Guide and tool
Print barcode labels on a thermal printer
Use exact media dimensions, a 100% print scale and calibration offsets to produce reliable labels for common thermal printers.
Create a thermal PDFHow it works
- Choose the physical label size
- Generate and preview the barcode batch
- Print at 100% scale and calibrate offsets
Start with the media, not only the printer model
A thermal printer can accept several roll widths and label lengths, so the model name alone is not a complete preset. Measure or read the media specification and select the exact physical label size used in the loaded roll.
The generated PDF page must match one label. A 100 × 150 mm shipping label is not interchangeable with a 102 × 152 mm preset, and a continuous roll needs a defined cut length before a fixed PDF can be prepared.
| Label size | Typical use | Check before printing |
|---|---|---|
| 58 × 40 mm | Products and small bins | Barcode width and readable text |
| 62 × 29 mm | Brother-style address media | Exact roll type and sensor mode |
| 100 × 50 mm | Cartons and warehouse locations | Feed direction and quiet zones |
| 100 × 150 mm | Shipping and logistics | Carrier layout and printer page size |
Configure the driver consistently
Set the same width and height in the printer driver, PDF viewer and generator. Print at actual size or 100%; Fit to page introduces scaling even when the preview appears correct.
Select the correct gap, mark or continuous-media sensor mode. Calibrate the media in the printer after changing a roll. Darkness and speed should produce solid bars without spreading them into narrow spaces; start with the manufacturer defaults and adjust using a scan test.
Calibrate position and verify readability
Use the calibration page to check a 100 mm line and 50 mm square before compensating for label offsets. Correct the driver scale first. Apply horizontal or vertical offsets only when dimensions are accurate but the whole design is displaced by a constant amount.
Test exported labels with the actual scanner. Preserve light quiet zones, avoid low-contrast colour combinations and keep the symbol away from curved edges, seams and reflective tape. For demanding GS1 or logistics workflows, confirm the required symbol and dimensions with the receiving specification.
- Print one label after every media or driver change.
- Scan at the shortest and longest expected working distance.
- Save a named printer profile only after the test passes.
Frequently asked questions
Should I select Fit to page?
No. Use actual size or 100% scale; automatic fitting changes barcode and label dimensions.
Why does the printer skip labels?
The driver may use the wrong page length or sensor mode, or the printer may need media calibration after a roll change.
Does higher darkness always improve scanning?
No. Excessive heat can widen bars and close narrow spaces. Use the lowest setting that produces complete, consistent bars on the selected material.