Employee Clothing Sizes – A Step-by-Step Guide to Sizing

It’s best to determine workwear sizes based on actual body measurements, rather than solely on the S, M, L, or XL sizes worn on a daily basis. Different manufacturers use different cuts and size charts, so the same employee may need a different size for a T-shirt, sweatshirt, or polo shirt. The right fit affects not only the appearance of the work uniform but also freedom of movement and comfort during long work hours. Learn how to choose the right size for workwear step by step and minimize mistakes when ordering for your entire team.

In this article, you’ll learn:

– How to choose the right size for an employee’s clothing?
– How to take an employee’s measurements correctly?
– How to read a workwear size chart?
– Workwear sizing vs. garment style
– Workwear sizes for women and men
– How to prepare a bulk clothing order for your team?
– Clothing size vs. prints and embroidery
– Expert opinion – what most often causes sizing issues?

How to choose the right size for an employee’s clothing?

The safest method is to measure the employee’s chest, waist, and hip circumferences, and then compare the results with the size chart for the specific garment model. For pants, you should also check the waist circumference and inseam. Do not assume that a size M from one brand corresponds to a size M from another manufacturer.

If you’re wondering how to choose the right size for an employee’s workwear, start with the measurements given in centimeters. For larger orders, it’s also a good idea to test a few representative sizes before launching full-scale production.

How do you take an employee’s measurements correctly?

The right size for workwear depends primarily on taking measurements correctly. It’s best to use a soft measuring tape and measure the body while the person is wearing light clothing, without pulling the tape too tightly.

The most important measurements are:

– chest – measured at the widest point,
– waist or hip – depending on the type of garment,
– hips – particularly important for pants and women’s styles,
– height – helpful when selecting the length of a sweatshirt, jacket, or pants,
– inseam – important for work pants.

It’s a good idea to record measurements in centimeters rather than simply asking employees for their self-reported S, M, or XL sizes. This allows you to match employee clothing sizes much more accurately to a specific product catalog later on.

How to read a workwear size chart?

A workwear size chart should be treated as the primary source of information before placing an order. It’s important to check whether the manufacturer provides body measurements or finished product measurements. These are two different values.

If the chart indicates the width of a T-shirt measured flat, the result must be interpreted accordingly. For example, a width of 55 cm measured from armpit to armpit corresponds to approximately 110 cm in the circumference of the garment itself. The garment should also have sufficient ease relative to the body, the amount of which depends on the cut and intended use.

If you’re ordering a custom-printed T-shirt, it’s a good idea to check the size chart for the specific model you’ve chosen before selecting a size, rather than relying on the size used for other T-shirts.

Workwear Sizing vs. Garment Style

Workwear sizing cannot be analyzed without considering the cut and intended use of the garment. A regular-fit T-shirt, a fitted style, and a looser cut may drape completely differently on a person with the same measurements.

How the garment is used also matters. Clothing worn during active work should allow for free movement of the arms and torso. For teams performing tasks on the move, custom-printed sports T-shirts may be a good solution, while polo shirts with a company logo are often used in customer service or during corporate events.

How do you choose the right size for workwear when the measurement falls between two sizes? It’s worth considering the fabric’s stretch and the nature of the tasks performed, rather than automatically choosing the smaller size.

Company Clothing Sizes for Women and Men

When putting together a clothing order for a larger group, it’s a good idea to consider separate styles. Custom-printed women’s T-shirts may have a more fitted waist, different shoulder proportions, and a shorter length than custom-printed men’s T-shirts.

Therefore, it’s best to collect corporate apparel sizes for a specific style that will actually be ordered. You shouldn’t automatically convert a women’s M to a men’s S or vice versa.

The same rule applies when preparing clothing for family events, competitions, or promotional campaigns, during which custom-printed children’s T-shirts are also needed.

Clothing Size vs. Printing and Embroidery

The product size must be determined before applying any markings, because with personalized clothing, a sizing error can be much more difficult to correct. It is therefore advisable to first approve the style and sizes, and only then select the appropriate clothing printing techniques.

Depending on the design, you can use screen printing, DTF printing on apparel, DTG digital printing, or custom computer embroidery. The choice should be based on, among other things, the type of fabric, the graphic design, the order size, and the desired effect.

Apparel can also be part of a broader brand identity system that includes promotional items for businesses.

Choose corporate apparel tailored to your team’s needs

At PrintExpress, you can select T-shirts, sweatshirts, and other corporate apparel items with prints or embroidery. Check out the available styles and sizes to put together a comfortable, cohesive outfit for your employees.

Check out our selection of printed apparel →

Expert opinion—what most often causes sizing issues?

The most common mistake is ordering apparel based solely on the size an employee recalls off the top of their head, without checking the size chart for that specific model. For larger orders, this poses a real risk of costly mistakes, especially once the garments have already been labeled. We recommend first selecting a model, checking its measurements, and gathering the team’s sizes; for large orders, we also recommend conducting a trial run with a few samples.

FAQ – Employee Clothing Sizes

1. How do I choose the right size for an employee’s clothing?

It’s best to take basic body measurements and compare them to the size chart for the specific product. How can I choose the right size for an employee’s clothing without measuring? You can rely on their current size, but this is a less precise solution.

2. Is size M the same across all manufacturers?

No. Different brands may use varying cuts and size ranges, so the workwear size chart should be checked separately for the selected product.

3. How do you choose a workwear size when two sizes are in between?

You should consider the cut, the fabric’s elasticity, and the nature of the work being performed. If an employee needs a great deal of freedom of movement, a size that’s too tight may be impractical.

4. What measurements should be taken for an employee?

Most commonly, you’ll need the chest circumference, waist or hip circumference, hip circumference, and height. For pants, it’s also a good idea to measure the inseam.

5. Are the sizing charts for women’s and men’s workwear the same?

Not always. Workwear sizing can vary both in the range of measurements and in the proportions of individual styles.

6. Is it a good idea to order sample garments before placing a large order?

Yes, especially if the clothing is to be branded later. Trying on several sizes allows you to verify the cut and the actual fit of the product.

7. Can you determine the size based on clothing an employee already owns?

Yes. You can measure a well-fitting T-shirt or sweatshirt while it’s laid flat and compare the measurements to the product dimensions provided by the supplier.

8. Why is it important to determine corporate clothing sizes before branding?

Personalization makes the right choice even more important. Approving corporate clothing sizes before printing or embroidery reduces the risk of producing ill-fitting garments.

9. Should an employee choose a larger size for workwear?

There is no general rule. The right size for workwear should ensure comfort, but you shouldn’t choose it solely “just in case” without checking actual measurements.

10. How can you avoid mistakes when ordering clothing for many employees?

It’s best to select a specific model, share its size chart with the team, compile the data in a single spreadsheet, and verify it before production. For large orders, it’s also worth using sample garments. This process makes it much easier to determine the correct sizes for employees and prepare a consistent order for the entire company.