When you pick up a vape—whether it’s a sleek pod‑mod, a compact disposable, or a more traditional box‑mod—you’re holding a miniature piece of engineering that brings together several distinct materials, each chosen for a specific purpose. Understanding what vapes are made out of helps demystify how they function, why certain safety standards exist, and what you should look for when shopping for a reliable device. Below is a deep dive into every major component of a modern vaping product, from the outer shell to the inner circuitry, and from the liquid that produces the vapor to the tiny bits of metal that heat it.
1. The Outer Housing: Plastics, Metals, and Alloys
1.1 Polycarbonate (PC) and Acrylonitrile‑Butadiene‑Styrene (ABS)
Most disposable vapes and many closed‑system pod‑mods use high‑impact plastics such as polycarbonate (PC) or ABS for the outer shell. These polymers are chosen for several reasons:
- Durability – Both PC and ABS can survive drops, knocks, and everyday wear without cracking.
- Moldability – Injection molding allows manufacturers to produce complex shapes, ergonomic grips, and branding details in a single step.
- Weight reduction – Compared with metal, plastics keep the device lightweight, which is crucial for portability.
PC also offers excellent optical clarity, making it a popular choice for devices with transparent or semi‑transparent sections that let users see the e‑liquid level. ABS, on the other hand, is slightly more resistant to heat deformation, which can be advantageous for devices that generate higher coil temperatures.
1.2 Aluminum, Stainless Steel, and Brass
Higher‑end box‑mods, mechanical mods, and some pod systems opt for metal housings. The most common alloys are:
- Aluminum 6061‑T6 – This alloy delivers a great strength‑to‑weight ratio, good heat dissipation, and a sleek, machined finish. It is also relatively inexpensive and easy to anodize for color variations.
- Stainless steel (304/316) – Known for its corrosion resistance, stainless steel is favored for devices that may be exposed to salty or humid environments (e.g., coastal cities). It also provides a premium “feel” and can serve as a heat‑sink, helping to keep the battery and coil region cooler during prolonged use.
- Brass (copper‑zinc alloy) – Often used in the construction of the coil housing or the inside of some pod systems because of its excellent thermal conductivity. Brass can also be plated with nickel or other finishes to improve durability and reduce oxidation.
1.3 Ceramic and Glass Components
In some premium vaping devices, ceramic or tempered glass is incorporated into the housing for both aesthetic and functional reasons. Ceramic wicks are appreciated for their ability to wick e‑liquids evenly while resisting dry‑hits, whereas glass mouthpieces can offer a “cleaner” taste by eliminating any metallic flavor transfer.
2. The Battery: Lithium‑Ion Chemistry
2.1 Cell Formats (18650, 21700, 20700, Integrated Pods)
The energy source in virtually every rechargeable vape is a lithium‑ion (Li‑ion) cell. The most common formats are:
- 18650 – 18 mm diameter, 65 mm length, delivering 2000‑3500 mAh. This size has been the backbone of the vaping industry since the early days of “mod” culture.
- 20700 and 21700 – Slightly larger in diameter and length, providing higher capacity (3000‑5000 mAh) and better energy density, which translates to longer vape sessions before recharging.
- Integrated pod batteries – In disposable vapes and many pod‑mods, the battery is permanently attached to the device’s PCB (printed circuit board). These are often smaller “button” cells (e.g., 14500 or 16340) or custom‑shaped Li‑ion packs designed to fit within a thin chassis.
The chemistry of Li‑ion cells typically involves a lithium cobalt oxide (LiCoO₂) cathode combined with a graphite anode. Some higher‑drain devices employ lithium manganese oxide (LiMn₂O₄) or lithium iron phosphate (LiFePO₄) chemistries to handle the high wattage output demanded by sub‑ohm coils.
2.2 Battery Management Systems (BMS)
A sophisticated BMS is embedded within the vape’s PCB to:
- Prevent over‑charging and over‑discharging – Both conditions can degrade cell health or cause safety hazards.
- Balance cell voltage – In devices with multiple cells, the BMS equalizes the voltage of each cell to extend overall lifespan.
- Monitor temperature – Thermal sensors protect against overheating, especially during rapid “continuous vape” draws.
- Control short‑circuit protection – By quickly cutting off power if a short occurs, the BMS mitigates the risk of fire or explosion.
