What is Better: Direct Thermal or Thermal Transfer?


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Most people don’t know which is better: direct thermal or thermal transfer? But then, everyone wants to get the best thermal printing solution for their label applications. We don’t want you to spend money on any equipment that will not meet your needs satisfactorily. So, in this article, we will show you the thermal printer type you need if you want to spend less, worry less, and meet your printing needs.

What is better: direct thermal or thermal transfer? Thermal transfer is the better option for companies dealing in long-life products and manufactured goods that require resistance to friction, dampness, and temperature changes. But direct thermal is the better option for companies dealing in perishable goods (1 year and below) because the labels are not long-lasting.

As you can see, there is no “one answer fits all” when it comes to thermal printers. The better option between direct thermal and thermal transfer would depend on your printing applications. As you read on, we will show you all the variables that you must consider to get the best thermal printer for your needs.

What is Better: Direct Thermal or Thermal Transfer

How To Choose The Better Option Between Direct Thermal And Thermal Transfer

To know the better option between direct thermal and thermal transfer printers, you need to ask four important questions. These questions are centered around the type of label you’re printing, the required durability for your labels, your preferences, and color limitations.

The process of making a decision may seem complex and confusing if you don’t know the right questions to ask. These four (4) basic questions we will show you will help simplify the process of deciding the better option between direct thermal and thermal transfer.

Four Questions To Ask

  • Does your printing application need durable imprints that can resist external influences?
  • Do you have a preference for label materials that contain potentially toxic substances, such as BPA and BPS?
  • Will you, at any time, need to use different types of label materials, synthetics, textiles, or cards?
  • Do you want the option of printing in other colors apart from just black?

If your answer is YES to any of the four questions above, you should go for a thermal transfer printer. But if all your answers are NO, a direct thermal printer will be a better printing option.

Direct Thermal vs. Thermal Transfer: Which Is Better?

Generally, thermal transfer seems to have better print quality and offers more flexibility than direct thermal. Thermal transfer labels also last longer. However, some printing applications do not require the durability, print quality, and flexibility that thermal transfer printing offers. Direct thermal printing offers a cheaper and more affordable solution for such applications.

So then, after you have asked the questions above, you would also need to consider a few other factors before you finally decide on which option is better for you. As you read on, we will show you these factors.

What To Consider In Choosing Between Direct Thermal vs. Thermal Transfer

In choosing between direct thermal and thermal transfer printing, you must consider the cost implications. You must also consider the lifespan of the printer and compare it with your printing environment. Thermal transfer printers are costlier but their printheads often last longer.

Here are three major factors to consider when you are deciding between direct thermal and thermal transfer:

Upfront and Running Costs

Thermal transfer printers generally cost more than direct thermal but you should look beyond this upfront cost before you make your final decision. You should also consider the running costs you would incur from buying printing supplies, among other things.

Thermal transfer printers require ribbons, and that would be an extra cost. But with direct thermal, you wouldn’t have to buy ribbons. However, direct thermal labels are more expensive than thermal transfer labels. You should consider your budget before you decide which option is the better one for you.

Printhead Lifespan

Thermal transfer printheads often last longer than direct thermal printheads, sometimes twice to four times as long.  This is mainly because of the constant friction between the label material and printhead elements in direct thermal printers. This causes the elements to wear out faster. Also, debris from label materials can accumulate on the printhead and damage it over time.

In thermal transfer printing, the ribbon protects the printhead elements from abrasion. And since the printhead does not directly touch the label, there is no risk of debris from the label accumulating on the printhead. You should consider the printhead lifespan because printheads are expensive.

Printing Environment

If you print in an indoor environment where you can control the temperatures manually, direct thermal printers would be ideal. But they don’t work too well in outdoor environments because of heat exposure and direct sunlight. You should not use direct thermal printers in the kitchen because the environment is not conducive to its operation.

Thermal transfer printers are better if your printing environment is rugged. They are suitable for both indoor and outdoor environments and can withstand extreme temperatures.

✅ Video – Direct Thermal vs. Thermal Transfer Printing

This video will refresh your memory on many of the things you have read in this article and make the information stick well. You will learn the differences between direct thermal and thermal transfer printing, as well as the different applications they are suitable for.

