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Common T-Shirt & Apparel Size Guide

Custom Apparel Size Guide: Precision Fitting for T-Shirt Printing & Embroidery

Finding the perfect fit for custom branded clothing ensures optimal print alignment and long-term garment utility. Avoid common sizing mistakes by using our comprehensive technical size matrices for Australia's leading apparel brands, featuring exact half-chest dimensions and retail fit notes.

How to Measure Garments for Custom Printing (The 2-Point Rule)

  • Half-Chest Measurement: Lay an existing t-shirt flat on a surface. Measure across the front chest from 2cm below the armpit seam to the opposite armpit seam. This is the most critical vector for custom decoration.
  • Body Length Measurement: Measure from the highest point of the shoulder line straight down to the bottom hemline of the apparel.

1. Men's & Unisex Custom Apparel Sizing Matrix

Our standard unisex garments feature classic retail silhouettes engineered with pre-shrunk combed cotton. Ideal for corporate merchandise runs, event uniforms, and high-density screen printing or Direct-to-Garment (DTG) customization.

AS Colour Staple Tee (Style 5001) – Size Guide

The premium industry benchmark for modern streetwear launches and high-resolution digital print fidelity.

Click to view AS Colour Staple Tee Measurement Table
Size Half-Chest (cm) Body Length (cm)
S 47 71
M 52 75
L 56.5 78.5
XL 61 82
2XL 64 83.5
3XL 68 85

Gildan Heavy Cotton Tee (Style 5000) 

A rugged, classic-fit 180 GSM open-end cotton textile optimized for cost-effective bulk promotional campaigns and industrial workwear.

Click to view Gildan Heavy Cotton 5000 Measurement Table
Size Width / Half-Chest (cm) Length / Body Length (cm)
XS 43 68
S 47 71
M 52 75
L 56.5 78.5
XL 61 82
2XL 64 83.5
3XL 68 85
4XL 75 87
5XL 80 89

AS Colour Barnard Tank (Style 5025) – Size Guide

Lightweight, sleeveless 150 GSM combed cotton with raw armhole edges, highly sought after for fitness apparel and summer event merchandise.

Click to view AS Colour Barnard Tank 5025 Measurement Table

Gildan Kids / Youth Heavy Cotton Tee (Style 5000B) – Size Guide

A resilient, classic-fit 180 GSM open-end cotton textile engineered specifically for youth garments. Optimized with twin-needle stitching to withstand high-friction school, sports, and community event wear while maintaining excellent print registration for bulk promotional graphics.

Click to view Gildan Youth Heavy Cotton 5000B Measurement Table
Kids Size Body Width (cm) Body Length (cm)
sz2 31 42
sz4 34 46
sz6 37 50
sz8 39.5 54
sz10 42 58
sz12 44.5 62
sz14 47 66
sz16 49.5 70

Note: A standard manufacturing tolerance variance of +/- 2.5cm applies across standard commercial textile lots. Measure body width flat across the garment, 2cm below the armpit line.

2. Women's & Ladies Custom Apparel Fit Matrix

Unlike standard boxy unisex profiles, tailored women's custom clothing features specialized side-seamed constructions, contoured silhouettes, and varying neckline drops to accommodate diverse body geometries perfectly.

Ladies Tee Fit Notes & Simple Sizing Recommendation Guide

When transitioning between generic unisex sizes and tailored women's garments, cross-referencing your standard Australian retail dress sizes is critical.

  • Ladies Tee Fit Notes: Tailored ladies styles like the AS Colour Maple or Crop feature shorter capped sleeves and tapered waistlines. If you prefer a relaxed or boyfriend-style fit, we advise selecting one size up or utilizing our Unisex Staple Tee spectrum.
  • Women’s Size Conversion Table (AU Size 6–24):
    AU Dress Size Equivalent Fit Profile
    Size 6 - 8 X-Small (XS)
    Size 10 Small (S)
    Size 12 Medium (M)
    Size 14 Large (L)
    Size 16 X-Large (XL)
    Size 18 - 20 2X-Large (2XL)

AS Colour Maple Tee (Style 4001) – Size Guide

The premium mid-weight combed cotton option providing an elegant, retail-ready feminine cut with excellent wash durability.

