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Thermal-transfer printing is a digital printing method in which material is applied to paper (or some other material) by melting a coating of ribbon so that it stays glued to the material on which the print is applied. It contrasts with direct thermal printing, where no ribbon is present in the process.
Thermal transfer is preferred over direct thermal printing on surfaces that are heat-sensitive or when higher durability of printed matter (especially against heat) is desired. Thermal transfer is a popular print process particularly used for the printing of identification labels. It is the most widely used printing process in the world for the printing of high-quality barcodes. Printers like label makers can laminate the print for added durability.
Thermal transfer printing was invented by SATO corporation. The world's first thermal-transfer label printer SATO M-2311 was produced in 1981. [1]
Thermal-transfer printing is done by melting wax within the print heads of a specialized printer. The thermal-transfer print process utilises three main components: a non-movable print head, a carbon ribbon (the ink) and a substrate to be printed, which would typically be paper, synthetics, card or textile materials. These three components effectively form a sandwich with the ribbon in the middle. A thermally compliant print head, in combination with the electrical properties of the ribbon and the correct rheological properties of the ribbon ink are all essential in producing a high-quality printed image.
Print heads are available in 203 dpi, 300 dpi and 600 dpi resolution options. Each dot is addressed independently, and when a dot is electronically addressed, it immediately heats up to a pre-set (adjustable) temperature. The heated element immediately melts the wax- or resin-based ink on the side of the ribbon film facing the substrate, and this process, in combination with the constant pressure being applied by the print-head locking mechanism immediately transfers it onto the substrate. When a dot "turns off", that element of the print head immediately cools down, and that part of the ribbon thereby stops melting/printing. As the substrate comes out of the printer, it is completely dry and can be used immediately.
Carbon ribbons are on rolls and are fitted onto a spindle or reel holder within the printer. The used ribbon is rewound by a take-up spindle, forming a roll of "used" ribbon. It is termed a "one-trip" ribbon because once it has been rewound, the used roll is discarded and replaced with a new one. If one were to hold a strip of used carbon ribbon up to the light, one would see an exact negative of the images that have been printed. The main benefit of using a one-trip thermal transfer ribbon is that providing the correct settings are applied prior to printing, a 100% density of printed image is guaranteed, in contrast to a pre-inked ribbon on a dot-matrix impact printer ribbon, which gradually fades with usage.
Thermal-printing technology can be used to produce color images by adhering a wax-based ink onto paper. As the paper and ribbon travel in unison beneath the thermal print head, the wax-based ink from the transfer ribbon melts onto the paper. When cooled, the wax is permanently adhered to the paper. This type of thermal printer uses a like-sized panel of ribbon for each page to be printed, regardless of the contents of the page. Monochrome printers have a black panel for each page to be printed, while color printers have either three (CMY) or four (CMYK) colored panels for each page. Unlike dye-sublimation printers, these printers cannot vary the dot intensity, which means that images must be dithered. Although acceptable in quality, the printouts from these printers cannot compare with modern inkjet printers and color laser printers. Currently, this type of printer is rarely used for full-page printing, but is now employed for industrial label printing due to its waterfastness and speed. These printers are considered highly reliable due to their small number of moving parts. Printouts from color thermal printers using wax are sensitive to abrasion, as the wax ink can be scraped, rubbed off, or smeared. However, wax-resin compounds and full resins can be used on materials such as polypropylene or polyester in order to increase durability.
So-called "solid ink" or "phaser" printers were developed by Tektronix and later by Xerox (who acquired Tektronix's printer division). Printers like the Xerox Phaser 8400 use 1 cubic inch (16 cm3) rectangular solid-state ink blocks (similar in consistency to candle wax), which are loaded into a system similar to a stapler magazine in the top of the printer. The ink blocks are melted, and the ink is transferred onto a rotating oil-coated print drum using a piezo inkjet head. The paper then passes over the print drum, at which time the image is transferred, or transfixed, to the page. This system is similar to water-based inkjets, provided that the ink has low viscosity at the jetting temperature 60 °C (140 °F). Printout properties are similar to those mentioned above, although these printers can be configured to produce extremely high-quality results and are far more economical, as they only use the ink needed for the printout, rather than an entire ribbon panel. Costs of upkeep and ink are comparable to color laser printers, while "standby" power usage can be very high, about 200 W.
