Enter your total units, choose a size curve, and instantly see how many garments to produce in each size — across multiple styles, with MOQ checks and cost estimates.
Production Styles
Style Settings
Size Curve
Load a preset, then fine-tune individual percentages. Toggle sizes on/off with the checkboxes.
Total:100%
Percentages apply to active (checked) sizes only. Inactive sizes receive 0 units.
Size Run Breakdown
Fill in the fields above — results appear instantly.
1. Add a style for each garment type in your run (e.g. "Classic Tee", "Hoodie"). Each style has its own settings.
2. Set the total units you plan to produce for that style and enter your per-unit cost if you want a cost estimate.
3. Choose a preset curve — Unisex US, Women's, Athletic, Event/Promo, or Flat — to load benchmark percentages, or pick Custom to enter your own from scratch.
4. Toggle sizes on/off using the checkboxes to exclude sizes you won't carry (e.g. no XS or 3XL for a small run). Adjust individual percentages; the total must equal 100% — use "Normalize to 100%" to auto-balance.
5. Set MOQ if your supplier requires a minimum order quantity per size. The calculator rounds each size up to the nearest MOQ multiple and flags any size that falls below.
6. Add a buffer % (typically 5–10%) to cover exchange requests, press samples, and damaged units.
7. Export CSV or print the size run breakdown to share with your factory or screen printer.
When & Why You Need a Size Run Calculator
Indie apparel brands, merch creators, and event organizers routinely over-order small sizes and under-order large ones — or vice versa — leading to dead stock and stockouts on the same SKU. A size curve calculator eliminates guesswork by anchoring your order to proven demand benchmarks, adjusted for your specific audience.
Common scenarios: a streetwear drop with a 200-piece run across two colorways, a band's tour merch order, a corporate uniform order, or a fitness brand producing their first run of performance tees. Each audience has a different size profile, and the MOQ rounding step ensures you never accidentally slip below supplier minimums.
FAQ
What is a size curve in apparel production?
A size curve (also called a size run or size ratio) defines the planned percentage of units to produce in each size for a garment style. For example, a 1-2-3-3-1 ratio across XS–2XL means 10% XS, 20% S, 30% M, 30% L, 10% 2XL. Factories need a size curve before cutting fabric so they know how many of each size to produce. Getting the curve wrong results in stockouts in core sizes and dead inventory in others.
What is a typical size ratio for a unisex T-shirt run?
For a general US adult mixed-gender audience, the widely cited benchmark is approximately XS 1%, S 10%, M 25%, L 35%, XL 20%, 2XL 9%. Large is the highest-volume size, followed closely by Medium. For orders under 50 units, you can safely skip XS and 3XL. This preset is loaded by default in the calculator — adjust it to match your actual customer demographics.
How does the women's size curve differ?
Women's-specific or fitted styles skew smaller: a common benchmark is XS 15%, S 30%, M 30%, L 15%, XL 10%. Women's cuts (narrower shoulders, tapered waist) run smaller than unisex equivalents, so customers often size down. If you're selling unisex styles to a female-leaning audience, apply the Unisex US curve but note that many customers will size down one step.
How do I handle minimum order quantities (MOQ) per size?
Many factories and blank-apparel suppliers set a MOQ per size (commonly 6, 12, or 24 units). Enter this in the MOQ field and the calculator rounds each size's calculated quantity up to the nearest multiple. This can increase your total unit count above your target — the adjusted total and the extra cost are shown automatically. If MOQ rounding produces a size count far above your budget, consider disabling that size or negotiating a lower MOQ with your supplier.
Should I add a safety buffer, and how much?
Yes. A 5–10% buffer is standard practice when selling to an unknown audience (e.g. online store launch, event merch). The buffer covers exchange requests (a customer requests a different size), photographer and press samples, and any units damaged in production or shipping. The calculator distributes buffer units proportionally across all active sizes. For pre-order drops where every customer selects their own size, a buffer of 2–3% is sufficient.
What does 'normalize to 100%' do?
When you manually adjust individual percentages, add or remove sizes, or change a preset, the total may drift above or below 100%. Clicking "Normalize to 100%" rescales all active size percentages proportionally so they sum to exactly 100%. For example, if you have S=15, M=30, L=40, XL=20 (total 105%), normalizing scales each down proportionally to 14.3%, 28.6%, 38.1%, 19%. Review the result and tweak any size you want to prioritize.
Can I plan multiple garment styles at once?
Yes. Use the "+ Add Style" button to add up to 6 styles (e.g. Classic Tee, Hoodie, Long-Sleeve). Each style has its own total unit count, size curve, MOQ, buffer, and cost settings. An "All Styles Summary" table appears when you have more than one style, showing the combined unit count and cost across all styles — useful for totalling a factory order.
This tool provides size distribution estimates based on published industry benchmarks. Actual demand for your brand and audience may differ. Results are for planning guidance only — always validate against your own sales data when available.