Size Set Sample: What It Is, Why You Need It

If you’re producing clothing for the first time (or scaling up), sizing can become your biggest headache. A sample that looks perfect in one size can turn into a disaster when you make the full size range. That’s exactly why Size Set Samples exist. A Size Set Sample is a set of samples made in multiple sizes (for example: XS, S, M, L, XL) so you can confirm the sizing is correct before bulk production. It helps you avoid expensive mistakes, refunds, and unhappy customers.

Types of Garment Samples In Garments Factory:

• Prototype Sample in Garment Production? (And How to Make One Step-by-Step)
• Fit Sample and Why You Need It in Garment Production.
• Size Set Sample: What It Is, Why You Need It.
• Counter Sample in Garment Manufacturing? (And Why Brand Owners Need It)
• Salesman Sample, And When Do You Really Need One?
• Pre-Production Sample (PP Sample) in Garment Manufacturing, and Why It Matters More Than You Think
• Top Production Sample (TOP Sample), and Why Brand Owners Actually Need It
• Shipment Sample in Garment Manufacturing?

What Is a Size Set Sample?

A Size Set Sample is a group of garments sewn in different sizes from your size chart, using the same approved design and construction. Instead of testing only one sample size (like “M”), you test the whole range. This lets you check whether:

• Each size matches the size chart measurements
• The size jumps between sizes are logical and consistent
• The garment keeps the same shape and proportions across sizes

Size Set Sample vs Fit Sample (Don’t Mix These Up)

Many small brands confuse these two:

• Fit Sample = checks how the garment fits in one size (often your base size, like S or M)
• Size Set Sample = checks if sizing is correct across multiple sizes

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Key idea:

• Fit Sample answers: “Does this garment fit well in size M?”
• Size Set answers: “Do ALL sizes fit and grade correctly from XS to XL?”

Why Size Set Samples Matter for Small Brands

1) Sizing mistakes are expensive

If you produce 300–1,000 pcs and discover size problems after bulk, you may face:

• Returns and exchanges
• Bad reviews (“Sizing is inconsistent”)
• Discounts to move unsellable stock
• Rework costs or even canceled orders

A Size Set Sample is cheaper than fixing bulk mistakes.

2) Your customers judge your brand by sizing consistency

Even if your product looks great, inconsistent sizing will ruin trust fast.

Customers remember:

• “Their small fits like a medium”
• “Their sizes change depending on color/style”

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Size Set helps you build a reliable size reputation.

3) It helps you confirm your size chart is realistic

Sometimes the issue is not the factory, it’s the brand’s size chart.

Size Set gives you a chance to confirm:

• Are your measurements achievable?
• Do the sizes “step” correctly?
• Do proportions still look good in bigger/smaller sizes?

When Do You Need a Size Set Sample?

You should request a Size Set Sample when:

• You are producing multiple sizes: If your order includes XS–XL or S–XXL, you need it.
• It’s a fitted style. Examples: Tailored pants, Bodycon dresses, Structured blazers, Shirts with precise shoulder/chest fit. The more fitted the garment, the higher the risk.
• New pattern / new factory / new fabric – Size behavior can change when: Fabric has more stretch, Shrinkage is different after wash, Construction method changes, Pattern maker is different
• You plan to scale production: If you plan to reorder or grow the brand, Size Set becomes your quality “checkpoint.”

What Sizes Should You Include in a Size Set Sample?

Small brands don’t always need every size. A smart approach:

• Minimum: smallest + base + largest – Example: XS, M, XL
• Better: full range if budget allows – Example: XS, S, M, L, XL

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If your brand sells plus sizes, include your highest size, because that’s where grading mistakes show up most clearly.

The Size Set Sample Process (Step-by-Step)

Size problems in bulk are expensive. A Size Set Sample is your chance to catch grading and measurement issues early, when fixes are still fast and affordable. Here’s the step-by-step process from using the approved Fit Sample as the base, to reviewing measurements and giving clear feedback so you can approve sizes with confidence. Here’s the typical workflow, explained simply.

