Direct thermal printing is broadly used by a number of industries to create barcode labels for multiple applications. Like
thermal transfer printing, it uses heat generated from a print head to create an image. However, direct thermal printing differs from thermal transfer in that it doesn't use ribbons, ink, or toner to print images on labels.
How does direct thermal printing work?
Direct thermal printing uses chemically treated, heat-sensitive media that turns black when it passes under a heated print head. This creates an image directly on the printed material without the need for ink, toner, or ribbons.
Direct thermal labels are typically used for applications requiring a short shelf life because they become unreadable when exposed to heat, long periods of direct sunlight, and abrasion. However, many thermal labels can last for months under the right conditions.
Benefits of direct thermal printing
Zebra designed its RW 420 direct thermal printer to withstand the hazards of the road. This mobile workhorse is ideal for printing receipts, invoices, and labels.
Direct thermal has several advantages, including:
Simple to use
- Prints directly onto the label material
- No ribbons, toner, or ink required
- Perfect for mobile printing applications
Good scanner readability and scannability
- Sharp, quality images
- Easy to scan
- Provides ample lifespan for many common barcode printing applications
Affordable
- Typically costs less to operate than thermal transfer printing
- Lower long-term maintenance costs because of minimal replacement supplies
- Virtually no waste due to batch or single-label print options
- Recyclable labeling materials available
Limitations of direct thermal printing
While a popular option for many companies, direct thermal printing has some limitations, including:
Sensitivity to environmental conditions
- Can fade over time
- Overexposure to heat or light darkens materials, making the barcode unreadable
- Doesn’t withstand abrasion
- Readability varies greatly depending on usage conditions
Usability issues
- Less rugged than thermal transfer labels
- Best for short-term applications
- Not recommended for lifetime identification applications
Ideal applications for direct thermal printing
Because of their shorter shelf life and good print quality, direct thermal labels are used for a variety of purposes, including:
- Shipping labels
- Compliance labels
- Receipts
- Pick tickets
- Invoices
- Patient wristbands
- Coupons
- Event tickets
- Citations
- Parking tickets
- Name tags
- Visitor passes
Not sure whether to use direct thermal or thermal transfer printing?
Compare the two print technologies.
