The single most common complaint about a custom rugby order is that the shirts came up small. Usually they did not.

Player fit is a tactical pattern

A match jersey is cut close through the body and the sleeve because a loose shirt is something to hold on to. Less spare cloth means less for a tackler to grab.

It is meant to feel slightly tighter than a shirt you would choose in a shop, and players who have worn a proper one recognise it immediately.

Supporter fit is a different garment

Longer in the body, easier through the chest, and comfortable over a base layer on a cold touchline. It is what somebody buying a club shirt actually wants.

Sold the player fit instead, they conclude the sizing is wrong and send it back. That is not a manufacturing fault, it is the wrong pattern for the wearer.

Order both, off one artwork

The artwork is the same, so a second pattern costs almost nothing. Most clubs are surprised how much better the relaxed version sells in the shop.

Label them clearly in the shop and on any order form. Half the problem is that nobody was told there were two.

Sizing a whole squad or a whole school

For a squad, take chest measurements once and keep them; the reorder is then a spreadsheet. For a school, quote by age band with a stated chest and body length rather than S-M-L across four year groups.

Print the band on the label and on the bag. Distribution becomes a sorting job instead of a fitting session.