Direct Thermal Boarding Passes in 2026: Why Card Stock Quality Determines Airport Efficiency

Boarding passes remain one of the highest-volume printed items in aviation, printed in real time at check-in counters, kiosks and gates. The material quality of the card stock determines whether thermal printers image reliably, whether barcodes scan at boarding gates, and how much print waste an airport generates.

What to specify for boarding pass stock

• Three-proof thermal coating: resistance to heat, light and friction - the three conditions that degrade thermal images in airport environments
• GSM matched to use: heavier card (e.g. 190gsm) holds its shape through passenger handling and archiving
• IATA-standard dimensions: 203.2 x 82.55 mm compatibility with existing printers and readers
• Perforation: detachable stub for gate agent retention procedures
• Print readability: consistent thermal imaging across printer models from different manufacturers

Cost of poor stock

Low-grade thermal paper causes barcode scan failures, faded prints and printer jams - each costing time at the busiest points of passenger flow. Airports and airlines that standardise on quality card stock reduce reprints and accelerate throughput, which is why boarding pass supply is increasingly managed as a certified, specification-controlled category.

Source: based on airline operations practice for direct thermal boarding pass materials (industry specifications)