Choosing the right printhead for different industrial applications | Xaar

Coating typically requires higher viscosity fluids (for example, primers, varnishes or protective layers), and controlled, repeatable laydown. With this in mind, a printhead designed for high viscosity is essential for coating applications.

At Xaar, our printheads are engineered to tolerate high viscosity fluids, handling fluids at viscosities of up to 100 centipoises (cP) at jetting temperature (1000cp at room temperature). Advanced features, such as Xaar’s TF Technology maintain continuous ink circulation, helping to eliminate sediment buildup and trapped air, factors that are especially important when working with particle-rich or functional inks. Additionally, Sure Flow self-cleaning and High Laydown Technology improve operational stability and enable the deposition of thicker layers, ideal for coating applications.

For OEMs developing digital coating systems, Xaar 2002 and Xaar Nitrox variants support improved coating uniformity, reduced material waste (compared with analogue processes) and easier integration into industrial environments. 

Battery manufacturing places stringent demands on coating precision, reliability and the ability to jet advanced functional fluids.

For next-generation battery coating applications, Xaar’s eX Series printheads are specifically designed to meet these requirements. Optimised for high viscosity and particle-containing fluids, they enable the deposition of uniform, functional coatings that improve battery protection, durability and performance.

3D and additive manufacturing is where digital inkjet really shines. No longer is 3D just FDM filament printing with binder jet and UV now much more commonplace for prototyping and the manufacturing of components.

Xaar’s printhead architecture, including features such as our unique Through Flow (TF) Technology and High Laydown (HL) Technology, mean our products can handle ultra‑high viscosity fluids while delivering high material laydown. Together, these allow the jetting of application‑specific materials that were previously difficult to process reliably, supporting new additive manufacturing applications.

The digital inkjet printing of phase change materials such as wax is another 3D application that is gaining popularity. This is seen in the 3D printing for jewellery producers which takes over from the resin printing which improves process efficiencies and cost.

Direct-to-shape printing, including bottles, containers and industrial components, requires precise droplet placement on non-flat surfaces.

 This means the selected printhead must provide accurate jetting at variable throw distances, consistent print quality across a broad spectrum of complex geometries and robust operation in production environments.

 Our Xaar Nitrox printhead is commonly used in these systems, enabling OEMs to design flexible, high-quality direct-to-shape solutions without compromising throughput.

As glass printing typically involves heavier ink laydown, inks with higher particle content and challenging production conditions, correct printhead specification is vital.

Whether it’s creative glass panels, architectural or automotive glass, printing decorative designs or adding logos and variable data to glass substrates, glass printing generally requires the ability to handle more demanding fluids.

Xaar’s printheads are compatible with inks that offer the necessary optical density, chemical durability and abrasion resistance for even the most challenging glass printing requirements. Printheads such as Xaar 2002 provide the ability to print complex fluids allowing for increased functionality such as conductive, anti-slip and energy efficiency properties.

Textile printing demands high productivity, consistent image quality and reliable operation at scale. Depending on the ink chemistry and fabric type, printheads must deliver stable jetting at high speeds while maintaining drop accuracy.

Xaar Aquinox offers consistent drop formation across wide print widths, compatibility with waterbased textile ink sets and reliability in
high-duty-cycle environments. These factors make Xaar Aquinox, and those with similar qualities, a strong choice for both traditional textile printing and emerging decorative fabric applications.

Digital embellishment, including varnish, tactile effects and selective coatings, requires precise control over droplet size and laydown. 
Our work with Kammann, for example, is powering the cutting edge of digital decoration due to our printhead’s ability to deliver fine detail,
and consistent results over both short and longer runs.

 Choosing a printhead such as Xaar Nitrox or Xaar 2002 allows for the jetting of higher viscosity embellishment fluids, ultimately allowing brands to enhance the flexibility and creativity of their designs without the setup costs of traditional embellishment processes. 

Interior décor printing, such as wallcoverings, panels and decorative surfaces, often requires the use of higher viscosity inks to deliver richness and depth.

Consequently, we often see Xaar 2002 selected by customers operating in this sector. This printhead is able to handle high viscosity fluids, allowing for the high ink laydown which is demanded by most décor printing, and is consistent and reliable over large print areas, a particularly valuable feature for décor printing applications.

Inkjet-based additive manufacturing places unique demands on printheads, particularly when jetting functional, high viscosity or particle-filled materials. 

Xaar 2002 printheads offer an ideal solution, as their structure and our unique technologies provide the ability to jet high viscosity fluids, including phase change materials such as wax.

What’s more, the drop size of Xaar 2002 allows for a smoother mould surface when used in 3D applications, in turn delivering a cleaner finish for the product. 

Packaging printing covers a wide range of functions, from coding and marking to graphics, varnish and coatings. 

The specific application will determine which Xaar printhead is best suited, based on the necessary print quality and speed, the selected ink type and viscosity and integration requirements.

The flexibility of Xaar’s printhead portfolio allows OEMs and converters to deploy digital inkjet across primary, secondary and tertiary packaging applications, with an appropriate option available for all printing requirements. 

Coding and marking applications require the high-speed printing of variable data such as barcodes, batch codes and serialised information across a wide range of packaging formats.

As industry requirements evolve, including the transition to 2D codes driven by initiatives such as GS1 Sunrise 2027, the ability to print high-quality, scannable codes consistently at production speed is becoming increasingly critical.

Xaar’s inkjet technologies support coding and marking across primary and secondary packaging, enabling flexible, on-demand printing of variable data. Printhead choice will depend on the required resolution, speed and substrate, with solutions such as Aquinox and Xaar’s 50X alongside integrated systems like Versatex or our Printbar supporting high-speed, production-ready applications.

There is no single “best” printhead for industrial inkjet, so it’s critical to consider elements like fluid density, production environment and system design requirements.

From high viscosity fluid handling for advanced manufacturing, precise drop placement for complex surfaces, to reliable variable data printing in packaging environments, selecting the correct technology has a direct impact on productivity, quality and system performance.

As applications continue to evolve, from next-generation battery production to increasing traceability requirements in packaging, Xaar’s portfolio is designed to support both current and emerging needs. By working closely with OEMs and integrators, Xaar helps ensure that each solution is optimised for long-term success.