Thermal inkjet vs piezoelectric inkjet: what are the differences and which one should you choose for your industrial application?

In the world of digital printing, choosing the right inkjet technology is a strategic decision. It directly influences print quality, ink compatibility, the type of printable media, and the durability of the production system. Two technologies currently dominate the market: thermal inkjet and piezoelectric inkjet.

While their objective is the same - to project ink droplets with precision - their operation differs radically. Here is a technical comparison to help you make the right choice based on your industrial constraints.

 

How thermal inkjet works

Thermal technology uses a heating element built into the ink chamber. When this heats up rapidly, it forms a vapour bubble that propels a drop of ink through the nozzle. This thermal cycle is repeated several thousand times per second.

Advantages:

  • Zero operational maintenance: The print head is integrated into the ink cartridge: each cartridge replacement provides a new print head, eliminating the need for cleaning or preventive maintenance.
  • Minimal footprint: Compact modules, often plug-and-play. Very easy to integrate even in confined spaces or existing lines.
  • Compatibility with very high speeds: Particularly well suited to high-speed production environments, especially in unit coding and marking or repetitive applications with a small print area.

 

Limits:

  • Limited range of applications: Mainly effective on porous substrates with water-based inks, this technology is not suitable for applications requiring technical inks (UV, solvent) or adhesion to complex materials (plastic, metal, glass, etc.).
  • Standard configurations only: With little flexibility in terms of technical customisation (resolution, variable drop, dynamic synchronisation), it does not allow for advanced adaptations for specific needs or complex environments.
  • Native print widths of 12.7 mm: The heads offer a fixed print width of 12.7 mm. For wider markings, several heads must be assembled, which can complicate integration.
  • Cartridge replacement must be anticipated: Cartridge replacement – and therefore print head replacement – must be integrated into the production cycle, with short but regular stoppages to be expected depending on the speed and volume printed.

 

Typical applications:

High-precision printing primarily on paper and porous media, ideal for office use and industrial coding/marking.

 

How piezoelectric inkjet technology works

The piezoelectric system is based on a piezoelectric crystal placed behind the ink chamber. When it receives an electrical pulse, this crystal deforms and exerts mechanical pressure, thereby expelling the ink drop without the need for heat.

Advantages:

  • Reduced maintenance, particularly in UV configuration: Thanks to the robustness of the printheads and the stability of UV inks, cleaning and replacement requirements are significantly reduced, even during intensive use.
  • Compatibility with high production rates: Piezo printheads support rapid ejection cycles, ideal for continuous printing on automated lines.
  • High agility in mechanical integration: Easy integration on various printing substrates.
  • High flexibility in terms of inks: Capable of printing with UV, aqueous, solvent, oil or functional inks, depending on adhesion requirements or expected performance.
  • High agility in programme control: Advanced software management allows precise control of droplet size, ejection frequency and firing sequences.
  • Adaptable printing configurations: Wide range of resolutions, droplet sizes, nozzle-to-support distances, number of heads and orientations available depending on application requirements.

 

Limits:

  • Higher initial acquisition cost: Piezoelectric heads are more expensive than thermal heads, which impacts the initial budget.
  • Potentially larger dimensions and footprint: Some piezo heads or modules, particularly high-resolution ones, can be larger than simple thermal systems, requiring adequate integration space.

 

Typical applications:

Printing on a wide variety of substrates (plastic, glass, metal) with various inks (UV, solvent, aqueous, oil), particularly suited to high-definition industrial printing, direct decoration and customisation.

 

In summary

The choice between these two technologies depends on the specific requirements of the project: nature of the substrate, type of ink, production speed and expected print quality.

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