Unlock Cannabis Vape Tech 3.0: New Innovations

Among cannabis consumption methods, vaporization remains second only to smoking in popularity in the United States, and for vapor devices continues to grow without signs of slowing.

Nevertheless, success for brands isn’t guaranteed. In fact, creating and maintaining a vape brand is far more complex than it initially might appear. Not only can consumers be notoriously fickle, but recent research has also identified multiple pathways of potential harm associated with both hardware and oils.

According to data collected by industry analysts at BDSA, distillate vapes currently command a market share of about 60 percent. If trending data is any indication, they won’t rule the landscape forever, though. Mature markets have seen increased demand for resin and rosin vapes over the past few years as consumers become more educated about concentrates and more aware of the potential for richer plant profiles in rosin and resin. As a result, hardware companies are being challenged to innovate and adapt their technology to accommodate more complex concentrates that behave very differently from distillates when vaporized.

Vaporizing rosin and resin extracts is challenging due to their whole-plant profiles, which often include lipids, fats, and waxes that can clog hardware and disrupt oil viscosity. Controlling viscosity is important not only for the vaping experience but also for safety. If the extract is too thick, it may not saturate the atomizer properly, leading to “dry hits” and the formation of harmful emissions. On the other hand, overly thin oils can leak, damaging hardware components. Other factors, including cannabinoid and terpene profiles and additives like thickeners or reducers, also influence viscosity, making hardware and formulations key factors in product development.

Established industries have set standards to ensure product safety and consistency. Ninety industries—including tobacco, beverage alcohol, and prescription drugs—adhere to standards developed by ASTM International, a 125-year-old organization that develops and publishes worldwide voluntary consensus technical standards. By adopting ASTM Standards, the cannabis industry could demonstrate its commitment to safety, helping build trust with regulators and the public alike. The sooner the cannabis industry embraces these standards, the better prepared companies will be when federal agencies like the U.S. Food & Drug Administration, U.S. Department of Agriculture, and others begin drafting federal guidelines.

Darwin Millard, technical director at Cannabis Safety and Quality (CSQ), a certification program for cannabinoid products that is accredited by the American National Standards Institute, is leading efforts within ASTM’s D37 Committee to create performance standards for cannabis vape formulations and hardware. He emphasized the need for hardware-specific standards in cannabis, rather than relying on the well-established standards for nicotine e-cigarettes. Cannabis oils differ significantly from nicotine e-liquids in character and composition, he said, making hardware designed for vaping nicotine products less than ideal for cannabis. Inconsistent or subpar components can lead to hazardous emissions, device malfunctions, and contamination from dissolved plastics or corroded metal parts. Furthermore, he added, “the lack of standards means variable components from batch to batch.”

To address these concerns, the ASTM D37 Vape Device Safety & Testing Initiative is working to define five key indicators that cannabis devices are reliable and fit for their intended use.

• Material specifications for metal wires and ceramics, designed to identify restricted substances and manufacturing tolerances.

• Power and voltage limits to reduce the risk of overheating, a major source of harmful emissions.

• Aerosol and emissions characterization to better understand what consumers inhale.

• Disassembly guidelines to ensure the safe disposal of all-in-one devices.

• Puff topography protocols tailored to cannabis extracts’ unique performance profiles.

Millard also warned that extracts high in acids, like live resin and rosin, can corrode hardware while they sit in the device. “Cannabinoids themselves are solvents, so they can dissolve plastics and other components, leading to contamination,” he said. “Elemental impurities are a real risk, and because they’re present at trace levels, they’re difficult to detect with standard testing methods.”

The ASTM vape device safety group is working to produce thirty-five to forty standards. As standards are finalized, CSQ will incorporate them into its accredited certification programs, allowing operators to become certified as adhering to the ASTM standards that best fit their use cases. “This is a challenge in itself to define, but we’re making progress, and collaborating with formulation and hardware manufacturers is crucial to achieving the safe, consistent products that cannabis consumers deserve,” Millard said.

Puff topography research reveals how cannabis consumers vape

Puff topography research examines how people use vaping devices by analyzing their puffing behaviors to determine device performance and safety considerations. While nicotine vapes have well-established puffing standards, cannabis vapes lack similar data-driven guidelines.

ACTIVE recently conducted the first large-scale human puff topography study specifically focused on cannabis vaporizers. Among the findings: Cannabis users typically take longer puffs (around five to six seconds), inhale larger volumes (110–220 milliliters), and have shorter inter-puff intervals (seven to ten seconds) compared to nicotine vapers.

The study’s results have significant implications for both safety and cannabinoid delivery. For instance, longer, deeper inhalations can increase not only the amount of THC and other cannabinoids reaching the lungs but also may spur the formation of potentially harmful thermal degradation byproducts. The research suggests that the development of cannabis-specific puffing standards is crucial for consumer safety and continued industry growth.

