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Toner particles: size matters

When laser printers first started to be used widely around 1990 and the Hewlett Packard LaserJet 2 was the latest thing, toner particles were an average of 12 microns in diameter. 12 microns is about half the width of a human hair. In the LaserJet 4, around two years later, the average toner particle size was down to about 8 microns. Customers were asking me, "Is your refill toner microfine?". Well we had to sell something that would get across that tight-rope and produce prints of the same quality as the original. The only way to do that was to have a toner powder of the right formulation. That involved not just the particle size, but the fact that HP 4 toner has a much lower resin content and a much higher iron oxide content than HP 2 toner.

8 micron toner coincided with 600dpi print resolution. 600 dpi refers to a laser beam diameter capable of making 600 dots per inch. Half the diameter of the 300pdi printers before. 

The last thing a laser printer does to our toner particle as it leaves the printer is melt it and squash it. The relative improvement of a 600 dpi machine printing with 8 micron toner does make sense. Your laser dots are half the size. Then you fill those half-size dots with toner particles that are two-thirds the size. Xerox, the originators of this whole xerography bandwagon and Canon, designers of the first desktop laser printer engines that reached a mass market, both think this results in finer print. I'm with them on this one. 

Thanks to Refilltoner