Badge Stock Specification Guide

Technical Specification Guide

Badge Stock for Zebra ZD621 Printer

Everything you need to know about badge media compatible with the Zebra ZD621 thermal printer: media types, coating, sensing methods, and the sizes SGPad supplies.

1. Media Type

The Zebra ZD621 supports two media formats. SGPad supplies fanfold badge stock as standard.

Roll Media

Roll

Wound on a core (0.5″–1.5″ diameter). Maximum roll diameter 2.6″–5.0″. Maximum width 4″, length 2″–12″ per badge. Used with label printers like the Brother QL-820NWB.

Fanfold Media

Fanfold SGPad Standard

Folded in a zigzag pattern for continuous stacking. Maximum width 4″, length 2″–12″ per badge. No core or spindle needed, feeds directly into the printer from a stack.

2. Coating & Print Method

The ZD621 uses Direct Thermal printing: no ink, no ribbon, no toner.

Direct Thermal Paper

The badge stock surface is coated with a heat-sensitive dye layer. When the print head applies heat, the coating darkens to form text, barcodes, and graphics. Only one side has this coating, the other side is blank with media sensing marks.

Property	Detail
Print Method	Direct Thermal (heat-activated, no consumables)
Print Colour	Black only
Printable Side	Coated side only (top side when loaded correctly)
Supports QR / Barcodes	Yes, high resolution suitable for scanning

Tip: If badges come out blank, the stock is loaded upside-down. Flip it so the coated (slightly glossy) side faces up.

3. Media Sensing

The printer uses a sensor to detect where each badge starts and ends. Two methods are used depending on the badge stock.

Method A

Mark Sensing SGPad Standard

A black line printed on the back of each badge tells the printer where to cut or tear. The mark should span the full width of the badge and be approximately 1/8″ (3mm) tall.

This is the sensing method used by SGPad’s thermal fanfold badge stock.

Method B

Gap / Notch Sensing

A physical gap or hole between each badge tells the printer where to separate. Common on label rolls. The sensor detects the absence of material (the gap) between badges.

Used by some third-party badge stock. Confirm your printer’s media type setting matches.

Important: When loading badge stock, ensure the black timing marks face down and the arrow on the stock points towards the front of the printer (the feed direction).

4. Badge Sizes Available from SGPad

We supply the two most common conference badge sizes, both compatible with the Zebra ZD621.

Badge Type	Size	Metric	Best For	Batch Size
Thermal Fanfold 4×6″	4 × 6 inches	102 × 152 mm	Large conferences, expos	250 badges
Thermal Fanfold 4×3″	4 × 3 inches	102 × 76 mm	Conferences, seminars, workshops	250 badges
Art Card Inserts (A6)	A6	105 × 148 mm	Corporate events, VIP badges	250 inserts
Adhesive Label Rolls	62mm wide	62mm continuous	Trade shows, quick check-in	250 labels/roll

Using third-party badge stock? The Zebra ZD621 accepts media up to 4″ wide and 2″–12″ long. Confirm your stock uses mark sensing (black line) or gap sensing and set the printer accordingly via the Print Wizard. Consult your registration software provider for supported badge dimensions.

Need Badge Stock for Your Event?

We supply badge stock in batches of 250. Tell us your attendee count and badge size and we’ll include the right quantity in your quote.

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