Direct Thermal Label Sizes & Core Guide

CHOOSING YOUR LABELS

What size direct thermal labels do I need?

The correct label size depends on what you are printing and the specifications of your thermal printer. Shipping labels, barcode labels, address labels, stock labels and warehouse labels can all require different dimensions.

It is important to check more than just the dimensions of the individual label. You should also check the roll core diameter, the maximum roll diameter your printer can accommodate and the maximum media width supported by your printer.

Printer specifications can vary between models from the same manufacturer, so knowing that you own a Zebra, TSC, Honeywell or Citizen printer alone is not enough to guarantee that a particular roll will fit.

LABEL DIMENSIONS

Understanding label width and length

Direct thermal label dimensions are normally shown in millimetres. Understanding which measurement refers to the width and which refers to the length helps you compare the label with your printer and application.

1

Label width

The label width is particularly important because your printer has a maximum media width. A label roll that is too wide for the printer cannot be correctly loaded or printed.

2

Label length

The label length determines how much printable space is available for information such as addresses, barcodes, product details or shipping information.

ROLL CORE SIZE

25mm vs 76mm label cores

The core is the tube in the centre of the label roll. Our direct thermal range includes different core options, with 25mm and 76mm cores available across a number of sizes.

25mm

25mm core labels

Smaller cores are commonly used with desktop and compact thermal printers. They allow a smaller overall roll configuration, but the exact roll diameter and media specification still need to match your printer.

76mm

76mm core labels

76mm cores are commonly associated with larger industrial thermal printers that can accommodate larger rolls. Larger rolls can be useful in higher-volume environments where labels are changed frequently.

Important: core size alone does not determine compatibility. Two rolls can use the same core but have different outside diameters, widths or label configurations. Always check the specification of your exact printer model.

POPULAR LABEL DIMENSIONS

Direct thermal label sizes available from Go2Products

Our direct thermal range includes a selection of popular sizes for shipping, barcode, warehouse, address and general business labelling. Core options vary by size.

102 × 38mm Direct thermal rolls

102 × 50mm Direct thermal rolls

102 × 76mm Direct thermal rolls

102 × 102mm Direct thermal rolls

102 × 127mm Direct thermal rolls

102 × 152mm Popular 4 × 6 format

76 × 38mm Direct thermal rolls

76 × 50mm Direct thermal rolls

76 × 76mm Direct thermal rolls

76 × 102mm Direct thermal rolls

View All Direct Thermal Sizes

PRINTER COMPATIBILITY

Four things to check before buying thermal labels

Your printer manual or manufacturer specification should provide the media information you need. These are the main measurements to compare with the label roll you are ordering.

01

Maximum media width

Check that the width of the label and backing liner is suitable for your printer.

02

Core diameter

Check the roll core sizes accepted by your exact thermal printer model.

03

Maximum roll diameter

The outside diameter of a full roll must fit the printer's media compartment or roll holder.

04

Print method

Make sure the printer supports direct thermal printing if you intend to use direct thermal labels without a ribbon.

PRINTER TYPE

Desktop vs industrial thermal printers

Thermal printers come in many sizes. One of the biggest differences when choosing labels is the amount of physical space available for the roll.

Desktop thermal printers

Compact desktop printers generally have less space for label rolls and commonly use smaller cores and smaller overall roll diameters. Always check the maximum media dimensions specified for the model.

Industrial thermal printers

Industrial printers are designed for higher-volume environments and can often accommodate larger label rolls, including rolls using 76mm cores. The exact maximum roll diameter and media width still vary by model.

SHOP BY PRINTER

Find direct thermal labels for your printer brand

Start with your printer manufacturer, then check the specifications of your exact model before ordering.

Zebra → Godex → Citizen → Toshiba → SATO → Bixolon → CAB → TSC → Datamax-O'Neil → WASP → Honeywell → Intermec → Printronix →

READY TO ORDER?

Shop direct thermal roll labels

Browse our full range of blank direct thermal labels and choose the dimensions and core configuration required for your printer.

Shop Direct Thermal Labels

SIZE & CORE FAQs

Direct thermal label size FAQs

How do I know what size thermal labels I need?

Start with the label dimensions required for your application, then compare them with the maximum media width supported by your printer. You should also check the required core size and maximum outside roll diameter for your exact printer model.

What does the core size of a label roll mean?

The core is the tube in the centre of the roll around which the labels are wound. Thermal printers can be designed for different core sizes, so the core of the roll needs to be suitable for the printer.

What is the difference between 25mm and 76mm cores?

A 25mm core is a smaller roll core commonly found in compact label roll configurations. A 76mm core is larger and is commonly used for larger rolls in industrial printing environments. Which one you need depends on the specification of your printer.

Does the outside roll diameter matter?

Yes. A roll can have the correct label width and core size but still be too large to fit your printer. Check the printer's maximum roll diameter before ordering.

What size is a 4 × 6 thermal shipping label?

A commonly used metric equivalent is approximately 102 × 152mm. This format is widely used for parcel and shipping labels, although the size you need depends on your carrier, software and printer setup.

Can I choose labels based only on the printer brand?

No. Printer-brand collections are a useful starting point, but models from the same manufacturer can have different media specifications. Always check the requirements of your exact printer model.

Do direct thermal labels need a ribbon?

No. Direct thermal labels use heat-sensitive material and are designed to print without a thermal transfer ribbon. Your printer must support direct thermal printing.

Direct Thermal Label Size & Core Guide