Polycarbonate – What is it in Vaping?

Definition

Polycarbonate is a tough, transparent thermoplastic polymer widely used in vaping hardware to manufacture clear tanks, pods, and drip tips. Lightweight yet impact-resistant, polycarbonate allows vapers to monitor e-liquid levels while withstanding everyday knocks and moderate heat. Its optical clarity makes it ideal for beginner-friendly pod systems and budget rebuildables, giving users a visual check on remaining juice without removing the tank. Unlike glass, polycarbonate will not shatter if dropped, though it can scratch or cloud over time. The material is compatible with standard Glycol)”>PG (Propylene Glycol) and Glycerin)”>VG (Vegetable Glycerin) ratios, but certain aggressive flavourings (citrus, cinnamon, anise) may cause cracking or “crazing” if left in contact for extended periods.

Technical Details

Polycarbonate (PC) grades used in vaping typically exhibit a tensile strength of 55–75 MPa, a heat-deflection temperature around 120–135 °C, and a light transmittance of 88–91 %. Most clearomisers and pods are injection-moulded to wall thicknesses of 0.7–1.2 mm, balancing durability with juice capacity. Two common variations appear in the market:

  • General-purpose PC: lowest cost, good clarity, prone to stress-cracking with high-acid juices.
  • UV-stabilised or “vape-grade” PC: contains proprietary additives that resist essential oils and UV yellowing, extending service life to 6–12 months of heavy use.

Manufacturers sometimes co-mould polycarbonate with stainless-steel sleeves to create hybrid tanks that survive higher Power Mode temperatures while maintaining visibility. PC is also laser-etchable, so serial numbers, Puff Count calibration marks, or branding can be engraved without weakening the structure.

Usage & Tips

To maximise the life of polycarbonate components:

  • Avoid “tank cracker” flavours—lemon, lime, aniseed, absinthe, strong cinnamon—unless the tank is labelled “crack-resistant.”
  • Rinse with lukewarm water only; hot water accelerates clouding and can induce micro-cracks.
  • When switching juices, dry the tank thoroughly—residual acidic liquid left overnight is the most common cause of failure.
  • Inspect weekly for spider-web lines; replace at first sign of crazing to prevent leaking onto the battery.
  • Store devices upright in cool shade; prolonged sunlight or car dashboards will yellow PC and lower impact strength.

If clouding occurs, polish gently with a micro-fibre cloth and a trace of non-abrasive toothpaste; deeper scratches mean the tank should be discarded.

History & Context

Polycarbonate entered the vaping scene around 2009 when early cig-a-like cartomisers gave way to user-refillable clearomisers. Chinese manufacturers adopted PC over acrylic for its higher impact resistance, enabling the first see-through tanks that survived daily pocket carry. As pod systems surged in popularity after 2016, polycarbonate remained the go-to material for ultra-portable pods due to its ability to be ultrasonically welded, creating leak-proof chambers that still allow easy juice viewing.

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