Manufacturing
Size Grading for Uniform Programmes
Size grading for uniforms from XS to 5XL, separate men's and women's grades, children's 4-16 for schools, and how to plan a size ratio from an employee list.
- Standard grades run XS to 5XL for adults and 4 to 16 for children's school styles
- Men's and women's ranges are graded separately from their own base patterns
- Every grade is checked on a laundered size-set sample before bulk cutting
- Size charts are issued per style so staff can be measured against the actual garment
Grading is the step that turns one approved pattern into a full size range. Done properly, a 4XL shirt is not simply an XL enlarged; the shoulder, sleeve length, body length and chest all grow at their own rates so that the garment fits a larger body rather than a taller one. For a uniform programme, where the buyer has to dress every person on the payroll, grading is what decides whether the order works for the people at the ends of the size list.
Ranges we grade
Adult styles are graded from XS to 5XL as standard. Men’s and women’s ranges are graded separately from their own base patterns, because the grade increments differ: a women’s chest grade needs to work with darts, and a men’s shoulder grade runs wider. Trousers can be graded in regular and long lengths so tall staff are not left with a short hem.
School uniform programmes add a children’s range, usually from age 4 to 16, alongside adult sizes for teaching and support staff. Children’s grading uses age-based rules that change proportion, not only size, so it is set up as its own block. Sizes beyond 5XL, where a programme needs them, are handled the same way, as a separate block sampled on its own.
Every range is confirmed on a laundered size-set sample before cutting. The finished-garment chart we issue to you is built from those measured samples, after washing, so that the number staff read on the chart is the garment they will receive.
Children’s ranges are described in more detail under school uniforms.
Planning a size ratio from the employee list
The most common cause of a uniform order going wrong is not the garment but the ratio. A programme ordered on a guessed spread of sizes ends up with a stack of unused mediums and three people waiting for a 3XL. The fix is simple: measure staff against the size chart before the order and send us the list. We convert it into a quantity per size for the cut plan, and add whatever spare stock you want per size for new starters.
If you cannot measure everyone, a size breakdown from the previous order is the next best input. A population estimate is the last resort, and we say so, because it will leave a few people without a fit. For programmes with a lot of turnover, we recommend holding a small buffer in the middle sizes and re-ordering the ends by name.
The quantity per size feeds the cut plan in bulk production.
Matching an existing size chart
Staff who already wear a size L in the old uniform expect an L in the new one. Where you send us the old chart we set custom grade rules to land on those measurements, so the size label stays meaningful. Where the old supplier’s grade is unknown and the garments are inconsistent, we grade to a clean chart and advise re-measuring staff once, which is less disruptive than it sounds.
Where the old chart cannot be matched, the new one is confirmed on a laundered size set during sample development.
§ 01When Buyers Need This
Situations this service answers
If none of these describe your project, this probably is not the step you need — tell us what you are actually trying to solve.
- Your staff list spans a wide size range and the uniform must fit everyone on it
- You are ordering a school uniform and need children's sizes alongside adult staff sizes
- Your current supplier's large sizes are simply scaled-up small sizes and fit badly
- You need a size chart to hand to staff before the order is placed
- You want to order by size ratio rather than name by name
- You are adding a women's cut to a style that was previously unisex only
§ 02Our Process
How this step runs
- 01
Base size approval
Grading starts only after the base-size fit sample is approved, so every size grows from a pattern that is known to fit.
- 02
Grade rule setup
Grade increments for chest, waist, length, sleeve and other points are set per style and per gender, following your chart or our standard rules.
- 03
Nest and check
The graded pattern nest is checked for smooth progression between sizes and for seams that must still match.
- 04
Size-set sample
A run across the size range is made, laundered and measured to confirm the grade in the actual fabric.
- 05
Size chart
A finished-garment size chart is issued for the style, listing measurements at each size after washing.
- 06
Size ratio planning
Your employee list or last order's size breakdown is converted into a quantity per size for the cut plan.
