How Does A Thermal Printer Work

A thermal printer is a type of computer printer which creates the printed output by the use of heat. These printers have no ink cartridges and instead rely on heated printheads.

It contains a roll of thermochromic paper which is coated with microcapsules filled with a dye precursor, wax, carbon powder or other coloring material. As heat is applied, the dye precursor is converted to a colored form, making it visible.

This article contains information on how does a thermal printer work and its pros and cons.

Components Of Thermal Printers

There are different types of thermal printer but almost all of them operate on the same principle. A thermal printer contains three basic components.

The uppermost layer (or printhead) consists of closely-spaced heating elements that can quickly melt the coloring material. This layer is removable and replaceable, allowing for different thermal heads to be used with the printer depending on what kind of printing needs to be done (text, graphics or images).

The middle layer (or platen) contains a smooth roller that allows paper to pass through smoothly while preventing it from curling as it exits the printer.

The bottom layer (or paper supply spool) contains the supply of blank thermal papers that feed through the center of the platen to be printed on by the printhead. The rolled thermochromic paper is usually coated with microcapsules filled with a dye precursor, wax, carbon powder or other coloring material. As heat is applied, the dye precursor is converted to a colored form, making it visible.

How Does A Thermal Printer Work- The Working Principle

There are two types of thermal printers. We’ll discuss their working principle below-

1. Thermal Transfer Printing

Thermal transfer printers use a special printhead that heats up the thermochromic paper with the help of thermal energy.

The heat is applied to melt the dye precursor inside each microcapsule, which produces different colors depending upon the dye used. This layer is then transferred onto plain paper by pressing it against an inked ribbon.

The process of transferring the dye to paper is known as thermal transfer.

2. Direct Thermal Printing

In direct thermal printing, the dye precursor doesn’t need to be melted and transferred onto paper. It is directly converted into a colored form as it reaches the printhead, which then transfers it to plain paper.

There are no heating rods involved in this process of converting the dye into its visible form. This technology is more efficient, cost-effective and popular in the market.

Advantages And Disadvantages Of Thermal Printers

Benefits Of Thermal Printers

1. Thermal Printing Is Cost-Efficient

Since it doesn’t require any ink cartridges, this technology is also one of the most economical means of printing text quickly and efficiently for larger companies that need to produce a large volume of printed materials.

2. Thermal Printing Produces A Really Fast Print

These printers can produce a printout within a minute if the printer is equipped with a fast processor, making it ideal for printing business cards or small documents.

3. Thermal Printing Is Environmentally Friendly

Another big advantage of going for a thermal printer is that it can help you save paper, which means helping the environment.

4. Thermal Printing Is Reliable

Thermal printers are considered to be one of the most reliable printing machines and rarely encounter any software or operational issues.

5. Thermal Printing Is Cheap

Compared to inkjet and laser printers, thermal printers are much cheaper to repair and maintain, so it is a cost-effective option.

Limitations Of Thermal Printing

1. Thermal Printers Produce Poor Quality Printouts

Since the printhead cannot produce any kind of graphics or images, thermal printing produces a poor quality printout that isn’t suitable for professionals who frequently need to produce CAD drawings or design plans.

2. Thermal Printers Can’t Produce A Color Print

Thermal printers only support monochrome printing and cannot produce a printout in color. Even if they did, the result would be of inferior quality compared to normal inkjet printers that uses thousands of dots per inch, while thermal printers only use a few dozen dots per inch.

3. Thermal Printing Can’t Print On Rough Surfaces

Thermochromic paper cannot be used in direct thermal printing because it doesn’t have a layer of wax. As a result, paper with special surfaces such as envelopes and transparencies can’t be printed on.

4. Thermal Printing Is Expensive

Thermal printers are low-cost, but they only seem cheap because other printing technologies such as inkjet and laser printers cost much more to purchase and maintain over time. When it comes to the total cost of ownership, thermal printers become less economical than other options.

5 . Thermal Printing Printer Doesn’t Support Color Or Graphics

Since it can only produce monochromatic prints, this technology isn’t suitable for graphic designers who need to produce high-quality color prints. It also cannot print on paper with special surfaces such as envelopes and transparencies.

What Is A Thermal Printer Used For?

1.  Cheque Printing

The traditional way of printing a cheque is to use a thermal printer, which will heat up the special cheques paper and produce a professional-looking black and white or color printout.

2. ID Badges And Membership Cards

A thermal printer can also be used to make your own membership cards or ID cards. The usual materials for making ID badges are thermal paper, PVC strip and lamination film.

3. Printing Of Receipts

Thermal printers are also used to generate receipts that can be printed on normal paper or thermal rolls. Since these printers don’t require any ink cartridges, this makes them ideal for printing large amounts of receipts.

4. Printing Of Shipping Labels

If you run a business that ships goods to clients, then using a thermal printer is an effective way of preparing shipping labels that can be attached to boxes or envelopes. You can either use pre-printed rolls of labels or create your own.

5 . Printing Of Tickets

Thermal printers are also used to print tickets for various purposes such as events, attractions and train journeys. Since they can produce professional looking tickets in black & white or color, these printers are best suited for the task.

6. Printing Of Barcodes And QR Codes

If you shop online, then you will notice that virtually every retailer or online store uses a barcode or QR code on their website. To print these codes, you must use a thermal printer that can produce custom-sized barcodes and ensure they are printed accurately.

7. Printing Of Receipts For Thermal Cash Registers

Some cash registers include an integrated thermal printer to generate receipts for customers. These can be simple black and white printouts or full color, depending on the model of cash register.

8. Ticketing For Events And Attractions

Most events or attractions use thermal printers to sell tickets for their various activities. If you want to buy a ticket online, then most service providers will send you an email with a QR code that you can scan to gain entry.

9. Printing Of Medical Labels

Thermal printers are used in a number of medical applications including the printing of identifying labels, packaging and storage containers for various medical instruments. These printers are also suitable for producing drug labels.

10 . Printing Of Stock And Warehouse Labels

In warehouses, shipping department and stock storage areas you need to label objects as a way of ensuring they are stored in the right place. Thermal printers can be used for this purpose as they can produce custom barcodes or alphanumeric labels quickly and efficiently.

Conclusion

So, that was all about how do thermal printers work.  Thermal printer industry has many significant aspects to cater to different application demands.

It is necessary to understand the pros and cons of thermal printers so that you can buy the right thermal printing machine for your business/office/home needs.

Thermal printers are widely used in retail outlets, airports, hospitals, warehouses etc. Buy a suitable model based on usage and budget for your business/office/home application.

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