3. The Coil Assembly: Resistance Wire and Wicking Materials
3‑1. Resistance Wire Types
| Wire Material | Typical Resistivity (Ω·cm) | Typical Use‑Case | Notable Characteristics |
|---|---|---|---|
| Kanthal A1 (FeCrAl) | 1.40 × 10⁻⁶ | Standard sub‑ohm builds, mouth‑to‑lung (MTL) | Stable at high temperatures, easy to work with, low cost. |
| Nickel (Ni200) | 6.99 × 10⁻⁶ | Temperature‑controlled (TC) vaping | Highly responsive to temperature changes; used with TC modes. |
| Titanium (Ti) | 4.20 × 10⁻⁶ | TC vaping, “snappy” flavor bursts | Requires careful handling (oxidation risk) and precise TC settings. |
| Stainless Steel (SS 304/316) | 7.20 × 10⁻⁶ | TC & variable wattage (VW) | Dual‑function: works as a resistance wire and a TC element. |
| Nickel‑Chromium (Nichrome) | 1.10 × 10⁻⁶ | High‑wattage, “dripping” builds | Low resistance enables high current draw, but can oxidize faster. |
| Platinum (rare) | 1.06 × 10⁻⁶ | Specialty builds, durability testing | Very expensive, used mainly for research or premium limited runs. |
The wire is typically wound around a small, cylindrical core made of silica, ceramic, or quartz. These cores act as an insulator, preventing short‑circuits while providing a stable platform for the coil. In many disposable devices, the coil is pre‑installed on a ceramic or stainless‑steel mesh that also functions as the wick.
3‑2. Wicking Materials
- Cotton (Organic or Synthetic) – The most common wick, prized for its fast capillary action and neutral flavor profile. Premium cotton is often “organic” and pre‑treated (e.g., “V2”), which reduces lint and improves longevity.
- Silica (Porous Glass) – Used in some disposable vapes because it can hold more e‑liquid and tolerate higher temperatures without collapsing. However, silica can impart a slightly “harsh” taste if the coil runs too hot.
- Ceramic – Ceramic wicks offer a consistent, “dry‑hit‑free” experience and resist carbonization. They are common in high‑end disposable units and some pod systems that claim “cleaner flavor.”
- Mesh (Stainless Steel or Nickel) – Mesh wicks provide a larger surface area for e‑liquid absorption, resulting in denser vapor clouds and smoother throat hits. The mesh is often paired with cotton or silica to combine the best of both worlds.
4. The E‑Liquid: Chemical Composition and Additives
4‑1. Base Ingredients – Propylene Glycol (PG) and Vegetable Glycerin (VG)
| Property | Propylene Glycol (PG) | Vegetable Glycerin (VG) |
|---|---|---|
| Viscosity | Low – thin, water‑like | High – syrupy, viscous |
| Flavor Carry | Excellent – transmits flavor sharply | Moderate – slightly mutes nuanced notes |
| Throat Hit | Strong – mimics cigarette “bite” | Soft – smoother, more “lung‑hit” feel |
| Vapor Production | Limited – produces less dense clouds | Abundant – creates thick, voluminous clouds |
| Allergenic Potential | Higher for sensitive individuals | Generally lower, but can be irritating at high concentrations |
Manufacturers blend PG and VG in various ratios (e.g., 50/50, 70/30, 80/20) to tailor the vaping experience. A higher VG ratio is favored for sub‑ohm, high‑wattage devices, whereas a higher PG ratio suits mouth‑to‑lung (MTL) setups and those who need a stronger throat hit.
4‑2. Nicotine Forms
- Free‑base nicotine – The traditional form used in most e‑liquids. It is highly volatile, delivering a rapid nicotine “rush” but can be harsh at higher concentrations.
- Nicotine salts – Created by reacting free‑base nicotine with an acid (commonly benzoic acid). This lowers the pH, reducing harshness and allowing for higher nicotine concentrations (e.g., 20 mg/ml or 50 mg/ml) without the unpleasant throat hit. Nicotine salts are the hallmark of many pod‑mod and disposable vape brands.
