Size mix calculator
Enter your headcount and team, and get an exact quantity per size for company apparel, with spares, in seconds. It is an estimate built from national body-size and workforce data; when you can, collect real sizes from your team.
Results
Total to order:263 pieces
Includes 13 spares (5%)
- Mixed office team
- 47% women
- unisex only
- T-shirt
- 5% spares
| Size | People (estimate) | Spares | Order | Share |
|---|---|---|---|---|
| XS | 8 | 0 | 8 | 3% |
| S | 34 | 0 | 34 | 13% |
| M | 63 | 5 | 68 | 26% |
| L | 66 | 5 | 71 | 27% |
| XL | 45 | 3 | 48 | 18% |
| 2XL | 23 | 0 | 23 | 9% |
| 3XL | 9 | 0 | 9 | 3% |
| 4XL | 2 | 0 | 2 | <1% |
| Total | 250 | 13 | 263 | 100% |
- XS8
- S34
- M68
- L71
- XL48
- 2XL23
- 3XL9
- 4XL2
Average US adult waist is 40.6 inches for men and 38.5 inches for women (CDC, 2021 to 2023), so 2XL and up matter. Leaving them out leaves people without a shirt.
This is an estimate. Real sizes from your team beat any curve. Team size collector (coming soon) or request a quote.
Size mix calculator
Mixed office team, 47% women, unisex only, T-shirt, 5% spares
Total to order: 263 pieces. Includes 13 spares.
Unisex
| Size | People (estimate) | Spares | Order | Share |
|---|---|---|---|---|
| XS | 8 | 0 | 8 | 3% |
| S | 34 | 0 | 34 | 13% |
| M | 63 | 5 | 68 | 26% |
| L | 66 | 5 | 71 | 27% |
| XL | 45 | 3 | 48 | 18% |
| 2XL | 23 | 0 | 23 | 9% |
| 3XL | 9 | 0 | 9 | 3% |
| 4XL | 2 | 0 | 2 | <1% |
| Total | 250 | 13 | 263 | 100% |
Branton Promo Group, hello@brantonpromo.com, 347.350.2745
Estimates only; final quantities are confirmed with your quote.
How the calculator works
It splits your team into men and women using BLS 2025 workforce data for your industry, then applies separate size curves for men in unisex sizes, women in unisex sizes, and women's cut.
The curves are Branton starting curves, set against CDC 2021 to 2023 body measurements and published group-order curves.
Hoodies, fleece, polos and outerwear shift part of each size up one size, because people size up for layering. Younger teams shift slightly smaller.
Spares go to your three most common sizes. Rounding keeps every total exact.
Starting size mix by team size
| Size | 100 | 500 | 1,000 | 5,000 |
|---|---|---|---|---|
| XS | 3 | 17 | 33 | 165 |
| S | 14 | 68 | 135 | 677 |
| M | 27 | 135 | 271 | 1,356 |
| L | 28 | 141 | 282 | 1,409 |
| XL | 19 | 95 | 191 | 955 |
| 2XL | 9 | 46 | 92 | 459 |
| 3XL | 4 | 18 | 36 | 179 |
| 4XL | 1 | 5 | 10 | 50 |
| Total | 105 | 525 | 1,050 | 5,250 |
When to collect real sizes instead
For fitted items, premium outerwear, or anything over $40 a piece, collect sizes from your team. The estimate works best for tees and event apparel.
Frequently asked questions
- What size ratio should I order for company t-shirts?
- For a mixed office team ordering unisex tees, a typical split is about 3% XS, 14% S, 25% M, 26% L, 18% XL, 9% 2XL, 4% 3XL and 1% 4XL. Use the calculator for your team and industry, since construction crews and healthcare teams look very different.
- How many extra shirts should I order?
- Add 3 to 5% for most orders and up to 10% when you expect late hires or exchanges. Put the extras in your most common sizes.
- Should we offer a women's cut?
- If your team is more than about 30% women and the item is fitted (tees, polos), offering a women's cut improves fit. Many women still choose unisex, so the calculator lets you set that share.
- Do we really need 2XL and larger?
- Yes. The average US adult waist is 40.6 inches for men and 38.5 inches for women (CDC, 2021 to 2023). Leaving out extended sizes leaves people without a shirt.
- Should I size up for hoodies and jackets?
- Yes, many people size up for layering. The calculator shifts part of each size up one step for hoodies, fleece and outerwear.
- What if I already know some sizes?
- Open More options and enter the sizes you have. The calculator estimates only the rest.
Sources
- BLS Current Population Survey table 18
- CDC body measurements
- Monday Merch sizing guide
- Rush Order Tees size guide
- Manatee Shirt size distribution
Last updated October 2026. Estimates only; final quantities are confirmed with your quote.