The vape industry is constantly evolving, and technology is at the heart of this transformation. One of the most significant innovations in recent years is mesh coil technology. While coils might seem like a small component, they have a major impact on how e-liquids perform — and that, in turn, affects flavour formulation. For brand owners and product developers, understanding mesh coils is essential to creating products that delight consumers.
What Is Mesh Coil Technology?
Traditional vape coils use a single wire wrapped around a wick. Mesh coils, by contrast, replace the wire with a fine sheet or mesh of metal. This increases the surface area that comes into contact with the e-liquid, providing more uniform heating.
The result is:
- Enhanced flavour delivery — e-liquids taste richer and more nuanced.
- Smoother vapour — fewer hotspots lead to a more consistent experience.
- Better coil longevity — even heating reduces burn-off and degradation.
For brands, this shift isn’t just technical — it changes the way flavours are experienced, opening up new possibilities in formulation.
Why Mesh Coils Change the Game for Flavour
Flavour is no longer just about the ingredients in the bottle. The delivery mechanism affects how the consumer experiences every note, from top-layer brightness to subtle undertones. Mesh coils allow formulators to:
- Enhance delicate flavours
- Light, intricate flavours such as floral blends, tea-inspired profiles, or complex desserts come through more clearly.
- Balance stronger notes
- Bold flavours like menthol or concentrated fruit don’t overwhelm the palate because heat distribution is even.
- Improve consistency across puffs
- Each inhale delivers the same rich, full flavour, helping build customer loyalty.
This means brand owners can be more adventurous with flavour profiles. Recipes that may have been muted or harsh on traditional coils can now shine.
Implications for Product Development
Mesh coils don’t just improve existing flavours — they influence the formulation process itself. Brand owners developing new vape products should consider:
- Viscosity adjustments
- Mesh coils work best with e-liquids that balance VG and PG for smooth wicking and optimal heat transfer.
- Flavour layering
- Complex blends can now be expressed more accurately, enabling signature ranges that stand out on the shelf.
- Nicotine delivery
- Consistent heat distribution ensures smoother throat hits for nicotine salts while maintaining flavour integrity.
By aligning formulation with mesh coil performance, brands can launch products that are both satisfying and market-leading.
Consumer Expectations Are Evolving
Today’s vapers are more discerning than ever. They expect crisp, clean flavours that match the marketing description, a smooth, enjoyable vapour with no burnt notes, and consistency across devices and puffs.
Mesh coils make it easier to meet these expectations, which means e-liquids must be formulated with precision. Brands that ignore this shift risk underwhelming their audience, even if the flavour itself is high-quality.
How Xyfil Helps Brands Leverage Mesh Coil Technology
At Xyfil, we understand that innovation in coil technology demands innovation in formulation. Our team works with brand owners to:
- Develop e-liquids optimised for mesh coils.
- Balance VG/PG ratios and flavour compounds for maximum impact.
- Test products across multiple devices to ensure consistency.
- Translate technical advantages into flavours that resonate with consumers.
By considering mesh coil performance from the start, brands can ensure their new products deliver an exceptional vaping experience every time.
Conclusion
Mesh coil technology has transformed how flavours are delivered and perceived. For brand owners, it’s more than a hardware upgrade — it’s an opportunity to rethink formulation, push creative boundaries, and satisfy a more demanding consumer base.
By embracing mesh coil-friendly e-liquids and optimising formulation strategies, brands can create products that stand out in a crowded market and deliver the full flavour experience vapers crave.