MicroDry is a computer printing system developed by the Alps Electric of Japan. It is a wax/resin-transfer system using individual colored thermal ribbon cartridges and can print in process color using cyan, magenta, yellow, and black cartridges, as well as such spot-color cartridges as white, metallic silver, and metallic gold, on a wide variety of paper and transparency stock. Certain MicroDry printers can also operate in dye-sublimation mode, using special cartridges and paper.
Usage of TT printers in industry includes:
Barcode printers typically come in fixed sizes of 4, 6 or 8 inches (100, 150 or 200 mm) wide. Although a number of manufacturers have made differing sizes in the past, most have now standardised on these sizes. The main application of these printers is to produce barcode labels for product and shipping identification.
In computing, a printer is a peripheral machine which makes a durable representation of graphics or text, usually on paper. While most output is human-readable, bar code printers are an example of an expanded use for printers. Different types of printers include 3D printers, inkjet printers, laser printers, and thermal printers.
Laser printing is an electrostatic digital printing process. It produces high-quality text and graphics by repeatedly passing a laser beam back and forth over a negatively charged cylinder called a "drum" to define a differentially charged image. The drum then selectively collects electrically charged powdered ink (toner), and transfers the image to paper, which is then heated to permanently fuse the text, imagery, or both, to the paper. As with digital photocopiers, laser printers employ a xerographic printing process. Laser printing differs from traditional xerography as implemented in analog photocopiers in that in the latter, the image is formed by reflecting light off an existing document onto the exposed drum.
Dot matrix printing, sometimes called impact matrix printing, is a computer printing process in which ink is applied to a surface using a relatively low-resolution dot matrix for layout. Dot matrix printers are a type of impact printer that prints using a fixed number of pins or wires and typically use a print head that moves back and forth or in an up-and-down motion on the page and prints by impact, striking an ink-soaked cloth ribbon against the paper. They were also known as serial dot matrix printers. Unlike typewriters or line printers that use a similar print mechanism, a dot matrix printer can print arbitrary patterns and not just specific characters.
Inkjet printing is a type of computer printing that recreates a digital image by propelling droplets of ink onto paper and plastic substrates. Inkjet printers were the most commonly used type of printer in 2008, and range from small inexpensive consumer models to expensive professional machines. By 2019, laser printers outsold inkjet printers by nearly a 2:1 ratio, 9.6% vs 5.1% of all computer peripherals.
Dye-sublimation printing is a term that covers several distinct digital computer printing techniques that involve using heat to transfer dye onto a substrate.
Dots per inch is a measure of spatial printing, video or image scanner dot density, in particular the number of individual dots that can be placed in a line within the span of 1 inch (2.54 cm). Similarly, dots per centimetre refers to the number of individual dots that can be placed within a line of 1 centimetre (0.394 in).
Digital printing is a method of printing from a digital-based image directly to a variety of media. It usually refers to professional printing where small-run jobs from desktop publishing and other digital sources are printed using large-format and/or high-volume laser or inkjet printers.
Thermal printing is a digital printing process which produces a printed image by passing paper with a thermochromic coating, commonly known as thermal paper, over a print head consisting of tiny electrically heated elements. The coating turns black in the areas where it is heated, producing an image.
MicroDry is a computer printing system developed by the ALPS corporation of Japan. It is a wax/resin-transfer system using individual colored thermal ribbon cartridges, and can print in process color using cyan, magenta, yellow, and black cartridges, as well as spot-color cartridges as white, metallic silver, and metallic gold, on a wide variety of paper and transparency stock. Certain MicroDry printers can also operate in dye sublimation mode, using special cartridges and paper. ALPS licensed the technology to Citizen and to Okidata. Alps also produced the actual printer hardware and ink ribbon cartridges for those companies.
A label is a piece of paper, plastic film, cloth, metal, or other material affixed to a container or product, on which is written or printed information or symbols about the product or item. Information printed directly on a container or article can also be considered labelling.
