Vape Pen Modifications Carry Risk of Explosions, Other Severe Injuries: Study

Researchers warn that vape pen battery rewiring and e-liquid tampering by users may raise serious health and safety concerns.

A new study warns that common vape pen modifications, especially rewiring batteries and adding substances like THC, may significantly increase the risk of explosions, lung damage, and other serious injuries.

The findings were published in the journal Scientific Reports on July 9, indicating that the vast majority of electronic nicotine delivery system (ENDS) users reported making at least one vape modification, with many engaging in high-risk behaviors that they may not fully appreciate. 

Vape pens and e-cigarettes are portable devices used to inhale nicotine or other substances as an alternative to smoking. However, health officials have linked their use to serious respiratory injuries, especially when modified. One such injury is e-cigarette or vaping-associated lung injury (EVALI), a condition that has been known to cause coughing, shortness of breath, chest pain, and in severe cases, permanent lung damage or death.

In addition to lung damage and addiction, physical injuries from battery failures are an increasing concern. Vape pens are powered by lithium-ion batteries, which can overheat or explode when damaged or tampered with. These incidents have led to burns, facial injuries, broken teeth and hand trauma, sometimes requiring emergency surgery or hospitalization.

In the new study, researchers from Georgia State University surveyed more than 1,900 current ENDS users, including teens (ages 13–17), young adults (18–29), and adults (30 and older), to assess how frequently they modified their devices and why. 

According to the survey responses, over 75% in each group said they had altered their vape devices, most commonly by modifying e-liquids or coils.

However, researchers found that younger users were far more likely to perform dangerous alterations. Among teens, 40% reported rewiring a battery, a modification that can cause overheating, fire or explosion. 

Youths also frequently refilled sealed pods not designed to be reused and added cannabis or other unapproved substances to e-liquids, often under the mistaken belief that it made vaping safer. “Enhancing flavor” and “trying new things” were common motivations among teens, while adults often cited saving money or making devices last longer. Social influences, such as peer behavior or online videos, played a larger role in teen modifications than among adults.

The study also found racial and ethnic disparities in modification patterns. Black and Hispanic adults were more likely than white users to engage in high-risk battery modifications, such as replacing batteries with unauthorized alternatives or wiring new ones into devices, practices that can increase the likelihood of battery failure.

In this new report, lead researcher Lucy Popova warned that these behaviors highlight the need for stronger regulation and education.

“Future research should examine how often and how consistently ENDS users engage in different types of modifications, including whether certain behaviors (e.g., battery rewiring, cannabis mixing) are one-time experiments or routine practices.”

-Lucy Popova, Prevalence and reasons for electronic nicotine delivery systems modifications among U.S. youth, young adult, and adult users

The study reinforces concerns about the dangers of lithium-ion batteries used in vape devices, which can enter thermal runaway, a chain reaction that often leads to overheating, fire or explosion. These events can occur while charging, during use, or even while the device is being carried in a pocket.

Users have suffered burns, hand trauma and facial injuries from sudden vape pen explosions. Many of these incidents are linked to faulty batteries or unauthorized modifications, which compromise the device’s safety features.

E-Cigarette Lung Injuries

Aside from mechanical failures, in 2019, the U.S. Centers for Disease Control and Prevention (CDC) launched an investigation into a surge of severe respiratory illnesses linked to vaping, later identified as EVALI.

Preliminary findings connected the condition to vaping products containing THC, the psychoactive compound in marijuana, and vitamin E acetate, a substance often used to thicken THC oils. When inhaled, vitamin E acetate was found to interfere with lung function and cause serious respiratory problems.

Federal officials confirmed the EVALI outbreak resulted in more than 50 deaths nationwide and thousands of hospitalizations involving life-threatening lung injuries.

As a result of these concerns, a number of vape pen and e-cigarette lawsuits have been filed nationwide, with individuals who experienced serious health issues after using e-cigarettes or THC vape products potentially eligible to pursue compensation through legal action.

Vape pen lawyers offer free consultations and only collect fees if compensation is recovered in an individual’s case.