If you’ve ever organised a corporate event, school programme, or promotional campaign in Singapore, you’ll recognise this problem immediately:

“Why are there so many XLs left… and no M sizes?”

This is one of the most common issues in custom t-shirt printing, and it has nothing to do with fabric or print quality.

It comes down to poor size planning.

This guide is written for event organisers, HR teams, schools, and businesses who want to avoid wastage, complaints, and last-minute panic when ordering custom t-shirt printing in Singapore.

---

Why T-Shirt Size Planning Is So Important

A wrong size mix leads to:

• Unused inventory

• Participants swapping shirts

• Complaints after distribution

• Extra reprint costs

And once an event starts, there is no second chance.

Unlike design issues, size issues are immediately visible and directly affect user experience.

---

Common Size Mistakes We See in Singapore Events

From real event orders, these mistakes happen repeatedly:

• Ordering too many small sizes

• Guessing sizes instead of planning

• Assuming male/female ratio incorrectly

• Ignoring Asian sizing differences

• Forgetting unisex fit issues

Most of these problems are avoidable with proper planning.

---

Step 1: Understand Who Will Wear the T-Shirts

Before choosing any sizes, ask this simple question:

Who is actually wearing these t-shirts?

Examples:

• Office staff

• Outdoor event participants

• Students

• Mixed public audience

Each group has very different sizing behaviour.

---

Step 2: Singapore Sizing Is Not the Same as Overseas

This is extremely important.

Many t-shirts are:

• Asian-cut

• Slim-fit

• Different from US or EU sizing

Someone who wears M overseas may prefer L in Singapore sizing, especially for unisex shirts.

👉 This is why trying to “estimate” sizes without experience often fails.

---

Step 3: Recommended Size Mix for Common Events

Below are realistic size distribution guidelines based on local usage.

Corporate Office Events (Unisex T-Shirts)

Size	Recommended %
S	10%
M	35%
L	35%
XL	15%
XXL	5%

This works well for:

• Company retreats

• Team-building events

• Internal branding

---

Outdoor Events / Roadshows

Comfort matters more than fit.

Size	Recommended %
S	5%
M	30%
L	40%
XL	20%
XXL	5%

Participants prefer looser fits, especially in Singapore weather.

👉 Fabric selection also matters here:
https://www.luminousprinting.com.sg/blog/best-t-shirt-fabric-for-singapore-weather

---

School Events & Camps

Students tend to prefer:

• Slightly oversized fits

• Comfortable wear

Size	Recommended %
XS	10%
S	25%
M	40%
L	20%
XL	5%

Always confirm age group before finalising.

---

Step 4: Male vs Female Distribution (Often Misjudged)

Many organisers assume:

“We’ll just order unisex sizes.”

This works only if:

• Design is neutral

• Fit is comfortable

Otherwise:

• Female participants may find shirts too long or loose

• Complaints increase

When possible, offering separate men’s and women’s cuts reduces issues significantly.

---

Step 5: Why Unisex T-Shirts Are Still Popular

Despite the issues, unisex t-shirts remain popular because:

• Easier inventory management

• Lower cost

• Faster production

For bulk t-shirt printing in Singapore, unisex shirts are still the most practical choice.

👉 Learn more about bulk printing here:
https://www.luminousprinting.com.sg/category/t-shirts-printing

---

Step 6: How Size Mix Affects Cost and Production

Incorrect size planning can:

• Increase leftovers

• Force reorders

• Delay distribution

Reprinting small quantities later is:

• More expensive

• Slower

• Often avoidable

📌 Cost implications explained here:
https://www.luminousprinting.com.sg/blog/what-affects-t-shirt-printing-cost-in-singapore-complete-breakdown

---

Step 7: When You SHOULD Collect Size Data

For important events, don’t guess.

Collect sizes if:

• Participants are known in advance

• Event is high-visibility

• Budget is tight

Simple tools:

• Google Forms

• Registration platforms

This dramatically reduces errors.

---

Step 8: When Guessing Is Acceptable

Guessing is acceptable when:

• Event is promotional

• Distribution is casual

• Audience is mixed

In such cases, follow proven size ratios, not instinct.

---

Step 9: Printing Method Does NOT Fix Size Issues

Some organisers think:

“We can fix it later.”

Printing method, fabric, or design cannot solve size problems.

That’s why planning comes first in custom t-shirt printing.

👉 If you’re still deciding methods, start here:
https://www.luminousprinting.com.sg/blog/how-to-choose-the-right-t-shirt-printing-method-in-singapore

---

Step 10: Final Size Planning Checklist

Before confirming your order:

✔ Know your audience
✔ Confirm shirt cut (unisex / fitted)
✔ Choose correct size ratios
✔ Factor Singapore weather
✔ Allow buffer for XL+ sizes

This checklist prevents most issues.

---

Real Advice From Experience

The most successful events are not the ones with the best designs.

They are the ones where:

• Everyone gets a shirt that fits

• No one feels uncomfortable

• Distribution is smooth

Good size planning often goes unnoticed — and that’s exactly the goal.

---

Final Thoughts

In t-shirt printing in Singapore, size planning is not a minor detail.

It affects:

• User comfort

• Event perception

• Budget efficiency

A well-planned size mix ensures your custom t-shirts are worn — not stored.