Direct Thermal vs. Thermal Transfer

Both methods offer crisp and quality prints but each option works differently and has its suitability. The ideal printing applications of the direct thermal mechanism are those that require good quality but only a short lifespan. Conversely, the ideal printing applications of the thermal transfer mechanism are those that require high quality and durability.

The direct thermal mechanism produces imprints when the label comes in contact directly with the thermal printhead. The heat from the printhead elements activates the label’s heat-sensitive dye to produce imprints.

The thermal transfer mechanism, on the other hand, produces imprints by using thermal transfer ribbons. The heat from the thermal printhead elements melt the ribbon’s ink and deposit it on the label to produce imprints.

Differences in Suitability

Here’s what each thermal printer type is suitable. This list should serve as a basic guide in deciding which option will work best for you:

The Suitability of Direct Thermal

You should use direct thermal printers if:

  • The label does not require archiving, typically if you need it for 1 year and below.
  • There will be no regular exposure to sunlight, typically indoor applications.
  • There will be no exposure to high-temperature conditions and harsh chemicals.

The Suitability of Thermal Transfer

You should use thermal transfer printers if:

  • The label requires archiving, typically long-term applications (1 year and beyond).
  • There could be regular exposure to sunlight and high temperatures.
  • The label would come in contact with abrasives or chemicals.
  • Your printing needs include high-density barcodes.
  • There is a need for various media, including papers, foils, and films.
  • You would need to print in other colors apart from black.

Differences in Applications

Some of the applications of direct thermal and thermal transfer printers overlap. But we have made this list based on the most suitable mechanism for each application.

Direct Thermal Printing Applications

Examples of direct thermal applications are as follows:

  • Barcodes and shipping labels
  • Parking tickets
  • Visitor passes
  • Hospital wristbands
  • Compliance labels
  • Event tickets
  • Receipts
  • Name tags
  • Invoices
  • Pick tickets
  • Coupons
  • Citations

Thermal Transfer Printing Applications

Examples of thermal transfer applications are as follows:

  • Inventory Identification
  • File tracking
  • Sample tracking
  • Product identification
  • Cold storage
  • Asset tagging
  • Certification labels
  • Permanent identification
  • Laboratory specimens

Related Questions

How Long Do Direct Thermal Labels Last?

The image life of direct thermal labels is usually between 6 months to 1 year. How long the label would last depends on its exposure to light, heat, and moisture. But even if you guard against these factors, the label would hardly last more than 12 months.

Direct thermal labels would either fade or darken over time. They are built for short-term applications so don’t expect them to last forever. If you are looking for a permanent printing solution that can withstand extreme elements and conditions, you should use thermal transfer labels.

Do You Need Ink for A Thermal Printer?

You don’t need ink for thermal printers. They use neither ink cartridges nor toners, so you can save costs on buying ink supplies. Thermal papers are, however, a bit more expensive than the regular printing paper.

Instead of ink, thermal printers use heat from their printheads to make imprints on labels. Direct thermal labels contain heat-activated ink pigments while thermal transfer printers use ribbons that melt under heat to make imprints on thermal transfer labels.

Can You Use Regular Paper In A Thermal Printer?

Regular papers are made for ink-based printing, so they would not work well if you use them in thermal printers. Thermal papers are made for thermal printers, so that’s what you should use in your thermal printer.

In the same vein, you should not attempt to use thermal papers in your normal printer. Thermal papers were not designed to absorb ink, so if you use them in your regular ink-based printer, the ink is likely to smear. More so, your print quality would be poor. For the best print quality, you must match the printer and paper correctly.

Conclusion

As you have seen from this article, the better option between direct thermal and thermal transfer depends on what your business requires. Thermal transfer will give you better quality but the printers cost more to buy. Direct thermal offers a cheaper solution but you might incur a higher running cost from printhead replacement.

If you want imprints that would last beyond 1 year, you should use thermal transfer. But if the label is only for a short-term use, direct thermal would do just fine. In the end, once you know what you need the printer for, you can easily decide which type would satisfy your needs. Just make sure you ask the right questions and consider the key factors before you make a final decision. 

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