For a mixed adult group, a safe starting split is about 10% small, 25% medium, 30% large, 20% extra large, 10% 2XL and 5% 3XL. Medium and large carry most of the order. The tables below turn that split into exact numbers for 50, 100 and 200 shirts. We also show how to adjust it for your own people, and how to avoid leftover stock.

TL;DR

• Start with 10% S, 25% M, 30% L, 20% XL, 10% 2XL and 5% 3XL for a mixed adult group, then adjust.
• Real sizes beat any formula. If you can ask your people, do it.
• Add a small buffer of spares, weighted to M, L and XL.
• Order women’s and kids’ cuts as separate lines. Their sizes do not match unisex sizes.
• Check the fabric weight and the print method before you lock in quantities.

Table of Contents

• The standard size breakdown for a mixed group
• How many of each size: worked examples
• Use your own history to build the split
• Adjust the split for your audience
• Unisex, women’s and kids’ sizes are not the same
• Add a buffer for late changes
• Fabric weight: what the numbers mean
• Choosing promotional tees for an Australian audience
• A simple process for ordering the right sizes
• Our view: size planning is part of the brand
• Get your tee order started with us
• FAQ
• Sources

The standard size breakdown for a mixed group

There is no single correct split. Every group is different. But a mixed adult group, with no size data, tends to cluster in the middle sizes. A starting template helps you avoid a pile of smalls and a shortage of larges.

Here is the template we suggest as a starting point:

Size	Share of order
S	10%
M	25%
L	30%
XL	20%
2XL	10%
3XL	5%

This template leaves out XS. Add it only if you know you have people who need it. It is a planning tool, not a promise about your group. Treat it as the first draft of your order.

How many of each size: worked examples

The table below applies the template to three common order quantities. The numbers are whole shirts and each column adds up to the total.

Size	50 shirts	100 shirts	200 shirts
S	5	10	20
M	13	25	50
L	15	30	60
XL	10	20	40
2XL	5	10	20
3XL	2	5	10
Total	50	100	200

For smaller orders, such as 20 or 30 shirts, keep the range tight. Order S, M, L, XL and one or two 2XL. A 3XL line of one shirt is only worth it if you know someone needs it.

Rounding without going over

Percentages rarely give whole shirts. Say you order 50 shirts and split them equally across three sizes. Each gets 16.67. If you round each one up, you order 51 shirts. The fix is simple. Round down, then give the remaining shirts to the sizes with the largest leftover decimals. Here that gives 17, 17 and 16.

For the 50-shirt column above, the split is 5, 12.5, 15, 10, 5 and 2.5. We set M at 13 and 3XL at 2, so the total stays at 50.

Use your own history to build the split

If you have ordered before, your past data beats any template. The method is a size curve. For each size, divide the units used by the total units. Then multiply by the quantity you plan to order. This is the general size curve calculation used in apparel planning. Round the results, then adjust so the quantities add up to your planned total.

Here is a simple example. Last year you ordered 200 tees. You used 40 mediums. That is 20%. This year you plan to order 120. Mediums come to 24.

Two cautions apply to past data:

• Stock-outs hide demand. If you ran out of large halfway through an event, your history understates how many people wanted large.
• A new cut changes the numbers. If you switch to a different fit or style, last year’s curve is less reliable. Do not copy one curve across different products or regions without checking it first.

Adjust the split for your audience

The template is a start. Your group changes it. Ask these questions before you finalise.

Who is wearing the shirt?

A staff uniform is different from a conference giveaway. Staff sizes are usually known, so ask for them. Giveaway shirts for the public need a wider spread, as you do not know who will take one.

What is the gender mix?

A mostly female group needs a shift towards S, M and L in a women’s cut. A mostly male group moves the weight towards L, XL and 2XL. If the mix is close to even, a unisex tee with the template split works well.

What is the age range?

Younger groups, such as school and sports clubs, often need youth sizes. Older groups may need more room in the body. If kids are involved, order a separate kids’ line. Our custom kids sports T-shirt is one option to look at.

Is it an event or a uniform?

Uniforms are worn for years, so exact sizes matter more. Event shirts are often worn once or twice. For events, go a little bigger. People tend to be happier with a shirt that is slightly loose than one that is tight.

Unisex, women’s and kids’ sizes are not the same

A medium unisex tee does not match a women’s medium. The cut, length and body width differ. Size labels also vary between brands, so always read the size chart for the exact garment you are ordering.

As a guide:

• Unisex or men’s tees are cut straighter. Chest ranges are listed in centimetres on the garment chart.
• Women’s tees are cut closer to the body. They are often labelled with Australian dress sizes, such as 8, 10, 12 and 14, alongside S, M and L.
• Kids’ and youth tees usually run by age or height, such as 6, 8, 10, 12 and 14.

If you are ordering for a mixed group, do not just put women’s staff into a unisex size. Offer a women’s cut where you can. You can see the range in our women’s basic tee, custom women’s shirt and men’s classic T-shirt pages. When in doubt, ask us for the size chart before you order.

