Size is the first decision and the one most people skip, which is why so many bandanas end up in a drawer rather than on a head.

22 inches: the classic

The format the category is built on. It ties around a neck, a wrist, a bag strap or a dog comfortably, folds small, and is the cheapest square to produce at volume.

Where it struggles is as a full head covering. It ties, but it pulls tight and sits high, and people who wear one all day notice within an hour.

27 inches: the wearable

Five extra inches turns the square into a garment. It ties as a proper head wrap, folds into a real neck scarf, and drapes over a shoulder. It is also considerably more comfortable to wear for a full shift.

It costs more per piece and it is worth it whenever the bandana is bought deliberately rather than handed out.

What size does to artwork

At 22 inches, artwork competes with a knot and a fold almost immediately, so the design has to survive being seen in fragments. At 27 the pattern has room to read as a pattern, which is why retail pieces and paisley designs almost always want the larger square.

A rule that works

Handed out: 22. Bought, worn all day, or the pattern is the product: 27. If you are doing both — a giveaway square and a retail square — order them together and save a setup.