Size chart

A size chart lists the actual flat-measured dimensions for each labeled size in a style — chest width (measured pit to pit, then doubled), body length (high point shoulder to hem), and sleeve length — rather than relying on the size label alone. Reputable suppliers publish these in inches or centimeters with a stated measurement tolerance, often a half inch to a full inch, since fabric and cutting introduce natural variance.

A Gildan 5000 XL measures about 24" chest width and 30" body length, while a Next Level 3600 XL runs closer to 22.5" chest and 28" length — same label, genuinely different garment, because sizing isn’t standardized across brands the way shoe sizes attempt to be. A buyer who orders “the same size” across two different blank styles for one job can end up with a mismatched fit across the run.

For any order where fit consistency matters — team uniforms, brand launches, anything shipping direct to a customer who can’t try it on — pull the actual chest and length numbers from the chart and compare against a shirt the buyer already owns and likes, not against the size letter. This matters doubly when switching print vendors or blank suppliers mid-run.

The recurring mistake is treating a size chart as a formality to skip because “everyone knows their size” — sizing varies enough between brands, and even between styles from the same brand, that skipping the chart is the single most common cause of fit complaints and reprint requests we see.