Click to view AS Colour Maple Tee Measurement Table

Extended Size Spectrum (S–5XL) – Custom Apparel Size Guide

Our comprehensive heavy-weight or mid-weight loose-fit unisex profiles are engineered for industrial workwear, sports team gear, and large-scale business event merchandising across Australia. Built with high-density carded or combed cotton to withstand rigorous commercial print processes, including screen printing and durable Direct-to-Film (DTF) transfers.

Click to expand S–5XL Standard Half-Chest Measurement Table
Size Half Chest (cm) Length (cm)
S 47 71
M 51 74
L 56 76
XL 61 79
2XL 66 81
3XL 71 84
4XL 76 86
5XL 81 89

Technical Measurement Protocols: Dimensions are taken flat across the fabric panels. Half-chest values are calculated by measuring 2cm below the armpit seam from edge to edge. Length measurements represent the vector from the highest point of the shoulder down to the garment's bottom hemline. An industry-standard manufacturing tolerance variance of +/- 2.5cm is normal across standard commercial textile manufacturing runs.

Women’s Ice Cotton Tee – Size Guide

An ultra-breathable, lightweight fabrication featuring specialized cooling properties ideal for active promotions and outdoor corporate activations.

View Women's Ice Cotton Tee Measurement Table

Women’s Ice Cotton Tee – Size Guide

An ultra-breathable, premium lightweight jersey fabrication engineered with specialized advanced cooling properties. This specialized weave provides a perfectly flat, low-pill surface texture optimized for flawless high-resolution Direct-to-Garment (DTG) print transitions and digital file clarity.

Click to view Women's Ice Cotton Tee Measurement Table
AU Retail Size Equivalent Fit Profile Half Chest Width Matrix (cm)
Size 6 Extra Small (XS) 39 – 41 cm
Size 8 XS – Small (S) Range Fit 46 cm (Flat Width)
Size 10 Standard Small (S) 41.5 – 43.5 cm
Size 12 Standard Medium (M) 46.5 – 48.5 cm
Size 14 Standard Large (L) 49 – 51 cm
Size 16 Large to Extra Large (L – XL) Transition Cut 51.5 – 54 cm

Technical Measurement Insight: To establish precise horizontal calibration before placing a custom printing order, measure an existing well-fitting t-shirt flat across the chest from 2cm below the armpit seam to the opposite side. Please note that industry-standard manufacturing tolerances permit a dimensional variance of +/- 2.5cm across distinct textile lots.

Women’s Crop Tee (Style 4062) – Size Guide

A trendy, high-fashion relaxed crop silhouette constructed with heavy-weight cotton, optimized for dance studios, fitness brands, and youthful retail collections.

Click to view Women's Crop Tee 4062 Measurement Table

Women’s Crop Tee (Style 4062) – Size Guide

A high-fashion, short-cut contemporary staple featuring a relaxed silhouette constructed from premium heavyweight combed cotton. Engineered with a smooth surface texture optimized for durable screen printing, vibrant Direct-to-Garment (DTG) graphics, or flexible Direct-to-Film (DTF) logo applications across trendy retail fashion collections and streetwear drops.

Click to view Women's Crop Tee 4062 Measurement Table
Size Body Width (cm) Body Length (cm)
XSM 47.5 44
SML 50 45
MED 52.5 46.5
LRG 55 47.5
XLG 57.5 48.5
2XL 60 49.5

* Sizing Pro Tip: Body width is measured as a flat half-chest dimension across the garment from side-seam to side-seam, 2cm below the sleeve attachment point. Fabric panel cuts are subject to an industry-standard manufacturing tolerance variance of +/- 2.5cm.