Step 1: Approve your Fit Sample first

You should not jump into Size Set until your Fit Sample is confirmed. Because Size Set uses the approved fit as the “base.”

Step 2: Confirm your size chart + measurement method

Before making Size Set, make sure everyone measures the same way. Examples of measurement confusion:

• Chest measured “flat” vs “around”
• Waist at natural waist vs garment waistline
• Inseam vs outseam mixing

Tip: Ask for a measurement guide or “how to measure” page in your tech pack.

Step 3: Factory grades the pattern (grading)

Grading means scaling the base pattern into different sizes. This is where many problems happen for small brands:

• Sizes increase too much in width but not length
• Armholes become too tight
• Shoulder slope changes incorrectly

Step 4: Factory sews samples in each size

This is the actual Size Set Sample. Ideally, they use:

• Correct fabric (or as close as possible)
• Correct trims (or close substitutes if not ready)

Step 5: Brand checks measurements + fit logic

This is your job as the brand owner. You should check two things:

A) Measurement accuracy

• Does each size match your size chart?
• Are tolerances acceptable?

B) Grading logic

• Does the shape look consistent?
• Do larger sizes look like the same style, just bigger?

Step 6: Feedback and correction (if needed)

If something is wrong, the factory should adjust:

• The pattern grading
• The size chart (if the chart is unrealistic)
• Construction details affecting measurement

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Only after Size Set is approved should you move to:

• PPS (Pre-Production Sample) or bulk production

What Should You Check on a Size Set Sample?

Once you receive your Size Set Samples, don’t rush to approve them just because the stitching looks nice. This is the stage where you confirm that each size matches your size chart and that the shape stays consistent from the smallest size to the largest. In the checklist below, you’ll see exactly what to measure, what to compare, and what problems to look for before bulk production.

Here’s a simple checklist for small brands:

• Measurement
• Proportion
• Fabric behavior

Measurement checklist (most common points)

• Chest
• Waist
• Hip
• Shoulder width
• Sleeve length
• Body length
• Hem opening
• Rise / inseam / outseam (for pants)

Proportion checklist (often ignored but critical)

• Neck opening feels consistent across sizes
• Armholes don’t get too tight in bigger sizes
• Sleeves don’t become oddly wide or short
• The garment still looks “balanced”

Fabric behavior checklist

If the style is washed or heat-processed, be careful:

• Shrinkage can change sizing
• Stretch fabric can “grow” after wear

If your garment will be washed, consider testing a washed sample or shrinkage calculation.

Common Size Set Mistakes Small Brands Make

Even when a factory delivers a full Size Set, small brands can still end up with sizing problems because the review step is rushed or inconsistent. The mistakes below are the most common reasons brands approve a Size Set too early leading to costly rework, returns, and unhappy customers.

• Mistake 1: Skipping Size Set to save money. This often costs more later through returns, rework, and reputation damage.
• Mistake 2: Only checking measurements, not proportions. A size can “match the chart” and still look wrong. Example: sleeve opening becomes too large in XL, making the style look sloppy.
• Mistake 3: Using the wrong base size. If your base fit is weak, grading will multiply the problem.
• Mistake 4: Unclear measurement method. If you and the factory measure differently, your feedback becomes messy and slow.

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Final Thoughts / Conclusion

A Size Set Sample may feel like an “extra step,” especially for small brands trying to save time and budget. But here’s the honest truth: skipping or rushing Size Set is one of the most expensive ways to learn sizing lessons. If sizing goes wrong in bulk, you don’t just lose money you lose customer trust, and that’s harder to win back. A Size Set Sample is one of the best “insurance steps” in apparel production, especially for small brands. It helps you confirm that:

• Your sizing is consistent
• Grading is correct
• Customers will receive reliable sizes
• Bulk production won’t turn into a costly mistake

If you want your brand to grow, don’t treat Size Set as optional. Treat it as the step that protects your quality and your reputation.