§ 03What We Need From You
Inputs required
The faster these arrive, the fewer rounds development takes.
- The approved base-size pattern or sample
- Your size chart if you have one, or the size range you need with any body measurement data
- Whether men's, women's, unisex or children's ranges are required
- An employee list with sizes, or a size breakdown from a previous order, for ratio planning
- Any sizes outside the standard range that must be covered
§ 04Options
Choices available
- Adult grades from XS to 5XL
- Separate men's and women's grades, or a single unisex grade
- Children's grades from age 4 to 16 for school uniform programmes
- Regular and long lengths for trousers
- Custom grade rules to match your existing size chart so staff keep their usual size
- Size ratio proposals based on your employee list or on typical uniform distributions
§ 05Limitations
What this cannot do
Constraints stated up front are cheaper for both of us than constraints discovered in production.
LimitationsWhat this cannot do
- 01Sizes beyond 5XL and children's ranges are a separate grading block, sampled and quoted separately
- 02Grading cannot fix a base pattern that does not fit; the base size must be approved first
- 03A unisex grade fits less well at the smallest and largest sizes than separate gender grades
- 04Matching another supplier's size chart exactly may not be possible if their grade rules are unknown
- 05Grade rules differ by fabric; a grade for a rigid twill is not reused on a stretch knit without checking
- 06Size ratios based on a general population estimate will leave some staff without a fit; an employee list is more reliable
§ 06Quality
How it gets verified
- The graded nest is reviewed for jumps between sizes and for matching notch positions on adjoining seams
- Every size in the size set is laundered and measured, not only the base size
- Post-wash measurements are compared with the intended chart and the grade is adjusted where needed
- The size chart issued to the buyer is built from the measured samples, not from the paper pattern
- During bulk, garments from each size are measured against the chart at the points that matter for fit
Step 6 of 13
Where this sits in production
Every order runs through the same sequence. Each step has its own page, its own approval, and its own way of going wrong.
- 01Private Label Uniforms
- 02OEM / ODM Uniform Manufacturing
- 03Sample Development
- 04Fabric Sourcing
- 05Pattern Making & Fit
- 06Size Grading
- 07Logo Embroidery & Printing
- 08Labels, Name Badges & Packaging
- 09Bulk Production
- 10Quality Control
- 11Uniform Programme Management
- 12Uniform Design
- 13Plus Size & Extended Size Uniforms
← Before this
Pattern Making & Fit
Uniform pattern making: fit for movement, tuck-in body length, women's darts versus unisex blocks, and how a pattern is corrected from fit sample comments.
After this →
Logo Embroidery & Printing
Logo embroidery, screen print, heat transfer and DTF for uniforms. Digitising, stitch count, placement standards and per-employee name embroidery explained.
Related Uniforms
Products this applies to
Related Fabrics
Fabrics this affects
§ 08FAQ
Size Grading — common questions
Frequently asked15 Q
What is your minimum order quantity for custom uniforms?
Minimum order typically starts at 100 pcs per style; exact MOQ is quoted per project. The figure depends on the fabric, colour and level of customisation involved, so send us the style, quantity and branding you have in mind and we will confirm the MOQ in the quotation.
How long does bulk production take?
Lead time is quoted per project because it depends on fabric availability, order quantity and the amount of embroidery or printing per garment. Once the sample is approved and the order confirmed, the production schedule is confirmed in the quotation and we update you at fabric arrival, cutting and final inspection.
What size range do you produce, and do you grade children's sizes?
We grade adult sizes from XS through 5XL as standard and can extend the range on request. For school uniforms we also grade children's sizes by age or height band, using your existing size chart or one we develop with you during pattern making. Every size in the run is checked against the approved measurement chart before packing.
Do you make hi-vis, flame-retardant or certified protective clothing?
