Zebra thermal label sizes guide, 4×6, 2×1, 3×2 & more
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Picking the wrong stock is the fastest way to waste a roll and a morning. This chart covers the thermal label sizes US Zebra users buy most often (shipping, product, warehouse) and how to set the matching artboard in free browser software.
Quick size chart (inches)
| Size (W × H) | Typical use | Common printers |
|---|---|---|
| 4 × 6 | USPS, UPS, FedEx, Amazon shipping | ZD420, ZD421, GK420d, ZP series |
| 4 × 3 | Larger product / pallet half labels | ZD / ZT 4" desktop & industrial |
| 3 × 2 | Warehouse bin, shelf, inventory | ZD420, ZD421, GK420d |
| 2 × 1 | SKU / product stickers, FNSKU-style unit labels | ZD420, ZD421 |
| 2.25 × 1.25 | Retail price / jewelry tags | Desktop Zebra 2" path or multi-up |
| 1.5 × 1 | Small goods, cables (flag labels) | Desktop with narrow media |
4×6, the US shipping standard
Almost every US carrier and marketplace assumes 4×6 inch thermal labels. Buy direct-thermal (no ribbon) for most e-commerce desks. Guides: how to print shipping labels, USPS, UPS, FedEx.
2×1 and 3×2, product & warehouse
SKU stickers and bin locations dominate second. Use CODE128 for internal SKUs; UPC-A for retail. Tutorial: inventory barcode labels.
Match size in mylabelmaker
- Open app.mylabelmaker.com.
- Set artboard width and height to the physical label (inches).
- Set DPI to the printer (203 on most ZD420/GK420d; 300 on some ZD421/ZD621).
- Leave quiet zones around barcodes. do not run bars to the edge.
DPI vs physical size
Label size is physical inches; DPI is dots per inch on the printhead. A 4×6 label at 203 DPI is a different pixel canvas than 4×6 at 300 DPI. Always match both. Fuzzy print fix: 300 DPI troubleshooting.
Buying tips (US)
- Prefer gap (not continuous) media unless you use black-mark stock intentionally
- Order a small sample pack before buying a case of an unfamiliar size
- For shipping, keep a spare 4×6 roll, empty mid-manifest hurts more than cost