wrong size distribution is one of the most common and avoidable first-drop mistakes. Over-buy smalls and you sit on inventory that does not move. Over-buy larges on a women's-targeted launch and you run out of mediums on day one. Both problems are fixable on a second run, but your first run teaches you the most. Give yourself the best chance by starting with a distribution based on real sales data rather than a guess.
The Standard Size Ladder
For a general unisex tee launch targeting an adult US audience, this distribution holds up consistently across brand types and price points. It skews toward medium and large because those are the two sizes that tend to sell first and leave you short if you underestimate.
- Small: 15%
- Medium: 25%
- Large: 30%
- XL: 20%
- 2XL: 10%
Real Numbers for a 50-Unit Run
Applying the standard ladder to 50 units gives you the following. Round to whole numbers and adjust by one unit on the edges (Small and 2XL) based on what you know about your specific audience.
- Small: 8 units
- Medium: 12 units
- Large: 15 units
- XL: 10 units
- 2XL: 5 units
- Total: 50 units
Real Numbers for a 100-Unit Run
At 100 units the math is clean and the rounding is easy. This is a solid starting point for a first general-audience launch.
- Small: 15 units
- Medium: 25 units
- Large: 30 units
- XL: 20 units
- 2XL: 10 units
- Total: 100 units
When to Adjust the Ladder
The standard ladder is a starting point, not a rule. There are situations where you should adjust before placing your blank order.
If your audience skews female, shift toward Small and Medium and reduce 2XL. A women's launch might run S 20%, M 30%, L 30%, XL 15%, 2XL 5%. If your audience skews male and older, bump Large and XL and trim Small. If you are launching a fitted style where customers tend to size up, add units to the next size above where you would normally stop. And if you have any pre-launch data (poll results, waitlist responses, DMs from your audience), let that override the standard ladder. Real signal beats averages every time.