Polo sizing and 2XL+ upcharges for company orders
Two things cause most polo reorders: guessing sizes and forgetting that 2XL and up cost more. Battle Born Clothing sees both every week. Here is how to avoid them.
Why 2XL+ costs more
Makers charge more for extended sizes because they use more fabric and sell fewer of them. On the polos we decorate, the blank upcharge is $1 to $7 per shirt depending on the size. The embroidery rate does not change. Our quotes list the upcharge per size so there is no surprise.
| Size | Blank | Note |
|---|---|---|
| XS-XL | $13.55 | Base price |
| 2XL | $13.55 + upcharge | Most common extended size |
| 3XL-4XL | $13.55 + upcharge | Available in most colors |
| 5XL-6XL | $13.55 + upcharge | Limited colors; confirm on the quote |
A typical size spread
If you do not have a roster yet, these spreads are close for most US workforces. Collect actual sizes if you can; a roster beats a guess.
| Crew type | S | M | L | XL | 2XL | 3XL |
|---|---|---|---|---|---|---|
| Mixed office (unisex sizing) | 4 | 10 | 14 | 12 | 6 | 2 |
| Field trades (men's heavy) | 2 | 8 | 14 | 14 | 7 | 3 |
| Women's cut (L500) | 8 | 14 | 14 | 8 | 3 | 1 |
Women's cuts
The Port Authority L500 and most performance polos have a women's companion. Women's sizes run smaller than unisex: a woman who wears a unisex M often wears a women's L. Collect sizes by cut, not by one chart. Ordering unisex only is fine when staff are used to it; offering a women's cut usually improves how often the shirt gets worn.
Youth and tall sizes
Most company polos run adult XS to 4XL or 6XL. Youth sizes exist on a few performance styles (for example the adidas A4000) and tall sizes on some Carhartt and Port Authority styles. Both are quoted per job because availability changes by color. If you need either, say so on the quote and we will confirm stock before you commit to a color.
Fit differences between styles
Not every polo fits the same at the same size. The Port Authority K500 is a classic, roomy cut. The Sport-Tek ST650 and other performance knits are trimmer through the body. The OGIO OG101 is tailored. The CornerStone CS410 is cut full to wear over gear. If a program mixes styles, size each style separately; a person who wears an L in a K500 may want an XL in a trim performance polo. We can send the maker's chart for each style you are considering.
Approximate chest measurements
| Size | Chest | Size | Chest |
|---|---|---|---|
| XS | 32-34 | 2XL | 47-49 |
| S | 35-37 | 3XL | 50-53 |
| M | 38-40 | 4XL | 54-57 |
| L | 41-43 | 5XL | 58-60 |
| XL | 44-46 | 6XL | 61-64 |
Have people measure a polo that fits them well, flat across the chest just below the armpit, and double it. That number against the chart is more reliable than a remembered size. Performance knits like the ST650 run true to size and are not meant to be ordered up.
Budgeting the upcharge
A 48-piece order with 6 2XL and 2 3XL polos carries 8 upcharges. At $1 to $7 each that is $8 to $56 on the order, listed per size on your quote. It is small next to the total, but it surprises buyers who priced the whole order at the base blank. Ask us to list the upcharge per size before you commit if your budget is tight.
Collecting sizes without a store
- Send staff a one-line form or a shared sheet: name, cut (men's/women's), size.
- Post the maker's size chart (we can send it) so people measure instead of guessing.
- Add one or two spares in M, L and XL for new hires.
- Send the roster with your quote request.
Mistakes that cause reorders
- Ordering unisex for everyone, then re-buying women's cuts.
- Guessing one size up for comfort on performance knits, which run true to size.
- Forgetting 2XL+ upcharges in the budget.
- Ordering 46 instead of 48 and missing the tier.
Need sizes checked before you order? Send the roster with the quote form and we will flag anything that looks off.
Questions
Can I mix sizes and cuts in one order?
Yes. Any mix of sizes, men's and women's cuts and colors in the same style or across styles counts toward one quantity tier.
Do you charge extra for tall sizes?
Tall sizes exist on some styles (for example, Carhartt) and carry the maker's upcharge. We list it on the quote.