What Is The Difference Between Direct Thermal And Thermal Transfer?


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You may know some of the differences between direct thermal and thermal transfer printing already. But this comprehensive article will give you a better view of these two types of thermal printing techniques. How are they similar? Where do they differ? Which one is best for you? We have all the facts and we am willing to share them with you.

What is the difference between direct thermal and thermal transfer? Direct thermal printers print directly on thermal papers. Thermal transfer printers, on the other hand transfer imprints from thermal ribbons to thermal transfer papers. The labels used by direct thermal papers have heat-sensitive chemicals, that turn dark during printing. Conversely, thermal transfer printers use melted pigments from thermal ribbons to create long-lasting imprints on label materials.

As you can see, both methods differ slightly in how they work. But that’s not all there is to the differences between the two thermal printing mechanisms. Each method has certain properties that make it different. We’ll take a look at these properties in the sections that follow.

Difference Between Direct Thermal And Thermal Transfer

What You Should Know About Direct Thermal Printers

The cost-effectiveness and simplicity of direct thermal printers set them apart. The only inventory you need are thermal label rolls. The printers use neither ink cartridges nor ribbons. But then, labels printed with direct thermal printers often have a short shelf-life, especially if you expose them to abrasion, heat, or direct sunlight. Because of this, people don’t use direct thermal printers for permanent applications.

The clarity and durability of labels that you will get from direct thermal printers vary. Clarity depends on the model of printer you are using and the settings you apply. Durability, on the other hand, depends on how you handle and use the label.

How Do Direct Thermal Printers Work?

The labels used in direct thermal printers have a layer of heat-sensitive ink pigments. So this mechanism requires no toner, ribbon, or ink. Direct heat from the thermal printhead activates these pigments and causes images to form on the thermal label. The printhead applies heat only on areas where your design requires imprints on the thermal paper.

Advantages of Direct Thermal Printing

Here are some of the advantages of using direct thermal printers:

  • Direct thermal technique is ideal for short-term printing applications, such as receipts and shipping labels.
  • The printers are easy to operate because you don’t have to replenish inks or move different parts. All you need do is buy thermal paper rolls for your printing.
  • Since you don’t have to buy any other printing supplies aside from thermal papers, the printers are cheap to maintain long-term.
  • In the direct thermal technique, you can print single labels or print in batches. There’s no room for unnecessary waste.
  • Direct thermal printing is friendly for the environment because recyclable materials are available.

Limitations of Direct Thermal Printing

Here are a few downsides of direct thermal printers:

  • The labels are very sensitive to heat, direct sunlight, and other environmental conditions.
  • Even after printing, the ink pigments in the unprinted areas of the paper remain chemically active and can turn black if proper storage and handling measures are not set in place.
  • Without a special top-coating, direct thermal papers can damage from exposure to UV light, abrasion, water exposure, and chemicals.

What You Should Know About Thermal Transfer Printers

Thermal transfer printers prints on labels that have a crisp, glossy printing surface. But aside from thermal transfer labels, these printers also require thermal ribbons to make imprints. Overall, thermal transfer printers produce clear images that could last much longer than direct thermal labels.

Thermal transfer printers are more expensive than direct thermal printers. They also require more inventory than direct thermals. But you will get better quality labels that are more durable. What’s more, thermal transfer printers can print on diverse kinds of synthetic media, include plastic and polyethylene labels.

How Do Thermal Transfer Printers Work?

Thermal transfer printers make clear prints on thermal transfer labels using thin ribbon rolls. The pigment material on these ribbons melt and adhere to the label when heated. So the printhead does not directly apply heat to the label. It applies heat to the ribbon instead and melts its pigments onto the label.

Typical applications of thermal transfer include permanent identification, asset tagging, product identification, and certification labels, among others. The technique is also suitable for laboratory specimens and several outdoor applications.

The lifespan of your label often depends on the type of thermal transfer ribbon you are using and how well it’s suitable for the media or print material you’re using. If you use a wax ribbon, it will only stay on the surface of your label material. But resin ribbon sinks into the material and becomes a part of it. So wax ribbons usually have a shorter lifespan than resin ribbons.

How Do You Match Thermal Ribbons Properly With Print Media

Wax ribbons are only ideal for paper media. Wax-resin ribbons can be used for synthetic media. But they are more appropriate to use them for paper media. Resin ribbons are the most suitable for synthetic media but you can use them for printing on paper media too.

