Apparel Sizing & Fit: Getting Your Size Run Right and Cutting Returns
By The Velocity Wear Team
Sizing is the most underrated decision in apparel — and the most expensive to get wrong. The majority of clothing returns come down to fit, and every return eats your margin and your customer’s trust. Here is how to get your size run right before you produce.
Choose a size run that matches your audience
A standard run might be S–XXL, but the right range depends on who you sell to. Streetwear often skews to oversized and broader sizing; corporate kit needs the full XS–5XL spread; a fashion-fit brand may run smaller. Decide deliberately rather than defaulting.
Measure — never assume
A “medium” means nothing on its own. What matters are the actual garment measurements — chest, length, sleeve, shoulder — at each size. Get these in writing from your manufacturer for the exact garment you are producing, because they vary between blanks, fits and brands.
Understand grading
Grading is how measurements step up from one size to the next. Consistent, sensible grading keeps the fit true across the whole run — a jump that is too small or too large between sizes is where fit complaints come from. Review the grade sheet, not just the sample size.
Always approve a fit sample
A photorealistic mockup shows the design; only a physical fit sample shows the fit. For anything beyond a small run, put the actual garment on a real person, check the key measurements against the spec, and adjust before committing to production.
Publish a clear size guide
- Give real garment measurements, not just S/M/L.
- State the fit (slim, regular, oversized) and any “size up/down” advice.
- Add a simple how-to-measure diagram.
- Use consistent units and include both cm and inches for the UK, USA and EU.
“A great size guide is the cheapest returns-reduction tool you have. Most fit returns are really information problems.”
Velocity Wear provides full garment measurements and fit samples for every product, with consistent grading across the size run, so your customers order with confidence. Request a spec and sample for your next product.