4‑3. Flavorings
Flavor compounds are typically food‑grade aroma chemicals derived from the FEMA GRAS (Generally Recognized as Safe) list. However, inhalation safety differs from ingestion safety, and a growing body of research examines the thermal degradation products of certain flavorings.
- Fruit & candy flavors – Often use esters (e.g., ethyl maltol, isoamyl acetate) that produce sweet or tropical notes.
- Menthol & mint – Contain menthol, menthone, and related compounds that impart cooling sensations.
- Tobacco & spice – May incorporate pyrazines, aldehydes, and natural extracts to mimic the complex profile of combustible tobacco.
Manufacturers must ensure that added flavorings do not exceed concentration limits set by local regulatory frameworks (e.g., the EU’s Tobacco Products Directive caps flavoring at 10 mg per 10 ml).
4‑4. Additives and Sweeteners
Some e‑liquids contain sucralose or ethanol as sweetening agents. Sucralose is a chlorine‑substituted sugar that remains stable at typical vaping temperatures, but at extreme heat it can decompose into potentially harmful compounds. Ethanol is occasionally used as a solvent for certain flavors, but it also lowers the boiling point of the overall mixture, influencing vapor density.
5. The Printed Circuit Board (PCB): Electronics and Sensors
The PCB is the “brain” of a vape, integrating a microcontroller, power regulation components, and safety sensors. Here’s a breakdown of its primary elements:
- Microcontroller (MCU) – Often a low‑power ARM Cortex‑M0 or similar 8‑bit/32‑bit processor that interprets user input (button presses, draw detection) and controls power output.
- Power MOSFETs – Act as electronic switches that regulate the current flowing through the coil, allowing the device to adjust wattage or temperature in real time.
- Voltage/Current Sensors – Provide feedback to the MCU, enabling accurate wattage calculation (W = V × I).
- Temperature Sensor (for TC coils) – Usually a thermistor or built‑in resistance measurement of the coil material (Ni, Ti, SS) to maintain a set temperature.
- OLED or LED Display – Shows wattage, battery level, puff counter, and sometimes coil resistance.
- Safety Features – Over‑current protection (OCP), short‑circuit protection (SCP), and reverse‑polarity protection (RPP) are implemented via hardware or firmware logic.
All PCB components are typically surface‑mounted (SMT) to keep the overall device profile thin. The board is coated with a conformal coating (e.g., silicone or epoxy) to protect against moisture and mechanical stress.
6. The Mouthpiece and Airflow System
6‑1. Materials
- Medical‑grade silicone – Frequently used for O‑rings and gaskets to create a tight seal while remaining flexible.
- Polypropylene (PP) – Often the material of the mouthpiece tube because it resists heat and is chemically inert to PG/VG.
- Stainless steel or brass mesh – In some devices, a small mesh screen sits at the mouthpiece to break up large droplets and ensure a “dry‑hit‑free” draw.
6‑2. Airflow Mechanics
Airflow channels are engineered through a combination of drilled holes, venturi tubes, and adjustable airflow rings. The design directly influences the draw resistance (how hard you have to pull) and the mixing of vapor with ambient air, which in turn impacts throat hit and cloud production.
- Restrictive airflow – Provides a tighter draw, enhancing flavor intensity and mimicking a cigarette‑like experience.
- Open airflow – Allows larger volumes of vapor, ideal for direct‑lung (DL) vaping and cloud‑chasing.
Manufacturers may offer adjustable airflow sliders that let the user fine‑tune the resistance without disassembling the device.
7. Disposable Vapes: Integrated Construction
Disposable vapes are a unique category where virtually every component is pre‑assembled and sealed. The typical architecture includes:
- Integrated battery‑PCB unit – A small Li‑ion button cell bonded directly to a single‑layer PCB.
- Pre‑filled e‑liquid reservoir – Often a sealed silicone or glass‑filled chamber that cannot be refilled.
- Fixed coil‑wick assembly – Usually a ceramic or porous silica wick wrapped around a stainless‑steel coil, pre‑impregnated with e‑liquid.
- One‑piece housing – Molded plastic that encloses all parts, with a break‑away mouthpiece that snaps off when first used.
Because the entire system is sealed, manufacturers must guarantee that the chosen materials can withstand the full lifespan of the device (often 3000‑8000 puffs) without degradation. This explains the prevalence of high‑temperature‑stable ceramics and rigid, low‑permeability plastics in disposables.
