Why Is My Ribbon Wrinkling? Here’s What to Check

Ribbon wrinkles driving you crazy? You’re not alone. Whether you’re using a newer all-electric model or an older pneumatic-driven TTO printer like the DataFlex+ or 6420, this common issue can sneak in and ruin an otherwise perfect print. The good news? You can usually fix it yourself once you know what to look for.

Let’s walk through the most common causes of ribbon wrinkle and how to troubleshoot each one, step by step.

1. Bad Cassette

A worn or poorly functioning cassette is one of the biggest culprits behind ribbon wrinkles. The cassette’s job is to maintain ribbon tension, and when something goes wrong, things get messy.

What to check:

• Friction cones: Spin the mandrels by hand—if they feel too loose, the black friction cones are probably worn out.

• Mandrel springs: Try rotating the mandrel while holding a ribbon core. If it slips, the springs may be shot.

• White rollers: These should spin freely. If they’re stuck or stiff, they’ll cause uneven ribbon tension and wrinkles.

2. Ribbon Motors Not Tuned Properly

Your ribbon motors are tuned to your cassette. If they fall out of tune, the ribbon may sag over time, especially after several prints.

What to look for:

• Slack in the ribbon

• Degrading print quality over time

• Errors like "Ribbon Break" or "Substrate Speed Detection Error"

Fix: Retune the ribbon motors using Clarity Config and an empty cassette (no ribbon). It’s free to do and can make a world of difference.

3. Printhead Cables Installed Incorrectly

Printhead cable design has come a long way over the years. The newer 6530 and 6330 models have eliminated this issue, but the older 6420 printers still struggle with it—especially the 110mm versions. In these older machines, the ribbon cables and calibration wires often hang too low, pushing into the ribbon path and causing wrinkles during printing.

Solution:
Use a zip tie or electrical tape to secure loose wires. If that doesn’t work, the cable may need replacing.

4. Dirty Peel Roller

The peel roller is the white roller near the printhead. If it’s dirty or sticky, the ribbon can bunch up right before printing.

Fix:
Clean it or replace it. Make sure it spins freely and is free from debris.

5. Dirty or Failing Printhead

A dirty or dying printhead can degrade the quality of your prints and create uneven heat transfer, which can wrinkle the ribbon.

Fix:
Clean the printhead with rubbing alcohol. If the problem persists, it might be time for a replacement.

6. Worn Platen Pad or Roller

Whether you’re printing intermittently or continuously, the rubber platen provides the backing pressure needed for a clean transfer. If it wears out, your ribbon and print quality will suffer.

Fix:
Inspect the pad or roller for wear. Replace if necessary.

Final Troubleshooting Order

Not sure where to start? Here's the recommended checklist:

1. Check the peel roller

2. Inspect the printhead cables

3. Clean the printhead

4. Evaluate the cassette

5. Inspect the platen pad or roller

6. Run a ribbon motor recalibration

Ribbon wrinkles are frustrating, but with a systematic approach, they’re usually fixable. Need parts like cassettes, peel rollers, or printheads? You already know where to find them—TTOParts.com has you covered.