Replacing a Zebra 105SL Plus: Upgrade or Like-for-Like?

When a Zebra 105SL Plus fails, the first decision is simple to state and easy to get wrong: replace it like-for-like with a refurbished 105SL Plus, or move the line to a newer 4 inch industrial printer such as the ZT410. A Zebra 105SL Plus replacement has to print the same labels, take the same media and talk to the same host.

This guide covers what Zebra says about the 105SL Plus lifecycle, what carries over to a ZT410 and what does not, and a migration checklist for the swap. If you only need the key differences, go straight to the replacement comparison table. For a side by side of the ZT410, 105SL Plus and 110Xi4 as three platforms, see our ZT410 vs 105SL Plus vs 110Xi4 comparison.

Products in our listing

Two 105SL Plus and two ZT410 printers are shown below, and each card links to the full product page. Every 105SL Plus and ZT410 part number we list is in the full range table further down.

Zebra102-801-00100Zebra 105SLPlus 4-Inch 203dpi Thermal Transfer / Direct Thermal Industrial Label PrinterIn stockView Details →

Zebra103-801-00000Zebra 105SL Plus 4.09-Inch 300dpi Thermal Transfer / Direct Thermal Industrial Label PrinterIn stockView Details →

ZebraZT41042-T010000ZZebra ZT410 4-Inch 203dpi Thermal Transfer Industrial Label PrinterIn stockView Details →

ZebraZT41043-T010000ZZebra ZT410 4-Inch 300dpi Thermal Transfer Industrial Label PrinterIn stockView Details →

All four printers shown are refurbished. Every unit carries the 30-Day Tech Seller USA warranty. Browse the full Zebra printer range.

What Zebra says about the 105SL Plus

Zebra lists the 105SL Plus as discontinued. Its product page states a printer discontinuation date of April 2, 2018 for most locations (December 31, 2019 in Asia Pacific) and a service and support discontinuation date of May 2, 2023 for most locations (March 31, 2025 in Asia Pacific). Zebra also states that customer support is not available after the service and support discontinuation date.

The successor Zebra names on its 105SL Plus product page is the ZT510, not the ZT410. Zebra has also discontinued the ZT410: its support page lists a product discontinuation date of October 1, 2020, a service and support discontinuation date of September 1, 2025 for North America, EMEA and Latin America, and names the ZT411 as its replacement. The practical choice is between two discontinued platforms, one older and one newer. Our ZT411 buying guide covers that route.

Replacement comparison: 105SL Plus vs ZT410

The table summarizes the points that decide a replacement. Manufacturer figures are from Zebra's published specifications. Store figures are from the units in our listing.

Like-for-like: when a refurbished 105SL Plus is the right call

A like-for-like swap is the least disruptive change. The replacement uses the same command language, media path, ribbon and position on the line, which matters most when nobody on site remembers how the old unit was set up.

A refurbished 105SL Plus makes sense when:

• The host prints over parallel. Parallel is standard on the 105SL Plus. The 105SL Plus units in our listing that record connectivity list USB, serial, parallel and Ethernet.
• Your labels are tuned to the 105SL Plus and you want the same settings to carry over.
• You run ribbon narrower than 2 inches. Zebra lists the 105SL Plus ribbon width from 0.79 inches, while the ZT410 starts at 2 inches.
• You need a short-term bridge before a planned line replacement.

The trade-off is age. Zebra support has ended, so you are extending a platform, not starting a new one.

Upgrade: when moving to a ZT410 makes more sense

The ZT410 is a newer 4 inch industrial printer with the same maximum print width as the 105SL Plus, so the label sizes you print today fit. Zebra lists it as smaller and lighter: 12.75 by 10.6 by 19.5 inches and 36 lbs, against 15.5 by 10.31 by 20.38 inches and 50 lbs for the 105SL Plus. The ZT410 units in our listing record USB, serial, Ethernet and Bluetooth.

Moving to a ZT410 makes sense when:

• The host prints over USB, serial or the network. Those connections carry over directly.
• You are replacing several printers. Standardizing a line on one newer platform simplifies spares, settings and training.

Keep the lifecycle point in view. The ZT410 is also discontinued and Zebra support for it has ended, so the upgrade buys you a newer platform rather than a supported one. If manufacturer support is a hard requirement, look at the ZT411 or ZT510 instead. For sizing against your real output, see duty cycle and print volume sizing.

ZPL compatibility: what carries over and what to test

Zebra lists ZPL and ZPL II as the command language on the 105SL Plus, and ZPL, ZPL II and EPL as resident languages on the ZT410. Formats sent as ZPL from an ERP, WMS or label design tool will generally print on both.

