How Many Shirts Should You Order for an Event?
June 27, 2026 — by Tee Print USA Team
Every event organizer faces the same two questions: how many shirts, and in what sizes? Order too few and volunteers miss out; order too many and you're storing boxes for a year.
The 10% rule
Take your confirmed headcount and add 10%. Late registrations, size swaps and "can my friend get one?" requests are inevitable, and reprinting a handful of shirts later costs far more per piece than printing spares now.
The size curve that works
For a general adult audience in the US, this distribution has served hundreds of our event orders well: S 10%, M 25%, L 30%, XL 20%, 2XL 10%, 3XL 5%. Skew larger for trades and construction crowds, smaller for youth-heavy events.
Don't forget
- Staff and volunteer shirts in a distinct color for visibility
- A few youth sizes if families attend
- Extras for sponsors — they funded the thing, after all
Planning an event order? Get a quote and mention your date — we'll make sure production comfortably beats it.