Add a buffer for late changes

Orders change. Someone joins late. A shirt arrives with a mark. A volunteer turns up unexpectedly. A small buffer protects you. Some print suppliers suggest adding roughly 5% to 10%, weighted to M, L and XL, even when you have collected actual sizes.

For a 100-shirt order, that is 5 to 10 extra shirts. A sensible spread would be:

• 2 extra M
• 3 extra L
• 2 extra XL
• 1 extra in a larger size if your group needs it

Spares are not wasted. Keep them for new starters, replacements and next year’s event.

Fabric weight: what the numbers mean

Fabric weight is measured in grams per square metre, or GSM. It tells you how thick and heavy the cloth is. As a general guide, tees fall into three bands:

Weight	GSM range	Feel
Lightweight	100 to 150	Thin, cool, good for warm weather
Midweight	150 to 180	Balanced, suits most uses
Heavyweight	180 to 240+	Thick, sturdy, holds shape

These bands are described in a T-shirt fabric weight guide. The same guide suggests that mid-range weights suit bulk buyers best, and that very light fabric can distort under print pressure.

In Australia, think about climate. Lighter tees suit summer events and outdoor work. Heavier tees feel more premium and last longer, which suits staff uniforms.

Weight and size are linked

Fabric weight affects fit. A heavier cotton tee drapes differently from a light one. If you are choosing between two weights, check the size chart for each. Do not assume a large in one is the same as a large in the other.

Weight and print method

The print method also matters. Screen printing and heat transfer behave differently on different fabrics. For a plain comparison, see this guide to screen print versus heat transfer. Tell us your logo and your garment early, and we will advise on the best option.

Logo size also depends on the garment size. A logo that suits a medium may look small on a 3XL. Our logo size on shirts guide and logo placement guidelines will help you prepare your file.

Choosing promotional tees for an Australian audience

A few practical points suit most Australian groups:

• Pick breathable fabric. Warm weather is common, and people wear shirts outdoors.
• Choose colours that suit your brand and hide wear. Navy, black, grey and white are easy to match with a logo.
• Think about reuse. A shirt people want to wear again keeps your brand visible for longer.
• Match the cut to the use. A relaxed fit suits giveaways. A neater cut suits staff.

You can browse our full range of promotional T-shirts and promotional shirts. If a cap or beanie would round out the order, see our branded beanies guide.

A simple process for ordering the right sizes

1. Count your people. Decide how many shirts you need, including spares.
2. Collect sizes if you can. A short form with S to 3XL and cut (unisex, women’s, kids) is enough.
3. Use the template if you cannot. Start with the split above, then adjust for gender and age.
4. Check the size chart for your garment. Each style has its own chart.
5. Add 5% to 10% spare. Weight it towards M, L and XL.
6. Round so the total matches. Do not order more than you planned by accident.
7. Send your artwork. We can help with the design.

Our view: size planning is part of the brand

We see the same thing on many orders. The artwork is ready, the colour is chosen, and the sizes are guessed in the last five minutes.

A shirt that does not fit does not get worn. If it stays in a drawer, your logo stays there too. That is why we treat the size breakdown as part of the brand plan, not an afterthought.

We source factory-direct through a global supply chain we have built over more than 25 years. Our aim is consistent quality at competitive prices across the full size range. We also offer free artwork design, so your logo is ready to scale across S to 3XL.

Our advice is simple. Ask for real sizes where you can. Use a template where you cannot. Keep a small buffer. Talk to us early, and we will help you build the split for your group.

PromoShop

Get your tee order started with us

Ready to order? We supply custom branded tees for teams, events and giveaways. Our offer includes custom branding, free artwork design and an express service for tight timelines. We also have a Price Beat Guarantee on all products.

Tell us your quantity and your size split, and we will help you check it. Browse our full range at PromoShop or look at our promotional T-shirts to get started. Need a hand? Get in touch.

FAQ

How many of each size should I order for 100 shirts?

For a mixed adult group, try 10 small, 25 medium, 30 large, 20 extra large, 10 2XL and 5 3XL. This is a starting point. If you know your group, adjust it. Add 5 to 10 spares in M, L and XL if you can.

What is the most common T-shirt size to order?

For most mixed groups, large and medium make up the biggest share of the order. That is why the template puts 30% in large and 25% in medium. Your group may differ, so check any known sizes first.

Should I order unisex or women’s tees?

If your group is mixed, offer both where you can. Women’s cuts fit closer to the body and use different size ranges. If you must choose one cut, unisex is simpler. Check the size chart for the exact garment.

What fabric weight is best for promotional tees?

Midweight tees, around 150 to 180 GSM, suit most uses. Lighter tees suit hot weather and one-off events. Heavier tees suit staff uniforms. Tell us how the shirts will be used and we can suggest a style.

How many spare shirts do I need?

A buffer of about 5% to 10% covers late joiners, swaps and marked items. Weight the spares towards medium, large and extra large. Keep leftovers for new staff and future events.

Sources

• How to Calculate Size Curves
• T-Shirt Fabric Weight Guide
• Screen Print vs Heat Transfer: Which Suits Your Order?

Recommended

• Classic Tee
• Tall Tee
• Men’s Classic T-Shirt
• Men’s Basic Tee