THERMAL VS. DIRECT THERMAL PRINTING

WHAT’S THE DIFFERENCE?

In simplest terms, thermal transfer printing utilizes a thermal ribbon and direct thermal printing does not.

THERMAL TRANSFER (TT):

Thermal transfer involves the thermal printhead elements (dots) heating the backside of a thermal transfer ribbon to melt and transfer the compounds on the front side of the ribbon to the label material, thus creating the printed image.

DIRECT TRANSFER (DT):

Direct thermal printing requires a heat sensitive paper or film material. The thermal printhead elements come in direct contact with the heat sensitive label material, where the heat from the elements cause a color change in the material to create the printed image.

Thermal Transfer Printing

THERMAL TRANSFER PRINTING

Direct Thermal Printing

DIRECT THERMAL PRINTING

THERMAL TRANSFER (TT):

ADVANTAGES

  • Long life of printed text and images.
  • Printed text and images do not fade in direct sunlight and are far more heat tolerant.
  • Availability of colored ribbons to choose from.
  • You typically have a longer printhead life.
  • Wide selection of labels to choose from.
  • You are able to print on Thermal Printable overlams and varnishes.
  • Good chemical resistance with some materials.

DISADVANTAGES

  • Operators must perform ribbon change-overs.
  • More mechanical parts in a combo printer means potential for more downtime and mechanical failures.
  • Opportunity for print quality problems due to mismatched labels and ribbon.
  • Opportunity for print quality problems due to incorrect ribbon adjustments.

DIRECT THERMAL (DT):

  • Simplified operator intervention; no ribbon to load or ribbon adjustments to make.
  • No potential ribbon wrinkle problems.
  • No mechanical failures associated with ribbon drive mechanisms. (When using a Direct Thermal only printer)
  • Fewer inventory items due to lack of ribbon and fewer spare parts.
  • No ribbon disposal.
  • Typically, slower print speeds.
  • Reduced thermal printhead life.
  • Will fade or “yellow” over extended periods of time.
  • Label will darken when exposed to extreme heat and direct sunlight.
  • Specialty material (i.e. direct thermal films) can be costly.
  • Limited selection of label material.
  • Limited chemical resistance.

So, what’s the best option to fit your label needs?

THERMAL TRANSFER

  • The label life will be greater than 1 year.
  • The label could be exposed to continuous sunlight.
  • The label could be exposed to high temperatures.
  • The label could be subjected to chemicals or abrasives.
  • You will be printing high density barcodes.
  • You may want to print on a variety of different label types, such as papers, films and foils.
  • You may want to print in colors other than black.

DIRECT THERMAL

  • The label life is less than 1 year.
  • The label will not be exposed to continuous sunlight.
  • The label will not be exposed for high temperatures.
  • The label will not be exposed to harsh environmental conditions.
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