No. We do not manufacture certified PPE such as EN ISO 20471 hi-vis, flame-retardant, arc-flash or NFPA/ANSI-rated garments. What we do make is everyday workwear and uniforms, including corporate, hotel, restaurant, chef, housekeeping, retail and school uniforms, all with your branding applied.
Can we mix sizes and colours within the minimum order?
Mixing sizes within one style is normal and does not affect the MOQ. Mixing colours is usually possible too, but each colour needs its own fabric lot, so the per-colour quantity may be subject to a minimum. Minimum order typically starts at 100 pcs per style; exact MOQ is quoted per project, including any per-colour split.
Do you offer separate men's and women's fits?
Yes. Most of our uniform styles are patterned in both a men's and a women's fit, with differences in shoulder, chest, waist shaping and length, and we can also supply a unisex block if you prefer one chart for the whole team. We recommend including both fits in the sample round so staff can try them before you place the bulk order.
Can uniforms be colour-coded by department or role?
Yes. Colour coding is commonly done with different body colours, contrast collars or piping, sleeve tape, or a coloured department label at the chest or hem. Each colour variant is treated as a separate fabric lot, so let us know the department split when you request a quote and we will confirm minimums per variant.
Which fabrics do you keep in stock and which do you source to order?
We regularly run polycotton twill, cotton drill, pique, oxford, poplin, polyester-spandex, gabardine and fleece or softshell, and standard colours in these are usually available quickly. Special colours, weights or finishes are sourced to order from our mills, which adds fabric lead time that is confirmed in the quotation. Send us a swatch or a reference garment and we will tell you which route applies.
Can we re-order small top-up quantities for new staff?
Yes. Repeat orders are made against your sealed sample and the approved lab dips, so new garments match the original run. Top-up orders are subject to minimums quoted per project, and reserving fabric from the first run can make small repeats easier, so mention expected staff turnover when you place the initial order.
Can you pack uniforms per employee by name and size?
Yes. We can bag each employee's garments together, label the pack with name, department and size, and carton them by site or branch so your team can hand them out without re-sorting. We need the distribution list before packing starts, and any extra packaging cost is confirmed in the quotation.
How do you check quality during production?
Fabric is inspected on arrival for shade and defects, then a pilot run from bulk is measured and compared with the sealed sample before cutting continues. During sewing, inline checks cover seams, logo placement and measurements, and a final inspection is carried out on finished garments before packing. You are welcome to appoint a third-party inspection company, and we will arrange access.
Can we get a size set for a fit trial before bulk?
Yes. After the sample style is approved we can make a graded size set so staff of different builds can try them on before you finalise the size breakdown. The size set is charged per garment and quoted per project, and any measurement adjustments you request are applied to the pattern before bulk cutting.
Do you work with uniform distributors and brands?
Yes. A large part of our production is for uniform distributors and workwear brands who resell under their own labels. We can hold approved samples and lab dips on file, run repeat programmes for their end customers and ship blind or with the distributor's own packaging and documentation.
Do you make school uniforms with children's sizing and school crest embroidery?
Yes. We produce school polos, shirts, skirts and trousers graded across children's sizes by age or height, and embroider the school crest to your artwork. Blazers and jackets can be added to the same programme. Because school orders cover many sizes in small quantities, send the size breakdown early and we will confirm the MOQ per style in the quotation.
Do you ship worldwide, and which Incoterms do you use?
Yes. We ship to customers worldwide by sea, air or courier depending on the quantity and urgency. The shipping terms (for example EXW, FOB or CIF) and any freight estimate are agreed with you and confirmed in the quotation, and we can work with your own forwarder if you prefer.
Request for quotation
Need size grading for your project?
Send your product requirements and we will come back with a plan for this step and a quotation for the whole order.
What to sendRFQ
- 01Logo file (AI / PDF / PNG)
- 02Styles and colours
- 03Quantity per style
- 04Size range or headcount
- 05Deadline and destination
Minimum order typically starts at 100 pcs per style; exact MOQ is quoted per project.