Thermal transfer printers will only give you optimal print quality when you match the ribbon with an appropriate media substrate. If the media substrate is not compatible with the ribbon, you’ll get a poor output and your printer might develop internal problems. If you select the proper ribbon-media combination, you’ll produce long-lasting labels that can withstand ultraviolet exposure, harsh chemicals, extreme temperatures, and sterilization.

Advantages of Thermal Transfer Printing

Here are some of the advantages of using thermal transfer printers:

  • Thermal transfer labels are often resistant to moisture and heat, so the images are durable. They offer better durability and quality than all other on-demand technologies.
  • Thermal transfer printers deliver high-definition graphics, texts, and barcodes for maximum scannability and readability.
  • Thermal transfer accommodates a wide range of print media stock, including many that are not available in direct thermal printing.
  • They are reliable for both office and industrial-grade applications
  • Thermal transfer printheads typically have a longer lifespan than direct thermal printheads because the ribbon functions as a buffer to prevent the abrasion of the printhead elements.

Limitations of Thermal Transfer Printing

Here are a few downsides of thermal transfer:

  • Thermal transfer mechanism requires the purchase of ribbons. This adds to the cost of supply and maintenance.
  • You can end up wasting single-pass ribbons if your print is scanty. With single-pass ribbons, you can only print a specific number of sheets with each roll of ribbon, regardless of how scanty or full the print on each page is.
  • Thermal ribbons are typically not good for recycling.

Thermal Transfer Labels vs. Direct Thermal Labels

Thermal transfer and direct transfer techniques do not use the same kinds of labels. And you can’t use the labels meant for one technique on the other. Thermal transfer labels will not work on direct thermal printers because they don’t have an ink layer. Conversely, direct thermal labels will print poor images on thermal transfer printers because ribbons are not designed to work on them.

Let’s take a closer look at both types:

Thermal Transfer Label

This label type requires ribbons when printing. You would feed both the ribbon and the labels into the printer. Then the printhead would heat the ribbon and melt its wax or resin on the label. You can get ribbons in black and various other colors.

Direct Thermal Label

This label type doesn’t need ribbons, so you only have to feed the papers into your printer. The printhead would heat the paper directly as it runs through the machine. Chemical reactions in the label stock are responsible for the creation of imprints in direct thermal printing. Most receipts use direct thermal labels.

How to Differentiate the Two Thermal Label Types

A simple scratch test can help you differentiate direct thermal from thermal transfer labels. Scratch the label with your nails like you’ll light a match. Do two or three hard strikes and see if you notice any dark mark of the label. The presence of a dark mark indicates direct thermal while its absence indicates thermal transfer.

✅ Video – Direct Thermal & Thermal Transfer Differences

This video illustrates everything you need to know about direct thermal and thermal transfer printing techniques. It demonstrates how to do the scratch test and what happens when you direct heat from a dryer to the thermal transfer label.

Related Questions

Which One Is The Better, Direct Thermal or Thermal Transfer?

You can count on thermal transfer labels if you’re looking for durability. But for cost-effectiveness, direct thermal would be your best bet. So your printing need would determine the best technique for you.

Thermal transfer prints last longer because they can withstand moisture, UV exposure, and abrasion. Direct thermal prints do not have these qualities. If you want a short-term cheap printing solution, go for direct thermal. But if you are looking for a long-lasting printing solution, go for thermal transfer.

Can A Thermal Printer Print Color?

Thermal transfer machines can print more colors than direct thermal. Most direct thermal labels can print only one color (black) but thermal transfer ribbons come in different colors. However, when you print with color ribbon, all your texts, logo, and graphics would be in that color.

Some new models of direct thermal printers now offer a two-color orienting system. In these printers, the printhead uses different heat levels to produce different colors. Besides, there are newer models with as much as 5 colors but they are quite expensive.

How Can I Stop Receipts From Fading?

Proper storage is the only way to make your thermal receipts last long. If you store your thermal receipts properly, they can last up to one year. The proper storage conditions for thermal labels include keeping them away from direct sunlight, heat, UV light, and plastic sleeves.

Heat and moisture are the two major reasons why thermal receipts fade quickly. If you can keep your receipts away from these two factors, they would last longer.

Conclusion

Direct thermal and thermal transfer mechanisms share lots of similarities but they also have major differences. More so, they are suitable for different applications. Before you settle for either option, compare its properties with your printing needs. That way, you’ll be able to choose the best option for you.

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