A barcode printer is a computer peripheral for printing barcode labels or tags that can be attached to, or printed directly on, physical objects. Barcode printers are commonly used to label cartons before shipment, or to label retail items with UPCs or EANs.
A label printer is a computer printer that prints on self-adhesive label material and/or card-stock (tags). A label printer with built-in keyboard and display for stand-alone use is often called a label maker. Label printers are different from ordinary printers because they need to have special feed mechanisms to handle rolled stock, or tear sheet (fanfold) stock. Common connectivity for label printers include RS-232 serial, Universal Serial Bus (USB), parallel, Ethernet and various kinds of wireless. Label printers have a wide variety of applications, including supply chain management, retail price marking, packaging labels, blood and laboratory specimen marking, and fixed assets management.
Wide format printers are generally accepted to be any computer-controlled printing machines (printers) that support a maximum print roll width of between 18 and 100 inches. Printers with capacities over 100 in wide are considered super-wide or grand format. Wide-format printers are used to print banners, posters, trade show graphics, wallpaper, murals, backlit film (duratrans), vehicle image wraps, electronic circuit schematics, architectural drawings, construction plans, backdrops for theatrical and media sets, and any other large format artwork or signage. Wide-format printers usually employ some variant of inkjet or toner-based technology to produce the printed image; and are more economical than other print methods such as screen printing for most short-run print projects, depending on print size, run length, and the type of substrate or print medium. Wide-format printers are usually designed for printing onto a roll of print media that feeds incrementally during the print process, rather than onto individual sheets.
An ink cartridge or inkjet cartridge is the component of an inkjet printer that contains the ink to be deposited onto paper during printing. It consists of one or more ink reservoirs and can include electronic contacts and a chip to exchange information with the printer.
In the distribution and logistics of many types of products, track and trace or tracking and tracing concerns a process of determining the current and past locations of a unique item or property. Mass serialization is the process that manufacturers go through to assign and mark each of their products with a unique identifier such as an Electronic Product Code (EPC) for track and trace purposes. The marking or "tagging" of products is usually completed within the manufacturing process through the use of various combinations of human readable or machine readable technologies such as DataMatrix barcodes or RFID.
A label printer applicator is a basic robot that can automatically print and apply pressure-sensitive labels to various products. Some types of labeling include shipping labeling, content labeling, graphic images, and labeling to comply with specific standards such as those of GS1 and Universal Product Code U.P.C. A pressure-sensitive label consists of a label substrate and adhesive.
Solid ink is a type of ink used in printing. Solid ink is a waxy, resin-based polymer that must be melted prior to usage, unlike conventional liquid inks. The technology is used most often in graphics and large-format printing environments where color vividness and cost efficiency are important.
Flatbed digital printers, also known as flatbed printers or flatbed UV printers, are printers characterized by a flat surface upon which a material is placed to be printed on. Flatbed printers are capable of printing on a wide variety of materials such as photographic paper, film, cloth, plastic, pvc, acrylic, glass, ceramic, metal, wood, leather, etc.). Flatbed digital printers usually use UV curable inks made of acrylic monomers that are then exposed to strong UV-light to cure, or polymerize them. This process allows for printing on a wide variety of surfaces such as wood or canvas, carpet, tile, and even glass. The adjustable printing bed makes it possible to print on surfaces ranging in thickness from a sheet of paper often up to as much as several inches. Typically used for commercial applications, flatbed printing is often a substitute for screen-printing. Since no printing plates or silkscreens must be produced, digital printing technology allows shorter runs of signs to be produced economically. Many of the high-end flatbed printers allow for roll-feed, allowing for unattended printing.
Thermal paper is a special fine paper that is coated with a material formulated to change color locally when exposed to heat. It is used in thermal printers, particularly in inexpensive devices such as adding machines, cash registers, and credit card terminals and small, lightweight portable printers.
The Okimate 10 by Oki Electric Industry was a low-cost 1980s color printer with interface "plug 'n print" modules for Commodore, Atari, IBM PC, and Apple Inc. home computers.