Short answer: Size planning is not just a measurement chart. For bulk production, buyers should confirm size range, base sample size, grade rules, size ratio, target market and quantity by size before deposit.
Why size ratio matters
A first bulk order can look clear by total quantity but still fail if the size split is wrong. Size ratio affects fabric planning, cutting, inventory balance, sell-through and reorder timing. It should be discussed before production starts, not after goods are packed.
Size planning inputs
| Input | What to confirm | Why it matters |
|---|---|---|
| Target market | US, EU, UK, AU or other market | Body fit expectations differ by market |
| Base sample size | The size used for sample approval | All grading starts from the approved base |
| Size range | XS-XL, XXS-XXL, plus sizes or limited sizes | Affects pattern grading and inventory risk |
| Size chart | Body measurements or garment measurements | Prevents confusion between fit and finished garment specs |
| Size ratio | Percentage or quantity by size | Turns total order quantity into production units |
| Category fit | Leggings, sports bras, tops or sets | Different categories need different fit checks |
Example first bulk size ratios
There is no universal correct ratio. Use your market, customer base and product type. If you do not have sales data yet, start controlled and avoid too many edge sizes.
| Order type | Example size range | Example ratio | Use when |
|---|---|---|---|
| Leggings first order | XS-XL | 10 / 25 / 35 / 20 / 10 | You need a balanced launch split |
| Sports bra first order | S-XL | 25 / 35 / 25 / 15 | Your buyer profile is core activewear sizes |
| Yoga set | S-L | 30 / 45 / 25 | You want fewer sizes for a simpler first launch |
| Plus-inclusive route | XS-XXL | 8 / 18 / 28 / 22 / 14 / 10 | Your brand already has customer demand data |
Size chart vs size ratio
A size chart tells the buyer how each size should fit. A size ratio tells the factory how many pieces to make in each size. Both are needed for a serious bulk order, but they solve different problems.
- Size chart: measurements, tolerance and fit expectation.
- Size ratio: quantity split for production and inventory.
- Size set: physical samples across multiple sizes for fit review.
- Grading: pattern changes from one size to the next.
When to request a size set
A size set is useful when fit risk is high, the style is new, the category is technical, or the order quantity is meaningful enough to justify extra review. Sports bras, compression leggings and fitted seamless styles often benefit from size-set review before full bulk production.
Related planning pages
FAQ
Do I need a size ratio before asking for a quote?
You can ask for an estimate without a final ratio, but serious bulk review should include size range and approximate size split.
What is the difference between body measurement and garment measurement?
Body measurement describes the wearer. Garment measurement describes the finished product. Activewear stretch makes this distinction important.
Should first orders include every size?
Not always. A focused first order may use fewer sizes to reduce risk, then expand after sales feedback.