Hardware manufacturers like Canada’s Greentank are using data from studies like this, combined with their own internal research, to develop safer devices. As the only cannabis vape hardware company to hold a Canadian federal research license, Greentank investigates the interplay between extracts and equipment. “We have a licensed lab in our headquarters to do in-house oil-to-coil testing for hardware compatibility studies with cannabis oils,” said Derek Champoux, head of marketing for the company. “Our lab team ensures every new formulation meets performance and safety thresholds.”

Moreover, the team works directly with brands to create devices tailored to the specific viscosity and composition of their novel extracts. “Brands might come to us with a new liquid diamonds formulation, and we’ll help design a vape product that perfectly matches it,” Champoux said. “There are many levers to pull—reservoir size, intake hole size, resistance levels—all of which we can tweak to match the brand’s formulation.”

Champoux said his company is tackling emerging challenges with a new generation of heating technology. Greentank’s proprietary Quantum Chip™ is a step up from traditional ceramic heating elements—long the industry’s workhorse. Acting like a sponge that absorbs and re-releases oil through repeated thermal cycling, ceramic has inherent limitations. “That thermal cycling of the core being heated and cooled hundreds of times degrades flavor, performance, and safety,” Champoux said. “Consumers notice the flavor drop after fifty to 100 puffs. We wanted to eliminate that.”

Inspired by semiconductor nanofabrication, the Quantum Chip features thousands of microscopic holes that do not absorb oil. Instead, the chip channels oil through the micro-channels, where it is vaporized instantly upon contact with the heating layer. “There’s no thermal cycling of the oil,” Champoux said. “It only gets heated once, so you get a fresh puff every single time from the first to the last.”

The technology also addresses concerns about emissions and heavy metals. Unlike ceramic, which can contain and release heavy metals or other particles when repeatedly heated, the Quantum Chip is made from 100-percent heavy-metal-free materials. “No ceramic particles or heavy metals like lead—virtually zero emissions of those chemicals,” Champoux said. He pointed to laboratory data backing up his claim, including a recent report from Virginia-based McKinney Specialty Labs confirming the chip’s emissions are “virtually zero.”

Greentank’s testing also discovered devices outfitted with Quantum Chips produce aerosol temperatures that are up to 52-percent cooler than the output from conventional ceramic-based hardware. “[The vapor is] a lot smoother and cooler,” said Champoux. “You get a more satisfying vapor, with better flavor and less harshness. That’s especially important, since hotter vapor can irritate the throat and lungs.”

Formulation and hardware risks in cannabis vaping

In vape manufacturing, every detail matters. Achieving a safe, high-quality product requires an in-depth understanding of the chemical interactions between extracts, additives, and hardware components as well as significant knowledge of formulation science and engineering best practices. Dr. Robert M. Strongin, a professor of organic chemistry at Portland State University, is one of the foremost researchers investigating the toxicological risks associated with cannabis vaping products. His work has made significant contributions to understanding the chemical safety concerns associated with devices and extracts, particularly in the areas of thermal degradation, adulterants, and harmful emissions that can damage consumers’ health.

Strongin has evaluated a wide range of devices and formulations. He confirmed poor temperature control and faulty hardware components can dramatically increase the formation of toxins in aerosols. “The wicking feature in vapes is one of the biggest failure points,” he explained. “When it doesn’t perform well, the oil can reach dangerous temperatures, creating carcinogens that are harmful for the lungs.” Even a slight temperature shift can have an outsized impact. “Ten degrees can change the rate of a reaction by a lot,” Strongin said. His work spotlights the urgency of rigorous hardware testing and formulation science for consumer safety.

While Strongin acknowledged steady improvements in hardware safety, he remains concerned about the additives used in formulations. “Just because an additive is safe to eat does not mean it’s safe to inhale,” he said. “The lungs are much more sensitive than the digestive system and lack the stomach’s ability to break down potentially harmful compounds. Many vape ingredients, especially flavorings, have never been tested for inhalation safety, which creates serious health risks.” A wild-west approach to vape formulation, he warned, could spark health crises reminiscent of previous vaping-related outbreaks if harmful or untested additives are used.

Perhaps the most notorious cannabis-vaporizer-related health crisis occurred in 2019, when an outbreak of severe lung illness and rapid respiratory failure left sixty-eight people dead and more than 2,800 hospitalized across the U.S. Some of those who recovered suffered irreversible lung damage. The cause of the syndrome, eventually dubbed EVALI (for e-cigarette or vaping product use-associated lung injury), never was isolated definitively, but vitamin E acetate was the primary suspect. Vitamin E acetate may provide antioxidant benefits when used in dietary supplements, but it can damage lung tissue when inhaled. Prior to the emergence of EVALI, the substance was used as a thickening agent for THC distillates, primarily in the illicit market.

Even some natural components of the plant itself can be problematic in vaping liquids, according to Strongin. He pointed out terpenes can present risks when heated. “Terpenes are composed of isoprene units, and when inhaled in large amounts, they can exceed safety thresholds,” he explained. He stressed the need for informed formulation. “Some terpenes are going to be more toxic than others or degrade more readily,” he said. “We’ve just started to scratch the surface of this research, and brands need to be aware of these differences when mixing and heating [vape liquids].”