Three things still need a test:

• Resolution. ZPL places fields in printer dots. A format written for a 203 dpi printer prints smaller and in a different position on a 300 dpi printer. Replace 203 with 203 and 300 with 300 unless you plan to rework the formats. Our 203 vs 300 vs 600 dpi guide explains the trade-off.
• Stored objects. Fonts, logos and formats saved to the old printer's memory do not move with the host. Reload them onto the replacement.
• Driver and settings. A Windows driver installed for one model may need to be changed for the other. Check darkness, print speed, media type and label position on the first test run. Our guide on label print position and offset calibration covers the registration settings.

Media, ribbon and interfaces

Zebra lists the same media roll limit on both printers, an 8 inch outside diameter on a 3 inch core, and both accept ribbon up to 450 meters on a 1 inch core with a 3.2 inch maximum roll. The exception is ribbon width: the ZT410 accepts ribbon from 2.00 to 4.33 inches, while the 105SL Plus accepts 0.79 to 4.33 inches. If you print narrow labels with narrow ribbon, check the ribbon width first.

Zebra's ZT410 user guide also states that standard ZT410 printers use ribbon coated on the outside, and that inside-coated ribbon needs an optional spindle. Confirm the coating side on your current ribbon before you order a ZT410. The label media and ribbon selection guide covers matching ribbon to label stock, and direct thermal versus thermal transfer explains when you need a ribbon at all.

On interfaces, parallel is the gap. It is standard on the 105SL Plus and optional on the ZT410 per Zebra, and none of the ZT410 units in our listing record it. Serial and Ethernet are on both. If the line still prints over parallel, either buy a like-for-like 105SL Plus or move the host to a USB, serial or network connection as part of the swap. Our guide on printer connectivity covers the options.

Footprint and printhead considerations

Per Zebra's published dimensions, the ZT410 is about 2.75 inches shorter and about 0.9 inches shallower than the 105SL Plus, and about 0.3 inches wider. It is 14 lbs lighter. Measure any enclosure or mount before ordering. Note that the 105SL Plus records in our listing show two listed weights, 35 lbs and 50 lbs, so use Zebra's 50 lb figure when planning a shelf or mount.

The printhead is the part most likely to send a 105SL Plus to replacement. Because Zebra service and support have ended for both printers, do not assume a replacement head is available for your exact model and resolution. Check availability before you commit to repairing an older unit, and weigh the cost of a head against a refurbished printer. See printhead failure diagnosis and replacement to confirm the head is the actual fault, and thermal printer maintenance to extend the life of the replacement.

Migration checklist

1. Record the full part number, resolution and firmware of the unit you are replacing.
2. Note the host connection: parallel, serial, USB or Ethernet, and the IP address if networked.
3. List stored fonts, graphics and formats on the old printer, and export them if you can.
4. Measure label width, ribbon width and ribbon coating side.
5. Confirm the media handling you need: tear-off, peel, rewind or cutter.
6. Match the resolution of the replacement to the old printer unless you are reworking formats.
7. Check the physical space, mount and door clearance against Zebra's dimensions.
8. Install the driver or confirm the raw ZPL path, then load stored objects.
9. Calibrate media and set darkness, speed and label position.
10. Print and scan every label format before you retire the old configuration.

For media modes, see printer media handling modes.

Which route fits your job

• Host still prints over parallel: a refurbished 105SL Plus, since parallel is standard on it and not listed on our ZT410 units.
• One failed unit on a line you plan to replace soon: a like-for-like 105SL Plus to bridge the gap.
• Several printers to standardize: the ZT410, at the same resolution as the printers it replaces.
• Tight space or a lighter mount: the ZT410, which Zebra lists as shorter and 14 lbs lighter.
• Ribbon narrower than 2 inches: the 105SL Plus, unless you change ribbon width.
• Manufacturer support required: neither; look at the ZT411 or ZT510, the replacements Zebra names.

Full 105SL Plus and ZT410 range in our listing

Every 105SL Plus and ZT410 part number we currently list is below. Select a part number to open its product page. "Not listed" means the field is not recorded on that product page.

Buying a refurbished replacement

Every 105SL Plus and ZT410 in our listing is refurbished. Check these before you order.

The printhead is the most expensive wear part. Ask about head condition and print a test label on arrival.

The media handling option must match your process. Our listing records a cutter on 102-801-00100, a peeler with rewinder on 102-801-00200 and a peeler on ZT41042-T31A000Z. Confirm the option on the exact part number.

The box contents, including power cord and media spindle, should be confirmed before ordering. Our refurbished hardware grading guide explains our condition descriptions, and new vs refurbished IT hardware covers the wider trade-off. For the desktop versus industrial question, see industrial versus desktop label printers. Browse all printers.

Common questions