8. Regulatory and Safety Standards Influencing Material Choice
8.1 ISO 9001 and ISO 14001
Many reputable vape manufacturers, including those supplying the Australian market, hold ISO 9001 (quality management) and ISO 14001 (environmental management) certifications. These standards affect material sourcing by requiring:
- Traceability of raw materials (e.g., ensuring cotton is organic and pesticide‑free).
- Controlled manufacturing environments that limit contamination of metals and plastics.
8.2 TGO 110 (Australian Therapeutic Goods)
In Australia, vape devices that contain nicotine are classified under the Therapeutic Goods Order (TGO) 110. The regulation mandates that:
- Batteries meet UN 38.3 testing for transport safety.
- Metal parts must be lead‑free and cadmium‑free.
- Plastics used in devices that come into contact with e‑liquids must be food‑grade (e.g., FDA‑approved PP or PET).
Compliance with TGO 110 ensures that the materials selected for housings, seals, and internal components are not only safe for inhalation but also meet strict import and distribution criteria.
8.3 European Union Tobacco Products Directive (TPD)
For brands that also sell in the EU, the TPD imposes a 2 ml maximum e‑liquid capacity for refillable containers and caps nicotine concentration at 20 mg/ml. The directive also requires that any flavorings be listed in a European Union’s Union List of Approved Substances, which influences the choice of flavor additives and the solvents used to carry them.
8.4 US FDA “Deeming Rule”
In the United States, the Food and Drug Administration (FDA) Deeming Rule treats e‑cigarettes as tobacco products. Manufacturers must submit Premarket Tobacco Applications (PMTA) that detail material composition, heating temperatures, and emissions testing. This drives the industry toward using high‑purity metals (e.g., 99.99 % pure nickel) and low‐outgassing plastics to minimize the formation of potentially harmful degradation products.
9. Environmental Considerations: End‑of‑Life for Vape Materials
9.1 Battery Recycling
Lithium‑ion batteries contain valuable metals (cobalt, nickel, lithium) and hazardous chemicals (electrolyte solvents). Responsible manufacturers partner with battery collection programs and recycling facilities that safely extract and repurpose these materials. In Australia, programs such as Call2Recycle provide drop‑off locations for used vape batteries.
9.2 Plastic and Metal Waste
While the outer housing of most devices is made from recyclable plastics (e.g., PET, HDPE), the mixture of metals, electronics, and adhesives often makes e‑waste processing challenging. Some brands have started take‑back schemes, offering discounts on new purchases in exchange for returning used units.
9.3 Disposable Vape Impact
Because disposables are designed for single‑use, they contribute disproportionately to waste. To mitigate this, certain manufacturers incorporate biodegradable polymers (e.g., polylactic acid, PLA) into the mouthpiece and capsule. However, the core electronic components (battery, PCB) still require proper e‑waste handling.
10. Frequently Asked Questions (FAQs) About Vape Materials
| Question | Answer |
|---|---|
| What type of plastic is safest for a vape housing? | Food‑grade polypropylene (PP) or high‑impact polycarbonate (PC) are preferred because they are chemically inert, heat‑stable, and approved for contact with consumables. |
| Can I vape if I’m allergic to nickel? | Yes, but avoid coils made from nickel or nickel alloys (e.g., Ni200). Opt for Kanthal, stainless steel, or ceramic coils, which contain minimal nickel. |
| Is the metal in a coil hazardous when heated? | When used within the device’s specified temperature range, the metal remains stable. However, overheating can cause oxidation, releasing metal oxides that may irritate the lungs. Temperature‑controlled vaping helps keep coil temperature in a safe window. |
| Do all e‑liquids contain propylene glycol? | No. Some “PG‑free” formulations use only vegetable glycerin (VG) with added sweeteners or alcohol to thin the liquid. These are marketed for users who experience sensitivity to PG. |
| Are nicotine salts safer than free‑base nicotine? | Nicotine salts reduce the harshness at higher concentrations but do not lessen nicotine’s addictive potential. Safety is comparable; the key is to choose a concentration that matches your consumption habits. |
