In the design of vapes, the tank is one of the core components, responsible for containing and storing e-liquid. The key performance requirements for the tank include heat resistance, chemical resistance, high impact resistance, dimensional stability, and food safety. As pod-based vapes have gained popularity, the choice of tank material has become increasingly important. Although PCTG is currently the dominant material in the industry, other materials such as transparent nylon are also starting to emerge in the market. This article delves into the choice of vape tank materials, analyzing alternatives to PCTG and how these materials affect the overall performance and safety of vapes.
1. PCTG: The Industry’s Leading Material
PCTG (polycyclohexylene dimethylene terephthalate) is one of the most widely used materials in vape tanks, especially since 2018. The TRITAN series from Eastman, such as Tritan TX1501 HF and Tritan TX1001, have become the top choice for tank materials due to their outstanding transparency and durability.
PCTG’s advantages lie not only in its transparency and chemical resistance but also in its excellent heat resistance and food safety properties, and it is free from harmful substances like bisphenol A (BPA). Initially, PCTG was primarily used in cosmetic packaging, plastic water bottles, and other industries. With the rise of the vape market, PCTG’s superior performance has made it an ideal material for tanks, bases, mouthpieces, and top caps.
Processing Characteristics of PCTG:
- Low Mold Temperature Requirement: The mold temperature for PCTG should be controlled between 15-40°C; the lower, the better.
- High Drying Requirement: PCTG plastic pellets need to be thoroughly dried during processing, or the quality of the finished product may be affected.
- Suitable Processing Temperature: Injection molding temperature should be controlled between 240-260°C, while extrusion and blow molding temperatures should be controlled between 190-220°C.
Despite PCTG’s wide application in the vape industry, it does have some challenges, such as its high drying requirements, which, if not properly managed, could lead to a high scrap rate. Additionally, the cost of PCTG is relatively high, and its supply is subject to fluctuations based on material suppliers, causing market instability and price volatility.
2. Transparent Nylon: A Strong Competitor
Transparent nylon has begun to enter the vape market, particularly in CBD-based vapes, gradually emerging as a material that competes with PCTG. Transparent nylon excels in heat resistance and chemical resistance, sometimes even outperforming PCTG, especially in its superior chemical resistance and resistance to environmental stress cracking.
In March 2025, Ispire partnered with Raw Garden to launch the one-piece CBD vape, Sprout™, made using PA12 material, marking a significant advancement in the use of transparent nylon in the vape industry.
Advantages of Transparent Nylon:
- Outstanding Transparency: Transparent nylon’s transparency even surpasses PC, approaching that of PMMA, making it suitable for vape tanks requiring high transparency.
- Excellent Chemical Resistance: Transparent nylon has strong resistance to chemical corrosion and performs exceptionally well in terms of oil resistance, solvents, and environmental stress cracking.
- High Mechanical Properties: Transparent nylon offers high mechanical strength and thermal stability, making it suitable for high-demand use.
- Good Processability: Transparent nylon is easy to mold and process, offers good dimensional stability, and has a low coefficient of thermal expansion.
The disadvantage of transparent nylon is that it is more expensive, which limits its application in the vape industry. However, in the high-end CBD vape market, transparent nylon is increasingly replacing PCTG as a new material due to its superior performance.
3. Polyester Materials (PETG, PCTG): Advantages and Disadvantages
Polyester materials, including PETG and PCTG, play an important role in the realm of transparent plastics. PETG, known for its high transparency and strong chemical resistance, is increasingly used in vape tanks. The advantages of PETG include good transparency, strong impact resistance, good chemical resistance, and ease of processing, making it suitable for mass production.
Advantages of PETG:
- High Transparency: PETG material has excellent transparency, allowing clear visibility of the e-liquid in the tank.
- Strong Chemical Resistance: PETG offers good corrosion resistance to many common solvents and chemicals.
- Ease of Processing: PETG is easier to process compared to other materials, making it ideal for mass production and cost-effective manufacturing.
- Impact Resistance: PETG has strong impact resistance, which helps protect the tank from daily wear and tear.
However, PETG has a lower heat resistance compared to PCTG. Under high temperatures, PETG may deform, and this can be a risk in high-heat environments, requiring extra caution to avoid issues like melting or distortion.
4. Other Potential Materials
In addition to PCTG, transparent nylon, and PETG, future vape tank materials may include emerging alternatives. With the growing emphasis on sustainability, biodegradable and other eco-friendly materials are becoming potential substitutes. Plant-based plastics, such as PLA (polylactic acid), and biodegradable plastics have been initially introduced in some premium products. While these materials may not yet match the performance of PCTG, their environmental benefits and biodegradability make them an important direction for future development.
Furthermore, with the advancement of nanotechnology and smart materials, the future of tank materials could include higher-performance coatings and materials. For example, hydrophobic coatings or self-cleaning materials could reduce surface contamination and cleaning difficulties, while nanocoatings could provide additional UV resistance, thereby extending the material’s lifespan.
5. The Impact of Materials on Vape Performance
The material used in the vape tank directly affects the product’s performance. First, transparency is crucial for user experience. The transparency of the tank allows users to clearly view the remaining e-liquid, helping them better manage usage. Transparent materials like PCTG and PETG provide superior visibility, which is essential for most vape users.
Secondly, heat resistance is another key factor. Vapes generate heat during use, and the tank material must withstand high temperatures without deforming or releasing harmful substances. PCTG and transparent nylon perform excellently in this regard, maintaining stability even at high temperatures, ensuring the safety of the product.
Additionally, chemical resistance is an important factor. Vape tanks need to resist the chemical components in e-liquids to avoid any reactions. The compatibility of materials with e-liquids directly affects the taste and user experience. PCTG, with its excellent chemical stability, is the preferred material for many vape brands.
6. Material Selection and Consumer Safety
The choice of vape tank material not only impacts the product’s appearance and performance but also has direct implications for consumer health. Low-quality plastics may release harmful substances such as styrene or dioxins under high temperatures, posing potential risks to human health. Therefore, vape manufacturers must choose materials that meet international food safety standards to ensure that their products do not harm consumers during long-term use.
PCTG, as a food-grade material, is widely used in food packaging and medical devices, and has been proven to be safe for human use. Other materials such as PETG and transparent nylon must also undergo rigorous testing to ensure that they do not release harmful substances when in contact with high temperatures and e-liquids over time.
Conclusion
The choice of vape tank materials is a complex issue that involves performance, safety, and environmental considerations. PCTG, with its outstanding transparency, chemical resistance, and heat resistance, remains the dominant material in the market. However, with the advancement of environmental regulations and technology, materials such as transparent nylon and PETG are gradually gaining traction, and new eco-friendly materials may enter the market in the future.
As consumers become more concerned about health and sustainability, vape manufacturers will need to continue innovating materials to ensure that their products not only deliver excellent performance but also meet strict safety and environmental requirements. The future of the vape industry will see ongoing innovations to provide consumers with safer, more eco-friendly, and higher-quality products.
