Manufacturing
Process Guide.
A complete step-by-step visual walkthrough of our pod device manufacturing process — from raw components to finished, quality-certified product. Every unit follows this exact precision workflow.
Coil & Heating Element Assembly
The foundation of every pod — precision coil winding, cotton-wick assembly, and silicone base preparation. These components directly determine vapor quality and consistency.
01
Heating Wire Threading
The heating wire (with precision-ground pin) is manually threaded through the silicone assembly with 3 sealed holes. Alignment must be perfect to ensure full electrical contact and prevent short circuits.
- Heating Wire (with Pin)
- Silicone Assembly (3 holes)
- Manual hand threading
02
Oil Storage Cotton Assembly
Two precision-graded oil storage cotton pieces are threaded onto the heating wire — upper and lower — maximising e-liquid absorption and ensuring consistent flavour delivery.
- Heating Wire
- Oil Storage Cotton (×2)
- Silicone Base
03
Steel Pipe & Silicone Base
The food-grade steel pipe is fitted with a silicone tube at the top and mounted onto the silicone base — forming the structural backbone and airflow channel for the coil assembly.
- Steel Pipe (food-grade stainless)
- Silicone Tube (top seal)
- Silicone Base (bottom mount)
04
Heating Wire Assembly Complete
The completed heating wire assembly — cotton and silicone base — is ready for oil cup insertion. Final visual QC confirms cotton placement and wire alignment.
- Completed Heating Wire Assembly
- Silicone Base (sealed)
- Visual QC inspection
Oil Cup Build & Atomizer Assembly
The oil cup houses the e-liquid reservoir, coil assembly, and airflow system. Each component assembled in strict sequence to ensure zero-leak performance.
05
Cotton-Wrapping & Oil Cup Prep
Cotton-wrapping sticks are prepared and the transparent oil cup reservoir is inspected for cracks or mould defects before assembly begins.
- Cotton-Wrapping Stick
- Oil Cup (transparent reservoir)
- Pre-assembly visual inspection
06
Steel Pipe Insertion into Oil Cup
The steel pipe assembly is inserted into the oil cup. The pipe provides the central airflow channel while the surrounding space forms the e-liquid chamber.
- Steel Pipe Assembly
- Oil Cup (transparent)
- Silicone Base (bottom seal)
07
Silicone Oil Cup Support Ring
The silicone oil cup and support ring are assembled. This double-layer silicone system creates a watertight base seal preventing any e-liquid leakage.
- Silicone Oil Cup
- Silicone Oil Cup Support Ring
- Double seal verification
08
Air Adjustment Component
The air adjustment component is fitted with the silicone rubber gasket — controlling airflow resistance and defining the draw tightness and overall vaping experience.
- Air Adjustment Component
- Electrode Plate
- Isolation Cotton (insulator)
- Silicone Rubber Gasket
09
Electrode Plate & Lower Cover
The electrode plate assembly — with isolation cotton — is installed into the lower cover. Lead wires (black and blue) are routed through silicone sealing holes.
- Electrode Plate Assembly
- Isolation Cotton
- Lower Cover Housing
- Lead Wire (Black + Blue)
10
Microphone Head Connector
The connector — with precision gold bent pin lines and sealing silicone — is assembled with lead wires. Creates the contact interface between the pod and main device body.
- Bent Pin Lines (gold-plated)
- Microphone Head Sealing Silicone
- Lead Wire (Black + Blue)
Oil Filling & Air Pressure Testing
Automated precision filling followed by 100% air pressure testing — every pod individually verified before proceeding.
11
Automated Oil Filling Station
Pods load onto a rotary turntable. The filling nozzle assembly — with 4 precision oil inlet tubes — simultaneously fills 4 pods per cycle with exact measured volumes to ±0.05ml accuracy.