Terpenes generally are preferred over synthetic flavorings, but although the natural aromas and flavors of these organic compounds can be appealing, Strongin urged caution when incorporating them into vape-bound extracts. Even seemingly benign organic flavorings can degrade and create harmful emissions when exposed to high temperatures in poorly controlled hardware systems, he said.

Beyond formulation concerns, the physical materials in hardware present another safety hazard. Research from the American Chemical Society revealed the metal components in vape cartridges, responsible for heating the oil, can leach harmful elemental metals into the oil even before the product is used. These contaminants also can end up in the aerosol consumers inhale, posing serious health risks.

While most state regulations mandate vape testing for just four heavy metals (lead, cadmium, arsenic, and mercury), researchers and some manufacturers in the industry suggest hardware makers should strive for pharmaceutical-grade standards that cover a broader range of twenty-four elemental impurities.

Flavor trends and terpene innovation in cannabis vape products

Despite the inherent formulation risks, consumer data from BDSA suggests flavor can have a significant impact on a vape product’s success. Of the twenty best-selling disposable products during 2024’s first quarter, nine featured fruit-forward or blended cannabis flavors. Meanwhile, nearly all top-selling cartridges were strain-specific products.

As vice president of research and development (R&D) at terpene-based flavor solutions provider Abstrax Tech, TJ Martin is hyper-aware of safety issues attached to aerosolized extract enhancers. For that reason, hardware compatibility is among the primary issues he and his team evaluate when helping clients develop safe and enjoyable vaping products. “The first thing I ask is what hardware they are using, because that plays a huge role in the performance of a product,” he said, adding he recommends clients “don’t cheap out on the hardware.”

Martin’s team primarily works with distillates containing a THC base that can be layered with terpenes to create unique, custom flavor profiles or recreate specific strain experiences (since the distillation process typically removes terpenes). Formulating customized vape liquids is one of the easiest ways to scale a brand across state lines or internationally, he said, since it allows companies to maintain product consistency while working with different regional cultivators and hardware manufacturers. “Flavors will be the same regardless of where a consumer buys the product,” Martin said.

In contrast, rosin and resin concentrates, which are crafted from whole-plant extracts, are inherently more variable. Their taste profiles can shift from batch to batch because brands must source their inputs from multiple cultivation and extraction facilities, which makes guaranteeing consistent flavor or potency challenging. However, Martin sees this as an opportunity, not a drawback. “The craft beer world is full of small-batch options like hazy IPAs and West Coast pilsners with taste profiles that can vary, and that’s part of the appeal,” he said. Similarly, in the world of live resin and rosin vapes, subtle variations are part of the allure many connoisseurs enjoy exploring.

Martin also highlighted how brands can harness distillate formulations for creative collaborative products. “I’ve recently seen some cannabis brands doing collaborations with breweries, recreating popular craft beer flavors like Simcoe® hops in vape products for co-branded opportunities,” he said.

Of course, the targeted consumer base makes a big difference in the flavor profiles a brand offers. Martin pointed out canna-curious consumers in their forties or fifties tend to actively avoid the gassy, dank, skunky taste more experienced consumers sometimes seek. Instead, novices in certain adult demographics lean toward fruity-tasting products with strawberry, blueberry, or fruit punch notes.

In traditional consumer packaged goods sectors, sensory science is a cornerstone of R&D, helping brands match market demand and avoid costly missteps that lead to warehouses full of unsold products. While not every cannabis brand has access to a fully trained sensory panel, even small-scale consumer feedback can offer invaluable insights into flavor preferences and guide formulation adjustments. Abstrax developed Sensei, a software platform that standardizes sensory evaluation during cannabis vape R&D. Sensei uses a dynamic cannabis aroma lexicon to train sensory panelists and aggregate data about consumers’ flavor and aroma preferences.

For example, panelists using Sensei might describe a vape liquid’s flavor as “cherry, berry, and gassy” or note an unexpected pineapple hint in a strain meant to evoke OG Kush. Such nuanced feedback helps product teams fine-tune formulations and better align the final product with consumer tastes.

Martin emphasized the importance of sensory evaluation for industry standardization, because the flavor landscape is constantly evolving. “[Plant] breeders in this industry are putting in a lot of work to find what’s new and different and push it to the limits,” he said. “Every year, we see new cultivars you’ve never seen before. If we looked at the sensory wheel from 2002, it wouldn’t have included things like Gelato, Zkittlez, or Runtz, or the more tropical strains like Tangie. It’s an evolving world, and staying in tune with those changes is critical to building a winning vape brand.”

As cannabis vapes continue to evolve, so too must the standards that govern them. Innovation is essential, but without science-backed safeguards and consistent regulation, the risks remain real. The brands that thrive won’t just chase trends; they’ll engineer trust, one puff at a time.

TL;DR: Key Cannabis Vape Safety and Innovation Takeaways