Plus Size and Tall Custom Shirt Sizing: What Vendors Can Offer

A custom shirt shop that only offers small through extra-large is turning away a meaningful share of potential customers before they ever get to checkout. Plus size and tall sizing questions come up constantly because most people do not fit neatly into a narrow standard range. Here is what extended sizing actually looks like in a print on demand catalog and how to offer it without adding any inventory risk.

What Plus Size and Big and Tall Sizing Actually Covers

• Plus size (width): Extended chest and waist measurements beyond the standard small-to-extra-large range, typically labeled 2XL through 5XL depending on the style.
• Tall (length): A longer body and sleeve length for taller frames, built on a separate cut rather than just a bigger version of the standard size.
• Big and tall: Combines both extended width and extended length in the same garment.

The Hanes Premium Tall Tee

Product	Brand	Free base	VIP base
Premium Tall Tee	Hanes	$31.95	$25.88

This is a dedicated tall-cut style built for a longer torso, not a standard tee stretched to a bigger size number. Vendors serving a customer base with a wide range of builds, from sports teams to community organizations, can list this alongside standard cuts to cover more of their audience.

Bear Grips Pro Shops: Custom Apparel for Your Team. No Minimums. Free Shipping.

How Far Standard Unisex Styles Extend

Most unisex tees, hoodies, and crewnecks in a general apparel catalog run from small through 3XL or larger, depending on the specific garment. This covers a substantial part of the plus size range for width without needing a separate style, though the fit through the shoulders and body stays proportional to the standard cut rather than a dedicated big-and-tall pattern. Vendors who want the closest fit for larger frames should look specifically for pieces described as extending to 4XL or 5XL, or a dedicated tall style like the Hanes tee above.

Why Offering Extended Sizing Widens a Shop's Reach

A shop that stops at extra-large is invisible to a meaningful share of potential buyers before they even see the design. Because single-piece printing has no minimum, offering the full size range a garment supports costs nothing extra to list. Nobody has to pre-buy or guess at a size breakdown; each size only prints when someone actually orders it. See the size chart guide for how the rest of the sizing scale is laid out.

Frequently Asked Questions

Does the catalog include a tall-specific shirt?

Yes. The Hanes Premium Tall Tee is built specifically for longer torsos and runs $25.88 VIP base, separate from the standard-cut tees.

How large do standard unisex shirts run?

Most unisex styles extend through 3XL or larger depending on the specific product, covering a substantial part of the plus size range.

Is there an extra cost to offer plus size or tall options?

No. Because there is no minimum order requirement, listing the full size range a garment supports costs nothing extra since nothing prints until a specific size is ordered.

Should a shop stock every size from small to 5XL?

Most shops list every size a given garment style supports since single-piece printing removes any inventory downside to doing so.