Troubleshooting Faded or Incomplete Prints
Faded, patchy, or missing prints can compromise product traceability and customer perception. These issues are common in industrial inkjet systems and often point to problems with ink flow, settings, or environment. This guide outlines the main causes and corrective actions for poor print visibility in CIJ, TIJ, DOD, and TTO printers.
Common Causes of Faded or Incomplete Prints
1. Low Ink Levels or Empty Cartridges
Symptoms: Gradually fading characters, missing sections
Solution: Check ink status, replace or refill cartridges promptly.
2. Blocked or Clogged Nozzles
Symptoms: Lines missing, intermittent dots, weak character edges
Solution: Run automatic cleaning, or flush printhead manually with proper solution.
3. Incorrect Printhead Distance or Angle
Symptoms: Uneven or distorted prints
Solution: Adjust printhead gap (usually 2–5 mm) and align perpendicular to the surface.
4. Low Ink Pressure (CIJ) or Bad Jetting (TIJ/DOD)
Symptoms: Droplet formation is weak or misaligned
Solution: Inspect ink pressure, conduct nozzle tests, ensure no air in the ink path.
5. Ink Drying Too Fast (Solvent Ink on Non-Porous Surfaces)
Symptoms: Ink appears light or flaky
Solution: Reduce head distance, increase line speed, or switch to slower-drying ink.
6. Incorrect Print Settings
Symptoms: Underprinting, low DPI, weak contrast
Solution: Increase resolution, bold fonts, or adjust contrast settings in the software.
7. Substrate Absorption Issues
Symptoms: Ink seeps into surface or fails to bond
Solution: Switch to pigmented or UV ink, pretreat surface if needed.
Printer-Specific Tips
CIJ (Continuous Inkjet)
- Check viscosity and conductivity sensors
- Verify makeup fluid dosing and ink age
TIJ (Thermal Inkjet)
- Inspect cartridges for air gaps or dried nozzles
- Replace cartridges regularly—even if partially used
DOD / Piezo
- Flush and pulse-clean heads
- Use appropriate waveform settings for ink type
TTO (Thermal Transfer Overprinter)
- Check ribbon tension and alignment
- Ensure ribbon matches material type and printhead temperature
FAQs
- What if print fades over time? Consider ink fade resistance (UV, water exposure). Switch to pigmented or UV-curable ink if needed.
- Can environmental factors cause fading? Yes. High humidity, dust, or temperature extremes affect drying and adhesion.
Conclusion
Faded or incomplete prints are often easy to fix once the root cause is identified. Regular maintenance, correct settings, and ink-substrate matching are key to long-term print quality. Still having trouble? Contact Cheef Inkjet at sales@cheef.cn for professional diagnostics and support.
