Introduction
The Avery 6404 is an industrial thermal label printer designed for applications that require reliable barcode, text, and label printing. When its printhead becomes worn or damaged, choosing the correct replacement is essential for maintaining print quality and avoiding compatibility problems.
The Avery 6404 printhead is commonly associated with the A0978 300 DPI near-edge thermal printhead, which is designed for a 4-inch printing platform. Depending on the printer configuration, related Avery/Novexx models can use the same or closely related printhead platform. However, printhead compatibility should be verified by part number, resolution, mounting configuration, and printhead orientation-not simply by printer model name.
This guide explains the compatible printer families and the key technical considerations when selecting a replacement printhead for Avery 6404 equipment.
Avery 6404 Printhead Specifications
The commonly referenced replacement for the Avery 6404 is A0978, with the following specifications:
| Parameter | Specification |
| Printer | Avery 6404 / 64-04 |
| Printhead Part Number | A0978 |
| Resolution | 300 DPI / 12 dots per mm |
| Printhead Type | Thermal transfer / direct thermal |
| Printing Technology | Near-edge |
| Print Width Class | 4-inch / approximately 107 mm |
| Configuration | Quick-change printhead assembly available |
| Typical Application | Industrial label, barcode and product identification printing |
The A0978 is listed for the Avery 64-04, TTX674, DPM, PEM and ALX924 (left-hand configuration), while other sources also associate the assembly with related 4-inch Avery/Novexx platforms such as XTP804.
Which Printers Can Use the Avery 6404 Printhead?
1. Avery 6404 / 64-04
The most direct application is the Avery 6404 / 64-04 industrial thermal printer.
For this printer family, the A0978 is a 300 DPI, 4-inch near-edge printhead designed for high-quality barcode, text and label printing.
Compatibility:
- Avery 6404/64-04
- A0978
- 300 DPI
- 4-inch near-edge configuration
This is the primary printer model that should be checked when a customer requests an "Avery 6404 printhead."
2. Avery TTX674
The Avery TTX674 belongs to the same general 4-inch near-edge printhead platform.
The A0978 is documented as compatible with the TTX674, making it an important cross-reference when customers are looking for replacement parts for this printer.
Compatibility reference:
A0978 → Avery 6404 / 64-04 / TTX674
However, the exact mechanical configuration should still be confirmed before ordering.
3. Avery DPM Series
The A0978 is also associated with Avery DPM print-and-apply systems.
The DPM platform uses thermal print technology for applying variable information such as barcodes, product identification codes and production labels.
The A0978 can be used in specified DPM configurations, but buyers should confirm the exact DPM model and printhead orientation before purchasing.
4. Avery PEM Series
The Avery PEM platform is another related application.
The A0978 is listed for DPM/PEM systems using the corresponding 4-inch near-edge printhead configuration. Because print-and-apply systems can be configured differently depending on the application and label direction, checking the original printhead part number is recommended.
5. Avery ALX924
The Avery ALX924 is another important compatible platform.
However, this is where technicians need to be particularly careful.
The A0978 is commonly specified for the ALX924 left-hand (LH) configuration, while A2817 is listed for the right-hand (RH) configuration on related DPM/PEM/ALX734/ALX924 systems.
Therefore:
A0978 ≠ automatically compatible with every ALX924 configuration.
The machine's orientation and existing printhead part number should be checked before replacement.
6. Avery/Novexx XTP804
Some technical suppliers also list the A0978 for the Novexx XTP804, another printer in the same 4-inch near-edge printhead family.
This makes XTP804 a useful cross-reference when searching for an A0978 replacement, although the exact mounting and mechanical configuration should always be confirmed.
Avery 6404 Printhead Compatibility Chart
| Printer Model / Platform | A0978 Compatibility | Resolution | Important Note |
| Avery 6404 / 64-04 | Yes | 300 DPI | Primary application |
| Avery TTX674 | Yes | 300 DPI | 4-inch near-edge platform |
| Avery DPM | Configuration-dependent | 300 DPI | Verify exact model/orientation |
| Avery PEM | Configuration-dependent | 300 DPI | Verify exact model/orientation |
| Avery ALX924 LH | Yes | 300 DPI | A0978 left-hand version |
| Avery ALX924 RH | Check A2817 | 300 DPI | Do not assume A0978 fits |
| Avery ALX734 | Configuration-dependent | 300 DPI | A2817 commonly associated with RH version |
| Novexx XTP804 | Reported compatible | 300 DPI | Verify mounting configuration |
The distinction between A0978 and A2817 is particularly important. A0978 is identified as a 4-inch, 300 DPI near-edge printhead for left-hand configurations, while A2817 is identified as a right-hand version for DPM/PEM/ALX734/ALX924 applications.
A0978 vs. A2817: Are They the Same Printhead?
No. They should not be treated as interchangeable simply because both are 4-inch, 300 DPI Avery printheads.
The key difference is the mechanical orientation:
- A0978: 4-inch, 300 DPI, near-edge, left-hand configuration
- A2817: 4-inch, 300 DPI, near-edge, right-hand configuration
The print resolution may be identical, but the mechanical installation direction and mounting configuration can differ.
This is a good example of why printhead compatibility cannot be determined by DPI alone.
Technical Rule
Same DPI + same width ≠ guaranteed compatibility.
A professional compatibility check should compare:
Printer model
Original printhead part number
DPI
Printhead width
Left-hand / right-hand configuration
Mounting bracket
Connector and cable position
Near-edge or flat-head structure
Is the Avery 6404 Printhead Compatible with Avery 6405 or 6406?
Not automatically.
Avery's 64-series printers use different printhead widths:
6404 → 4-inch printhead
6405 → 5-inch printhead
6406 → 6-inch printhead
6408 → 8-inch printhead
For example, the A0978 is associated with the 4-inch 6404 platform, while A0979 is associated with 6405 and A0980 with 6406.
Therefore, a 6404 printhead should not be substituted for a 6405 or 6406 printhead merely because the printer series looks similar.
Conclusion
The Avery 6404 printhead is primarily associated with the Avery 6404 / 64-04 4-inch industrial thermal printer and the A0978 300 DPI near-edge printhead.
Depending on the exact configuration, A0978 is also associated with Avery TTX674, DPM, PEM, ALX924 LH and Novexx XTP804 platforms. Related models such as ALX734 and ALX924 RH may require the A2817 right-hand version instead.
The most important lesson is that printhead compatibility is determined by more than the printer model or DPI. Part number, printhead width, mounting structure, connector position and left/right-hand orientation should all be checked.
For distributors, service companies and industrial printer users, verifying these specifications before purchasing can prevent installation problems, print defects and unnecessary equipment downtime.
If you are unsure whether your Avery/Novexx printhead is compatible, provide the printer model, original printhead part number and a photo of the printhead. A professional compatibility check can then be performed before ordering.