| How long does a typical lithium‑ion battery last in a vape? | Most high‑quality Li‑ion cells retain ~80 % of their original capacity after 300‑500 full charge cycles. In daily vaping (one full charge per day), you can expect 1–2 years of optimal performance. |
| Can I recycle the coil wires? | Metallic coil wires (Kanthal, SS, Ni) can be collected with metal scrap, but many recycling programs require separation from the e‑liquid residue. Some specialty e‑waste recyclers accept them directly. |
| Why does my vape feel “metallic” on the inhale? | A metallic taste usually indicates a dry‑hit (insufficient e‑liquid on the wick) or an over‑heated coil causing oxidation. Adjusting airflow, lowering wattage, or re‑wicking should resolve the issue. |
| What is the purpose of the O‑ring in a vape? | O‑rings, typically made of silicone, create airtight seals between the tank, mouthpiece, and coil chamber, preventing leaks and maintaining consistent airflow. |
| Are glass atomizers better than metal ones? | Glass (or quartz) atomizers provide superior flavor neutrality and reduce metal taste. However, they are more fragile and may break under impact. Metal atomizers are more durable but can impart a subtle metallic note if the coil overheats. |
11. How Manufacturers Choose Materials: A Decision Matrix
When a brand like IGET or ALIBARBAR develops a new vape, the engineering team evaluates each component against a set of criteria:
| Component | Primary Considerations | Typical Material Choice | Why It Makes Sense |
|---|---|---|---|
| Housing | Durability, weight, cost, brand aesthetic | Aluminum 6061‑T6 (premium), ABS (budget) | Aluminum offers a premium feel and good heat dissipation; ABS keeps costs low for entry‑level models. |
| Battery | Energy density, safety, size | 18650 Li‑ion (high‑capacity mods) or integrated 16340 (compact pods) | 18650 provides long life for high‑wattage devices; integrated cells simplify disposable designs. |
| Coil | Resistance range, temperature stability, longevity | Kanthal A1 for fixed‑resistance, SS 304 for TC, Mesh for cloud production | Kanthal is inexpensive and stable; stainless steel offers flexibility for both VW and TC; mesh expands surface area for vapor. |
| Wick | Capillary action, resistance to carbonization | Organic cotton for flavor purity, ceramic for dry‑hit protection | Cotton gives clean flavor; ceramic eliminates dry‑hits, extending coil life. |
| E‑liquid base | Viscosity, throat hit, vapor density | 70/30 VG/PG for sub‑ohm, 50/50 for MTL | Higher VG yields larger clouds; balanced PG provides stronger throat hit. |
| Flavorings | Regulatory compliance, taste profile, thermal stability | FIA (Food‑grade) esters, menthol, sucralose (optional) | FDA‑approved esters ensure safety; menthol adds menthol‑cool effect; sucralose adds sweetness without extra sugar. |
| PCB | Power regulation, safety features, firmware capability | 8‑bit MCU with MOSFETs, conformal coating | Balances cost with reliable performance; protective coating guards against moisture. |
| Mouthpiece | Comfort, heat resistance, leak‑proofing | Medical‑grade silicone O‑rings, PP tubing | Silicone provides a soft seal; PP resists heat and chemicals. |
This matrix illustrates how each material is selected not in isolation, but as part of a holistic design philosophy that balances user experience, regulatory compliance, and manufacturing economics.
12. Emerging Materials and Future Trends
12‑1. Graphene‑Enhanced Conductors
Researchers are experimenting with graphene‑coated copper wires for coils, which promise lower resistance and faster heat transfer, potentially enabling lower wattage for the same vapor production. Early prototypes show improved flavor fidelity and reduced oxidation, but large‑scale production remains costly.
12‑2. Bio‑Based Plastics
Companies are testing polyhydroxyalkanoates (PHAs)—biodegradable plastics derived from bacterial fermentation—for disposable vape casings. PHAs degrade under industrial composting conditions, offering a greener end‑of‑life scenario, though they currently have lower impact resistance compared to traditional PC.
12‑3. Ceramic‑Infused Wicks
Beyond plain ceramic, some manufacturers are embedding nano‑porous ceramic particles within cotton wicks, creating a hybrid that combines cotton’s flavor neutrality with ceramic’s dry‑hit resistance. Lab data suggests a 30 % reduction in coil temperature spikes during rapid draws.
