Order your roster count plus 10 to 15 percent extra in the most popular sizes. That covers last-minute additions, sizing mistakes, and replacements. A team of 15 needs 17 to 18 shirts. A league of 100 needs 110 to 115. The extras save you from rush reorders that cost double.
Size Distribution by Group Type
| Group Type | YXS-YS | YM-YL | YXL | Adult S | Adult M | Adult L | Adult XL+ |
|---|---|---|---|---|---|---|---|
| Youth Team (ages 6-10) | 40% | 50% | 10% | 0% | 0% | 0% | 0% |
| Youth Team (ages 10-14) | 5% | 35% | 30% | 20% | 10% | 0% | 0% |
| School Event (K-5) | 30% | 50% | 15% | 5% | 0% | 0% | 0% |
| School Event (6-12) | 0% | 10% | 20% | 25% | 25% | 15% | 5% |
| Mixed Age Group | 10% | 15% | 10% | 15% | 25% | 15% | 10% |
| Adult Team/Company | 0% | 0% | 0% | 10% | 30% | 30% | 30% |
These percentages come from hundreds of team orders we have processed across Gildan, Bella+Canvas, Comfort Colors, Next Level, and Hanes. They are starting points. Adjust based on what you know about your specific group.
How Many Extras to Order
The rule of thumb is 10 to 15 percent extra, distributed across the most common sizes for your group. Do not order extras evenly across all sizes. Put the extras where the demand is.
For a youth team of 12 in the 8-10 age range: order 2 extra youth medium and 1 extra youth large. Those are the sizes most likely to be wrong or needed for late additions. For what sizes fit which ages, see our 8 year old sizing guide and 10 year old sizing guide.
For a school event of 200 students: order 20 to 30 extras weighted toward adult small and adult medium for a high school, or youth medium and youth large for an elementary school.
For a company event of 50 adults: order 5 to 8 extras in adult medium and adult large. Those two sizes cover the peak of the bell curve for American adults.
The Sizing Collection Method
The number of shirts you order is only as good as the sizes you collect. There are three methods, ranked from most accurate to least:
Method 1: Try-on session. Bring sample shirts in every size to a practice, meeting, or event. Have each person try on the right size and record it. This is the gold standard. Accuracy rate: 95%+.
Method 2: Measurement form. Send a form asking for name, chest measurement (in inches), and preferred fit. Assign sizes based on measurements. Accuracy rate: 85%.
Method 3: Self-reported sizes. Ask each person what size they want. This is the most common method and the least accurate. People are wrong about their own size about 30% of the time. Accuracy rate: 70%.
If you are using method 3 because you do not have time for a try-on session, add more extras to your order. You will need them.
Minimum Order Quantities
Most custom shirt printers have minimum order quantities. For screen printing, the standard minimum is 24 pieces. For DTG (direct to garment), there is often no minimum, but the per-shirt cost is higher.
If your team has 15 people and the printer's minimum is 24, use the extra 9 shirts as giveaways, spares, or coach shirts. Do not cut your order below the minimum to save money. The per-shirt price drops significantly at the minimum threshold.
The Youth-to-Adult Crossover
For teams in the 12 to 14 age range, the biggest ordering challenge is the youth-to-adult transition. Some kids need youth XL while others have jumped to adult small. Our Youth XL vs Adult Small guide covers exactly where that crossover happens. For the exact measurements at each youth size, see our Youth XL Size Chart. For a deep dive into what youth large actually measures, check What Size Is Youth Large.
How many shirts should I order for a team?
Order your roster count plus 10 to 15 percent extra in the most common sizes. A team of 15 needs 17 to 18 shirts. The extras cover sizing mistakes, late additions, and replacements. Put the extra shirts in the sizes where most of your team falls, not spread evenly across all sizes.
What size distribution should I use for team shirts?
It depends on the age range. Youth teams ages 6-10 are mostly youth small and youth medium. Youth teams ages 10-14 spread from youth medium to adult small. Adult teams peak at medium and large. See the distribution table in this guide for exact percentages by group type.
How do I avoid ordering the wrong sizes?
Run a try-on session with sample shirts at practice or a meeting. If that is not possible, send a measurement form asking for chest measurements in inches rather than self-reported sizes. People are wrong about their size about 30% of the time. Measurements are accurate 85% of the time.
Related Sizing Guides
- Custom Team Shirt Sizing for Coaches
- How to Size Custom Shirts for Youth Sports Teams
- Custom T-Shirt Sizing for Schools
- What Size Shirt for a 10 Year Old?
- What Size Shirt for a 12 Year Old?
- Gildan Youth Sizing Guide
- Youth vs Adult T-Shirt Sizing Guide
- What Size Is Youth Large?
Let Us Handle the Math
Tell us your roster size and age range, and we will recommend the exact quantity and size breakdown. No guessing, no wasted shirts. Start your order here and we will have a quote to you within one business day.