troubleshooting guide
Fix pre-flight checklist: 7 things to verify before dropping off at usps, ups or fedex. Check scale, paper size, margins, orientation and barcode whitespace before reprinting.
Best next step
Start with the tool or template that matches this guide before printing paid postage again.
Last reviewed: 2026-06-15
Before handoff, compare the print with the original PDF: confirm the complete barcode and tracking number, readable addresses and service text, unchanged scale, matching paper/orientation, flat placement, and no tape, fold, seam, blur or crop across scan-critical content.
Symptom-led fix
Follow the symptom that best matches your bad print. Each step points to the safest next tool before you buy postage again.
A full Letter or A4 page is being fitted onto one 4×6 thermal label.
Inspect the PDF page box. Get the issuer's 4×6 format or extract only a complete label area; do not enlarge the miniature output.
Inspect the PDF pageA true 4×6 source prints proportionally smaller on matching 4×6 media.
Confirm 4×6 in the driver, disable Fit, print one blank template, then calculate a correction only if the media path already matches.
Measure the scale errorThe label boundary is correct, but fine lines are fuzzy, gray or broken.
Treat this as print quality, not page scale. Test density, speed, media and printhead condition before another live label.
Run a print-quality testUse the downloaded carrier or marketplace PDF as the reference. Confirm that no address line, tracking number, service mark, routing mark, barcode or surrounding white space disappeared during printing.
Match the selected paper or roll to the source label, use 100% / Actual Size, and disable Fit to Page. If the print dialog changed the page, fix the setup and reprint before evaluating the barcode.
The barcode should be sharp, complete, flat and free of tape glare. Keep it away from a package seam or edge when possible. Remove or fully cover obsolete labels and barcodes so automated equipment does not see conflicting routing information.
Do not use this checklist as carrier approval. Stop and reprint when active content is cropped, distorted, wet, blurred, folded or covered. Ask the carrier or issuing platform when package shape, special service or current instructions create doubt.
This page is a practical print-setting checklist, not official carrier policy or a promise that a label will be accepted.
Confirm the current format in your platform or carrier account, keep the original PDF, and stop if a test print is cropped, blurred or incorrectly scaled.
Troubleshooting advice is general. Record the printer model, paper size, PDF viewer and scale setting so you can verify each change.
No. It reduces preventable print and placement errors but does not replace current carrier or platform policy.
No. It is a useful diagnostic only and does not verify all carrier routing fields or automated equipment.
No. Remove or fully cover obsolete labels and barcodes so they cannot conflict with the current shipment.
After matching source page and printer media, start with 100% / Actual Size rather than Fit to Page.
Any crop, blur, distortion, fold, tape or missing content across the barcode, address, tracking number, service text or quiet zone.
Understand barcode risk before drop-off.
Avoid repairs that damage barcode scanning.
Check paper, scale and orientation before printing.
Download a blank 4×6 shipping label template.
Fix tiny labels, scaling problems and bad print settings.