3. Youth & Kids Custom Apparel Sizing Vector

Sizing for children requires rigid adherence to age-indexed vectors and durable fabrications. Our youth ranges feature double-needle stitched hems to survive extreme playground wear and frequent wash cycles.

AS Colour Kids Premium Tee (Styles 3005 / 3006)

Super soft, low-irritant combed cotton cuts engineered specifically for sensitive skin profiles across school groups, sports associations, and family events.

Click to view AS Colour Kids Premium Tee Measurement Table

AS Colour Kids Premium Tee (Styles 3005 / 3006) – Size Guide

A premium, mid-weight 190 GSM combed cotton crewneck engineered specifically for high-density youth garment decoration. Features side-seamed paneling, double-needle stitched neck bands, and pre-shrunk fabrication calibration to secure exceptional wash durability and protect print registration alignment across active youth use-cases.

Click to view AS Colour Kids Premium Tee (3005/3006) Measurement Table
Kids Size Body Width (cm) Body Length (cm)
sz2 31 42
sz4 34 46
sz6 37 50
sz8 39.5 54
sz10 42 58
sz12 44.5 62
sz14 47 66
sz16 49.5 70

*Technical Sizing Metric: Body Width is captured as a flat half-chest vector, calculated across the face of the garment 2.5cm directly below the armhole sleeve junction. An industry-standard manufacturing tolerance variance of +/- 2.5cm is accepted across loose apparel textile construction runs.

4. Outerwear & Fleece Sizing Vector

Fleece items are layered over base garments. Fabric weights typically range between 290–350 GSM, which necessitates looser tolerances compared to lightweight cotton shirts.

AS Colour Supply Hoodie (Style 5101) – Size Guide

A classic mid-weight anti-pill fleece hoodie featuring a kangaroo pocket and matching drawcords, configured for winter workwear lines and promotional clubs.

Click to view AS Colour Supply Hoodie 5101 Measurement Table

AS Colour Supply Hoodie (Style 5101) – Size Guide

A classic, mid-weight 290 GSM anti-pill fleece hoodie featuring a kangaroo pocket and matching drawcords. Engineered with a premium cotton-mix facing substrate that provides an ultra-smooth profile for crisp screen printing and durable Direct-to-Film (DTF) transfer applications across commercial workwear and club apparel lines.

Click to view AS Colour Supply Hoodie 5101 Measurement Table
Size Body Width (cm) Body Length (cm)
XS 49 69.5
S 52 72
M 55 74.5
L 58 77
XL 61 79.5
2XL 64 82
3XL 67 84.5
4XL 70 85.5
5XL 73 86.5

Note: Outerwear panels are designed with loose garment styling tolerances to accommodate under-layering. A standard manufacturing tolerance variance of +/- 2.5cm is standard across standard commercial textile lots. Measure body width flat across the garment, 2cm below the armpit line.

Frequently Asked Sizing Questions: Custom Apparel Australia

How much do cotton garments shrink after digital printing?

Premium pre-shrunk combed cotton garments experience negligible residual shrinkage of approximately 1% to 3% across standard commercial laundering cycles. To completely defend against thermal shrinkage, avoid exposing cured Direct-to-Garment (DTG) or Direct-to-Film (DTF) ink deposits to high-temperature automatic dryers. Always line dry your decorated apparel inside out in the shade.

Why do half-chest measurements have a manufacturing tolerance margin?

A standard manufacturing tolerance variance of +/- 2.5cm is a textile production reality allowed across all major apparel brands. Because fabric panels undergo automated slicing, tension-shifting on the sewing line, and thermal curing variations during dying, two identical garments from the same manufacturing batch may possess slight dimensional deviations. Always account for this vector when analyzing strict size requirements.

Need to calculate costs or explore bulk print method differences now that you have your sizes ready?
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