Fit problems are one of the main reasons customers return clothing, and inconsistent sizing is one of the main reasons they do not reorder. A good size chart solves both: it helps shoppers choose the right size and gives your manufacturer clear numbers to produce.
Here is how to build one, step by step.
Two charts, two jobs
| Body size chart | Garment measurement chart | |
|---|---|---|
| Who uses it | Customers | Manufacturer and quality control |
| What it shows | Body measurements for each size | Finished garment dimensions |
| Where it lives | Product pages | Your tech pack |
The difference between the two is ease: the extra room a garment has beyond the body. An oversized hoodie has much more ease than a fitted performance top, even in the same size.
Step 1: Define your fit and customer
Decide the fit intention for each style (slim, regular, relaxed, oversized) and who you are designing for. A streetwear audience and a yoga audience expect very different fits from the same size label.
Step 2: Choose a base size and reference garment
Start with one size, usually a medium, and a garment whose fit you love. Measure it carefully. That becomes your starting point for adjustments.
Step 3: Set your points of measure
Points of measure (POMs) are where each measurement is taken. Common ones for tops include:
- Chest width: measured flat, 1 inch below the armhole.
- Body length: from the high point of the shoulder to the hem.
- Shoulder width: seam to seam.
- Sleeve length: from shoulder seam or centre back to cuff.
- Hem width, armhole, bicep and neck opening.
For bottoms such as pants, jeans or leggings: waist, hip, front and back rise, thigh, knee, leg opening and inseam.
Define exactly how each is measured so everyone measures the same way.
Step 4: Grade your sizes
Grading sets how much each measurement changes between sizes. Chest might grow by a set amount per size while sleeve length grows by less. Grading can be even across the range or adjusted for larger sizes. Your manufacturer’s pattern team can help set grade rules that keep proportions right.
Step 5: Add tolerances
No garment is cut and sewn to the exact millimetre. Tolerances, for example ± ½ inch on chest, define the acceptable range. Tighter tolerances on key fit points, looser on less critical ones.
Step 6: Test with samples
Make samples in more than one size and try them on real people who match your audience. Wash them and re-measure to check shrinkage. Read our garment sampling guide for an inspection checklist.
Step 7: Publish a customer-friendly chart
- Show body measurements, and optionally key garment measurements, for each size.
- Explain how to measure with a simple diagram.
- Describe the fit in words: “relaxed fit, size down for a closer fit”.
- Offer both inches and centimetres if you sell internationally.
Choosing your size range
Start with the range your audience buys most, then expand. A realistic size split also matters for production: ordering equal quantities of every size often leaves you with extra small and extra large stock. See MOQ explained for planning quantities.
Size chart mistakes to avoid
- Copying another brand’s chart without testing it on your garments.
- Mixing body and garment measurements in one table without labels.
- Skipping tolerances in your tech pack.
- Not re-measuring after washing.
Frequently asked questions
What is the difference between a body size chart and a garment measurement chart?
A body size chart tells customers which size to choose based on their body measurements. A garment measurement chart lists the actual finished dimensions of the garment and is what the factory produces to.
What is grading in clothing production?
Grading is the process of scaling a base pattern up and down to create each size in your range, using defined increments at each point of measure.
What are tolerances on a spec sheet?
Tolerances are the acceptable variation from a measurement, for example plus or minus half an inch on chest width. They define what counts as correct during production and inspection.
How many sizes should a new clothing brand offer?
Many brands start with a core range such as S to XL or XS to XXL based on their audience, then add sizes once they have sales and return data.
Need help with fit and grading?
Our pattern and sampling team can build your measurement chart, grade your sizes and make samples in 7 to 10 business days.
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