A merch drop is exciting, but the ordering behind it can be stressful. Order too few of a popular size and you sell out early. Order too many of the wrong one and you are stuck with inventory. There is no perfect formula, but a careful process helps you make better guesses. Here is a practical way to plan the sizes, colors and quantities for your next drop.
1. Start with your audience and history
The best predictor of what will sell is what has sold. If you have past orders, event sign-ups or a customer list, look at which sizes people actually bought. If you are launching from scratch, think about who your buyers are. A team or family-oriented audience usually skews differently than a streetwear crowd, and a fitted women's cut changes the mix again. Write down your assumptions so you can compare them with what really happens.
2. Build a size curve
A size curve is your estimate of what percentage of your total order should go to each size. Most drops center on the middle sizes (typically M, L and XL), with smaller amounts of the smallest and largest sizes. The exact split depends entirely on your audience, so treat any generic split as a starting point, not a rule. Include extended sizes if your customers are likely to want them; running out there loses sales you could have kept.
3. Check the size charts
Different styles fit differently. A boxy, oversized tee and a slim fit tee in the same labeled size can measure very differently. Before you commit, open the size chart on each product page and compare measurements, not just labels. If you are mixing styles in one drop, do this for each one.
4. Limit your colors and styles
Every extra color multiplies the number of size and color combinations you have to forecast. Two or three colors in a full size run are usually easier to manage than eight colors with thin size coverage. Choose colors that make your artwork readable: light ink on dark shirts, dark ink on light ones.
5. Order samples first
Before placing a large order, get a sample of the blank you are considering. Check the fit, feel and color in person, then test your print on it. See our how to order page for details on how ordering works.
6. Decide between pre-order and stock
If you are unsure about demand, a pre-order model lets you collect orders first and buy blanks based on real numbers. If you are selling in person at an event, you will need stock on hand and should lean on your size curve. Some brands run a hybrid: a core stock plus a pre-order window for extras.
7. Add a small buffer, and know your costs
Printing can produce misprints, and a few pieces may be lost to testing. Adding a small buffer to your quantities is common practice. Then price your product using your full cost: blank, decoration, packaging and shipping. Larger orders can also bring savings, so review our bulk pricing and volume discounts, which apply automatically based on your order total.
8. Keep notes for next time
After the drop, record what sold, how fast and in which sizes. That record becomes the best guide for your next order.
Get started
Explore our T-Shirts collection to compare styles and size charts. If you have questions about planning your order, email support@thedifferentapparelstore.com and we will help where we can.