Problematic small font readability maybe wider question, eg. print label to use on pen.
Here I has faced that Zebra Designer application produce worse quality printed small fonts compare to other label design software even MS Word.
I did test, printed some text formatted in Arial system font normal and bold size 6 pk. on 203 dpi printer (TLP 2844, GK420t) on direct thermal label from Zebra Designer and MS Word. I had same setting (darkness, speed etc), use same zebradesigner driver. I has tested also from another desktop and is same. Please find attached final labels, where printed text is self descriptive.
Any Ideas how to improve ZebraDesigner printed system font quality?