Structural Parts

The structural parts of vape are typically made from materials such as PCTG, PC, ceramic, TPU, and resin:

PC (Polycarbonate): Used in areas without direct e-liquid contact, such as separate oil tanks.

PCTG (Polyethylene Terephthalate Glycol): Ideal for components in contact with e-liquid, such as integrated pod systems.

Ceramic: Commonly found in CBD atomizers like CCELL.

TPU (Thermoplastic Polyurethane): Often used in dual-color injection molding alongside PC.

Resin: Popular for drip tips, such as 510 and 810 sizes.

Mouthpieces are designed for ergonomics, available in flat or round shapes. Flat mouthpieces are thinner for a better vaping experience but may transfer heat, while dual-color TPU layers enhance comfort during use. Mouthpiece length is optimized to prevent overheating, and transparent designs may reveal condensation. Silicone mouthpieces are less common due to challenges with color matching and durability.

Atomizers

Atomizers are divided into metal and ceramic types:

• Metal Atomizers: Include spiral wound wires and mesh (single, dual, or multiple configurations).
• Ceramic Atomizers: Feature thick-film printed or metal-embedded designs.

The heating wire’s resistance (measured in ohms, Ω) determines power output—lower resistance increases power but requires compatibility with the device’s board for optimal flavor and to avoid burning. Atomizers consist of:

• Heating Element: Spiral wires, etched/stamped mesh, or thick-film metal paste.
• Wicking Material: Cotton or porous ceramic, leading to cotton cores or ceramic cores.

Cotton cores excel in vapor production and flavor fidelity, while ceramic cores deliver a smoother taste. Heating wire materials include Kanthal A1, iron-chromium-aluminum, nickel-chromium, stainless steel, pure nickel, and pure titanium, with mesh typically made from iron-chromium-aluminum.

• Spiral Wound Wire Atomizers: Feature spring-like wires, fiberglass ropes, insulated leads, and tubes. Used in disposable vape (600-4000 puffs), though they have shorter lifespans and may burn.
• Mesh Atomizers: Include mesh, insulated leads, atomizing tubes, and wicking cotton. Common in disposables with 5000-60000 puffs.
• Ceramic Atomizers: Comprise ceramic cores, wicking cotton, CNC metal parts, and seals. Used in CBD, MOD, or pod systems.

Oil Tank Accessories

Oil tank accessories are constructed from PETG, PCTG, PA12, and glass:

• PETG: Found in small-capacity disposable vape with cylindrical tanks.
• PCTG: Used in large-capacity disposables or pod cartridges.
• Glass and PA12: Typically seen in CBD atomizers.

Tanks require chemical, heat, and weather resistance. Transparent or semi-transparent designs allow e-liquid monitoring. PETG suits extrusion processes, while PCTG works for both injection molding and extrusion.

Batteries

Batteries come in cylindrical (e.g., 13450, 18250) or rectangular (e.g., 802030) shapes, sized to fit the e-cigarette’s structure. Materials include pure cobalt or cobalt + ternary blends. High-rate batteries (5A-10A discharge) support high-power vapor output. Emerging capacitive and solid-state batteries improve sustainability and recyclability.

Battery capacity is calculated as:
mAh×3.7V÷1000=Wh\text{mAh} \times 3.7\text{V} \div 1000 = \text{Wh} mAh×3.7V÷1000=Wh

PCBA (Scheme Board)

The PCBA manages switching, power regulation, temperature control, lighting, and sound effects. As vape grow smarter, PCBAs require advanced microcontrollers (MCUs). Power output is calculated as:
V2Ω=W\frac{V^2}{\Omega} = W ΩV2​=W

Display Screens

Display options include LED segment displays, LCDs, TFTs, flexible displays, OLEDs, and touch capacitive screens. Costs depend on size, brightness, color range, resolution, and dynamic capabilities.

Microphones (Mics)

Mics serve as airflow sensors, detecting inhalation. Traditional electret condenser mics are giving way to silicon mics, which offer better acid resistance and sensitivity. Types include:

• Electret Mics: Plug-in or wired.
• Silicon Mics: Forward, reverse, surface-mount, or wired.

Sensitivity ranges from -70 to -400 KPA. 

Silicone

Silicone seals e-liquid or airflow in components like mouthpiece plugs, tank seals, and mic seals. With a hardness of 50-70 Shore A, silicone surfaces may be sandblasted for texture.

Absorbent Cotton

Absorbent cotton prevents condensation and leakage, placed in mouthpieces, tank bottoms, and near batteries. It’s typically made from polyester fiber composites.

E-Liquid

E-liquid comprises propylene glycol (PG), vegetable glycerin (VG), nicotine, flavorings, and additives. Ratios influence vapor, flavor, and throat hit. Common flavors include:

• Tobacco
• Fruits
• Desserts
• Beverages

Vapepie provides a variety of e-liquid components and flavors.

Vapepie Popular Flavor

• Crisp Apple Flavor Vape

• Mint Flavor Vape

• Peach Flavor Vape

• Watermelon Vape

• Mango Vape

• Blue raspberry vape

• Strawberry Vape

• Lemon Flavor Vape

• Cherry Flavor Vape

• Grape Flavor Vape

• Kiwi Flavor Vape

• Passion fruit vape

Summary

Vape vary widely—disposables, CBD/THC devices, pods, mods, MTL, DTL, heat-not-burn, and hookahs—but share similar core components. This guide details these components and their roles, offering insight into e-cigarette design and function.