12‑4. Solid‑State Batteries
Solid‑state lithium batteries, which replace the liquid electrolyte with a solid polymer, promise higher safety margins (no risk of electrolyte leakage) and higher energy density. While still in early adoption phases, a few high‑end brands have announced prototypes that could extend a vape’s battery life by up to 40 % without increasing size.
13. Practical Tips for Consumers: Evaluating Material Quality
- Check for certifications – Look for packaging that references ISO 9001, ISO 14001, or TGO 110 compliance. These indicate that the manufacturer follows rigorous material‑selection protocols.
- Feel the weight – A heavier device often contains metal housing and a larger battery, which can mean longer sessions; lighter devices may rely more on plastic and smaller batteries.
- Inspect the coil – If the coil is visible (e.g., in a clear pod), you can usually determine if it’s Kanthal, stainless steel, or mesh. High‑quality coils will have smooth, uniform winding without visible burrs.
- Read the e‑liquid label – Look for separate listings of PG, VG, nicotine, and flavoring percentages. Avoid “black box” liquids that omit this information, as they may conceal undesirable additives.
- Verify battery safety – Reputable sellers provide a battery safety sheet, detailing max charge voltage (typically 4.2 V per cell) and recommended chargers.
- Consider the warranty and return policy – Brands confident in their material choices often back their products with at least a 12‑month warranty on the device and a satisfaction guarantee.
14. Summarizing the Core Materials
| Component | Core Material(s) | Why It’s Used |
|---|---|---|
| Housing | Polycarbonate, ABS, Aluminum 6061‑T6, Stainless steel | Combines durability, weight management, and aesthetic appeal |
| Battery | Lithium‑ion (LiCoO₂, LiMn₂O₄) | High energy density, rechargeable, reliable power delivery |
| Coil Wire | Kanthal A1, Nichrome, Stainless steel, Ni200, Ti | Provides specific resistance values, temperature‑control capability, and durability |
| Wick | Organic cotton, silica, ceramic, mesh | Capillary action, flavor neutrality, and resistance to dry‑hits |
| E‑Liquid Base | Propylene glycol (PG), Vegetable glycerin (VG) | Control viscosity, throat hit, and vapor production |
| Nicotine | Free‑base, nicotine salts (benzoic acid‑based) | Adjust harshness and nicotine delivery efficiency |
| Flavorings | Food‑grade esters, menthol, sucralose, ethanol | Deliver a wide variety of taste profiles while adhering to regulatory limits |
| PCB & Electronics | FR‑4 fiberglass board, copper traces, MOSFETs, MCUs | Manage power, safety, and user interface functions |
| Mouthpiece/Seal | Medical‑grade silicone, polypropylene, stainless‑steel mesh | Provide comfort, heat resistance, and leak‑proof sealing |
| Disposable Components | Integrated button‑cell Li‑ion, pre‑filled sealed chamber, ceramic or silica wick | Ensure compact, ready‑to‑use design with long shelf‑life |
15. Closing Thoughts
Understanding what vapes are made out of goes far beyond curiosity—it equips you with the knowledge to make safer, more satisfying choices. The combination of high‑impact plastics or precision‑machined metals for the housing, robust lithium‑ion cells for power, carefully engineered coil‑wick assemblies for vapor generation, and meticulously formulated e‑liquids for flavor and nicotine delivery creates a product that is both sophisticated and accessible. Regulatory frameworks like Australia’s TGO 110, the EU’s TPD, and the US FDA’s Deeming Rule shape the material landscape, pushing manufacturers toward higher standards of safety and transparency.
For brands like IGET and ALIBARBAR, adhering to these standards while innovating with new materials such as graphene‑enhanced coils or bio‑based plastics can set them apart in a crowded market. As new technologies emerge—solid‑state batteries, nano‑porous wicks, and biodegradable casings—the core principle remains the same: each material is selected to deliver a specific performance characteristic while safeguarding the user’s health and the environment.
When you hold your next vape, take a moment to appreciate the intricate dance of polymers, alloys, electrolytes, and flavor compounds that make that smooth puff possible. Knowing the science behind the device empowers you to choose products that align with your preferences, your values, and the regulatory standards that protect you. Happy vaping, and may every draw be as balanced and informed as the materials that make it possible.