Sizing is the single thing most businesses get wrong when they order custom apparel for the first time. Either you order too many smalls (and they end up in a box), or too few larges (and someone wears a tee that fits like a vest). Here's a no-fluff guide to getting it right the first time.
The base sizing chart we use
Most of our wholesale men's tees are standard Australian sizing on a 100% cotton crew neck. For unisex teams that means:
| Size | Chest (cm) | Length (cm) |
|---|---|---|
| XS | 86–91 | 66 |
| S | 91–96 | 68 |
| M | 96–101 | 70 |
| L | 101–107 | 72 |
| XL | 107–112 | 74 |
| 2XL | 112–117 | 76 |
| 3XL | 117–122 | 78 |
Chest is measured around the fullest part. Length is from shoulder seam to hem.
How AU sizing compares to US and EU
Quick rule of thumb when you're trying to translate a US or EU spec:
- US sizing generally runs one size larger than AU. A US Medium is closer to an AU Large.
- EU sizing often uses chest measurement directly (48, 50, 52). 48 EU = AU S, 52 EU = AU L roughly.
- UK sizing matches AU very closely. They're effectively the same.
If you've worn brands that ship from the US (Patagonia, Hanes, Carhartt), you've probably been wearing a size smaller than your actual AU equivalent. Order accordingly.
The mixed-gender team problem
If your team is mixed-gender and you want everyone in the same tee (most events do), you're using unisex sizing — which means you need a women's size adjustment.
A women's L body usually fits a unisex S or M. A women's M usually fits a unisex S. Tell people to size down one from what they'd normally buy for fitted clothing.
If you have budget for separate men's and women's runs, that's nicer to wear, but it doubles your size-grid complexity for ordering and storage. For most events, unisex works.
The simple sizing survey
Send this to your team 2 weeks before you place the order. Six questions:
- Full name
- Team / role
- Tee size (XS, S, M, L, XL, 2XL, 3XL)
- Preferred fit: regular or oversized?
- Any allergy/sensitivity to specific fabrics?
- Phone number (for delivery follow-up)
The third question is the only one that affects the order, but the rest reduce post-order chaos.
Default size mix when you can't survey
For events with last-minute crew or pop-up volunteers, this is the safest default mix per 100 units:
- S — 10 units
- M — 25 units
- L — 30 units
- XL — 20 units
- 2XL — 10 units
- 3XL — 5 units
For tradies, security, hospitality and trades-heavy events, shift one row larger: subtract 5 from S, add 5 to XL. For office or design teams, shift one row smaller.
Print size by tee size
A 30cm wide chest print looks balanced on a Medium. On a 3XL the same print looks small. On an XS it looks like a billboard. Two options:
- Standard everything — print one size for all, accept some visual variation.
- Scale print to size — costs more (multiple screens) but looks tailored.
For most events option 1 is fine; for premium brand merch, option 2.
Fit notes for specific roles
- Bar staff and FOH — fitted, dark colours (hides spills), short-sleeve.
- Riggers and setup crew — oversized, 100% cotton (synthetic blends melt on hot lights), high-vis colours or hi-vis vest over.
- Volunteers — unisex, branded clearly on front + back (helps attendees spot them).
- Office uniforms — polos, not tees — polo program is its own animal, plan accordingly.
What about polo shirts and jackets?
Polos run a size tighter than tees for the same chest measurement. If a staffer wears AU M in a tee, they may need L in a polo — especially in fitted polo cuts (BIZ COOL, Podium Cool, and similar).
Jackets are even less forgiving — measure over a layer of clothing if you can. The default jackets we wholesale (windproof shells, 310gsm) fit roughly true to size for AU labels.
Ready to order?
If you've got a team size to spec out, the next step is the wholesale application form. Tell us how many units, what size mix, and we'll come back to you within 1 business day with pricing and timeline.