Polyester-based chemical toner with a low fusing temperature is demonstrated. The toner composition is based on spherical toner particles produced using the proprietary Chemical Milling process of DPI Solutions with a diameter centered about 6 μm. It exhibits the fusing latitude in the range of 100-150 °C, of which the low fusing temperature is significantly lower than commercial ‘low temperature’ toner used in a printer with a ribbon fuser architecture. The low fusing temperature with excellent blocking resistance is achieved through a new amorphous resin with a linear polyester chemical architecture in which the alkyl group length of alkylene diol monomers was optimized for the glass transition temperature about 60°C. We present the molecular design principle and the thermo-physical performance of the resin as well as toner processing characteristics of the resin in this paper.