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We helped an emerging independent vape brand develop a high-performance big-smoke DTL pod system with fully patented atomization structure in 60 days, solving leak & inconsistent vapor issues, and helping the brand stand out in competitive sub-ohm market after pre-launch beta testing.
Client
Emerging Independent Vape Brand
Industry
Vape Hardware & DTL Enthusiast Market
Location
Global DTL enthusiast market
Project Cycle
60 Days To Engineering Sample Approval
The client is a new emerging vape brand targeting sub-ohm DTL vapers. They wanted a high-performance pod system with huge vapor output, while generic off-the-shelf pod kits suffered from leakage and unstable smoke volume. They needed exclusive patented mechanical design to avoid copycats and build unique selling points.
Generic pod structures can not maintain consistent big smoke under high power settings.
Eliminate liquid leakage problem under high airflow and sub-ohm working conditions.
Need original mechanical design to apply for patent and prevent competitors copying.
Keep compact body size while ensuring vapor and flavor consistency in mass production.
Our R&D team designed a brand-new patented split atomization structure, optimizing airflow channel and sealing system, to deliver stable big vapor for direct lung inhale, together with full hardware customization and patent application support.
Developed original split atomization structure, redesigned airflow path and multi-layer anti-leak sealing structure specially for DTL sub-ohm use.
Fine-tuned mesh coil parameters to maximize vapor density while maintaining consistent flavor output for DTL direct lung hits.
Custom housing shape, surface finish, logo engraving, magnetic pod connection and adjustable airflow to match brand positioning.
Complete mechanical simulation, 3D printing prototype, leak & drop reliability testing, plus assistance for patent application of the unique internal structure.
Demand discussion, NDA signing, concept sketch confirmation
Internal patented structure design, 3D prototype manufacturing
Leakage, airflow and vapor performance test, structure optimization
Appearance confirmation, final sample validation, patent document preparation
Client signed off engineering sample, ready for mold development & mass production
The patented DTL pod system successfully eliminated leakage and achieved stable big vapor performance. The exclusive structure helped the brand build strong differentiation and attract DTL enthusiast community attention during beta pre-launch.
From concept to sample approval
Leakage rate in reliability test
Original atomization structure
Beta tester satisfaction rate
We needed a truly unique DTL pod kit to compete in the enthusiast market. Their ODM team delivered a patented structure that solved our leakage and vapor consistency pain points. The prototype performance exceeded our expectation, and we received positive feedback from our beta testers. We are now moving forward to mold development and mass production.
Mark Kael
Founder, Emerging Vape Brand
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Tell us your DTL / MTL pod system requirements, our R&D team supports custom patented structure development.