• The two materials must be thin enough for the sheet to lie flat in the paper tray. Orient the form in the tray so that
the pressure‑sensitive area feeds into the printer first. The form should have no adhesive exposed in the overlay
area or anywhere along the front or back of the form.
• We recommend designing a non‑adhesive strip with a minimum width of 1 mm (0.04 in.) along the edges of the
overlay.
• To help prevent material from slipping in the fuser, we recommend knurling, which roughens up the exposed silicon
area at the glue joint.
• The face sheet of a dual web form is usually a paper pressure‑sensitive product; therefore, the guidelines for paper
labels are applicable to dual web forms.
• The following diagram shows the recommended dual web form design. The non‑print area may vary, depending
on the printer model.
Leading edge
(8.5 in.)
0.0625 in.
1.6 mm
Liner edge
Stripped edge
0.0625 in.
1.6 mm
Reference edge
(11 in.)
Non-print area
Non-print area
Pressure-sensitive
Paper
0.33 in.
8.38 mm
Overlay
0.25 in.
6.35 mm
(Not drawn to scale)
Vinyl and polyester labels
• Vinyl labels work well within specified design parameters. Vinyls are heat‑sensitive, so the liners need to be thick
enough to absorb excess heat and prevent melting. A total strip matrix may cause adhesive contamination.
• Thin liners or weak pull strength may lead to labels peeling off the form inside the printer, which will require printer
servicing. For more information on recommended label designs, see “Label design guidelines” on page 25.
• For Optra S, Optra T, and Lexmark T printers, a leading and trailing edge stripped area is recommended to be a
maximum of 3 mm. This area is recommended to prevent adhesive being close to the edge, which can contaminate
your printer.
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