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Why Do So Many Customers Order the Wrong Size From My Print on Demand Shop?

Print on demand size charts go wrong when blanks change or partners differ. We build size charts from each blank's real data and track wrong-size returns.

Updated 3 min readBy SpiderHunts Technologies

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Quick answer — TL;DR

Wrong-size orders are expensive in print on demand because a printed garment cannot be restocked, and they often come from size charts that no longer match the blank being printed. We build size charts generated from each partner's blank data, attach the right chart to each listing and variant, update them when blanks or routing change, and track wrong-size claims by product so you can fix the listing, not just refund.

'It came up two sizes small'

A customer ordered your women's fit T-shirt in a medium and says it is far too small. You check the listing's size chart. It is the chart for the unisex blank you used when you first listed it. Since then, you added a women's fit option, and the chart was never changed. Another customer's hoodie was printed by your second partner, whose blank runs smaller than the first partner's, and the chart on the listing is from the first.

You offer a replacement in a larger size. The first shirt goes in the bin, or to the customer to keep. Either way, you paid for two prints.

Size charts are copied, blanks change

Size charts are usually added once, as an image or a table, when a listing is created. The blank behind the listing keeps changing.

  • One listing can offer several fits, each with different measurements.
  • Different partners print the same product type on different blanks.
  • Partners replace blanks with other brands with different sizing.
  • Size charts are images, so they cannot be updated in bulk.
  • Charts show measurements in one unit when customers think in another.

So the chart a customer reads can describe a garment they will not receive.

What wrong sizes cost

Every wrong-size order costs a second print and shipping, and the first garment has no resale value because it is printed. On marketplaces, a return counts against you. Customers who get the wrong size once are less likely to order again. Most sellers absorb these costs without knowing how many are caused by the chart rather than the customer.

Time goes into each exchange: messages, a new order, sometimes a return label.

The size chart system we build

  1. Size measurements are pulled for every blank you use from each partner's product data, or entered from their size guides where no API provides them.
  2. Each listing variant is linked to the blank it prints on, including the partner that routing will send it to.
  3. Size charts are generated from that data, in your style, with both centimetres and inches, and added to each listing.
  4. When a blank is replaced or routing moves a product to a different partner, the affected charts update and you are told if the sizing changes noticeably.
  5. Wrong-size claims are recorded with product, size ordered and size wanted.
  6. A monthly list shows which products attract the most wrong-size claims, so you can check the chart or add a fit note.
SituationWhat changesWhat you see
New fit added to a listingSeparate chart for that fitChart added to the variant
Partner replaces a blankMeasurements updatedAlert if sizing shifts
Routing moves a productChart follows the new blankAlert if charts differ
Many wrong-size claimsProduct flaggedReview chart and fit note

Your exchange policy stays yours. The system makes sure the information customers read matches what they will receive.

Charts that match the garment

Every listing shows a chart for the blank that will actually be printed. When a partner changes a blank, you get a note showing the differences and the charts update. When wrong-size claims pile up on one product, you see it in the monthly list and add a note like 'runs small, consider sizing up'.

The exchanges that remain are genuine customer choices, not the result of an out-of-date chart.

Signs your size charts are out of date

  • Size charts are images added when the listing was made.
  • Different fits on a listing share one chart.
  • You use more than one partner for the same product type.
  • Wrong-size claims are common and not tracked by product.
  • Your charts show one unit of measurement only.

FAQ

Frequently asked questions

The questions readers ask us after this guide.

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Can every channel show a generated chart?

Most accept an image or text in the description. The chart is produced in the format each channel supports.

Where do the measurements come from?

From each partner's product data or published size guides. Where they differ from what customers experience, you can add your own notes.

Will this stop all wrong-size orders?

No. It removes the ones caused by wrong information. Customers will still sometimes choose the wrong size.

Does it handle exchanges?

It records the claims. Exchanges can be handled by the misprint claims flow if you use it, or your current process.

What drives the cost?

How many blanks and partners you use, how many listings need charts and your channels.

Keep reading

More on Problems We Solve

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