A sheet and a roll have different constraints
An A4 job needs margins, gaps and a count that fit the sheet; a thermal job needs a page matching the chosen label stock and the printer driver. Measuring only the label artwork is insufficient if the adhesive sheet has an offset from its edge. Begin with the stock manufacturer’s layout or a careful measurement. Keep those figures separate from printer scaling settings, which can change the final result after the PDF has already been generated.
Work through the three visible stages
Enter Label content and select Barcode format or QR as appropriate. Under Label size, choose a preset or enter Width (mm) and Height (mm), then use Generate design and select a valid candidate. Finally choose Print type, inspect Preview and download using Download A4 PDF or Download Thermal PDF. Review the selected orientation and any manual spacing before exporting. The result repeats the chosen content; it is not an automatic mail merge from a stock database.
Calibrate the first physical page
Print a test on ordinary paper before using a full adhesive sheet. Set the PDF viewer and driver to actual size or 100%, then compare the outer margins and the distance between successive labels with the stock. A fit-to-page option can shift every later row even when the first looks close. Check the actual hardware’s unprintable area as well: a correctly measured PDF cannot force ink or thermal transfer outside the printer’s physical capabilities.
Separate dot alignment from document geometry
For thermal output, the 203 or 300 dpi setting belongs to the real device and its rasterisation path. Merely renaming the file or changing metadata does not improve narrow bars. Use a label size that leaves sufficient room for readable text and quiet zones. Inspect the printed code after the driver has handled it, especially on a continuous roll where offsets can accumulate. Keep the accepted PDF and print settings together so a later operator can reproduce the tested run.
- Can I mix different workbook rows on this sheet?
- This page repeats its selected label content. Use the separate Excel Bulk Labels workflow when the names and codes must change between records.
- Should I choose fit to printable area?
- Start with actual size or 100% for a measured label PDF. Compare the test page with the stock before considering any deliberate adjustment.
- Will the PDF automatically configure my thermal printer?
- No. Select the matching media size and appropriate options in the printer driver. Browser export cannot verify your connected hardware or its calibration.
- Why does the screen preview align but the sheet drift?
- The preview describes the document. Driver scaling, unsupported edge printing, incorrect gaps or media feeding can change the physical output; measure successive labels to identify the cause.