- Oil Inlet Tubes (×4)
- Filling Nozzle Assembly
- Rotary Turntable Platform
- Automated weight verification
12
Air Pressure Integrity Test
Every filled pod undergoes a mandatory air pressure test using a calibrated air gun and air supply unit. Any pod failing the pressure test is immediately rejected from the production line.
- Air Gun (calibrated)
- Steel Pipe Test Fixture
- Air Supply Unit
- 100% individual unit testing
Pod Body & Airflow Assembly
Assembling the complete pod cartridge — oil cup pressed into lower cover, airflow intake installed, pod sealed for device integration.
13
Press Machine — Lower Cover Seal
The oil cup assembly is mechanically pressed into the lower cover using an industrial press machine with calibrated press head. Creates a permanent, leak-proof mechanical seal — no adhesives required.
- Lower Cover
- Oil Cup Assembly (filled)
- Press Machine + Press Head
14
Airflow Intake Adjustment System
The 4-position air intake push button system is installed — letting users customise draw resistance. Each position is verified to deliver the specified airflow resistance rating.
- Air Intake Hole Support
- Air Intake Push Button
- Silicone Buckle (4th position)
- 4-position function check
15
Pod Outer Body — Complete
The completed pod assembly is fitted into the kraft outer shell with silicone lining. The transparent oil cup window allows liquid level visibility. Pod is now ready for integration with the main device body.
- Kraft Outer Housing
- Silicone (inner lining)
- Oil Cup (completed)
- Final pod seal verification
Electronics & Battery Assembly
Solution board, battery, button, and charging circuit assembled into the device housing with precise wire routing and thermal management.
16
Battery & Solution Board Assembly
The lithium-polymer battery (3.7V, 300mAh) is connected to the solution board via positive (red) and negative (black) wires. EVA cotton thermal padding placed between battery and PCB prevents heat transfer.
- Battery (3.7V LiPo — 300mAh)
- EVA Cotton (thermal padding)
- Solution Board (PCB)
- Positive Wire (Red) + Negative Wire (Black)
17
Electronics into Device Housing
Battery, solution board, and button are installed into the support bracket within the device housing. All wires routed per specification and secured to prevent movement during operation.
- Solution Board (with button)
- Battery (wired)
- Support Bracket + Device Housing
- Charging Port connection
Soft Screen & Outer Housing
Device display, bracket assembly, and transparent outer housing assembled in a precise 7-step process — completing the main body.
18
Soft Screen Installation (7 Steps)
The flexible OLED display is installed in 7 documented stages: bracket placement → cable connector alignment → flexible cable routing → screen positioning → bracket securing → clip engagement → final verification. The cable connector must engage perfectly for full display function.
- Device Body with Bracket
- Soft Screen (flexible OLED)
- Flexible Cable + Cable Connector
- 7-stage assembly verification
19
Pod + Main Body Integration
The completed oil cup assembly (pod) is joined with the bracket assembly (electronics). The lead wire (red) connects to the bracket charging circuit. Charging port alignment verified before final clip-lock.
- Oil Cup Assembly (complete pod)
- Bracket Assembly (electronics)
- Lead Wire (Red)
- Charging Port alignment check
20
Transparent Outer Housing & Clips
The transparent outer housing is fitted over the complete internal assembly. Four precision clip-lock points engage with the bracket. Button and charging port cutout alignment verified before final clip engagement.
- Outer Housing (transparent PC)
- Clips (×4 — press-lock)
- Button alignment verification
- Charging Port cutout check
Final QC Inspection & Cleaning
Every finished unit undergoes function testing, puff testing, and final visual quality inspection before cleaning and packaging.
27
Final Cleaning & Quality Inspection
White-gloved technicians perform final visual inspection and cleaning. The finished device is wiped with a lint-free cloth to remove fingerprints and residue. Only units passing all function and visual checks proceed to packaging.
- White cotton gloves (anti-static)
- Lint-free cleaning cloth
- Full device function test
- Puff count verification
- Final visual defect inspection
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