Vape Mods Linked to Explosions, Major Injuries: Study

Vape Mods Linked to Explosions, Major Injuries: Study

Introduction

A new study published on July 9 in Scientific Reports warns that modifying vape pens—especially through battery rewiring and the addition of substances like THC—can significantly raise the risk of explosions, severe lung damage, and other major injuries.

These alterations, which are commonly made by users of electronic nicotine delivery systems (ENDS), may involve dangers that many do not fully understand.

Vape Modifications Widespread Across Age Groups

The research, conducted by Georgia State University, surveyed more than 1,900 current ENDS users, including teens (13–17), young adults (18–29), and adults over 30. The findings revealed that over 75% of users in all age groups had made at least one modification to their vape devices. The most common changes included tweaking e-liquids and adjusting or replacing heating coils.

Teens More Likely to Engage in Risky Alterations

The study found that teenagers were significantly more likely to perform high-risk modifications. Around 40% of teens reported rewiring their vape pen batteries—an especially hazardous practice that can cause the devices to overheat, catch fire, or even explode. Many teens also reported refilling sealed pods that were not designed for reuse and adding substances like cannabis or THC oils to their devices.

These behaviors often stemmed from misconceptions, with some young users believing that customizing their devices made vaping safer. Common motivations for teens included curiosity, flavor enhancement, and influence from peers or online trends.

Health Risks of Modified Vape Devices

Vape pens and e-cigarettes are marketed as alternatives to traditional smoking and are commonly used to inhale nicotine or THC. However, modified devices pose major health risks. One well-documented issue is e-cigarette or vaping-associated lung injury (EVALI). This condition can lead to coughing, chest pain, shortness of breath, and in severe cases, irreversible lung damage or death.

Additionally, physical injuries from vape pen explosions have become a growing concern. Vape pens are powered by lithium-ion batteries, which are prone to overheating or exploding when tampered with. Battery-related incidents have led to serious injuries including burns, facial disfigurement, hand trauma, broken teeth, and even emergency surgeries.

Battery Modifications Pose Significant Dangers

The study emphasizes that tampering with the battery is among the most dangerous modifications users can make. When ENDS devices are rewired or fitted with unauthorized batteries, they are more likely to experience thermal runaway—a chain reaction within lithium-ion batteries that leads to intense heat, fires, or explosions. 

These events can occur during use, while charging, or even when stored in a pocket. Many injuries reported in recent years have resulted from these types of battery failures. Explosions have caused users to suffer painful burns and traumatic injuries, highlighting the lack of safety when devices are altered beyond their intended design.

Racial and Ethnic Disparities in Vape Modifications

The survey also identified racial and ethnic differences in modification practices. Black and Hispanic adult users were more likely than their white counterparts to engage in high-risk battery alterations. These included replacing the original batteries with unauthorized versions or connecting new batteries to the device—both actions that significantly increase the chances of malfunction or explosion.

EVALI Outbreak and THC-Related Lung Injuries

In 2019, concerns about vaping intensified when the U.S. Centers for Disease Control and Prevention (CDC) launched an investigation into a surge of mysterious lung illnesses. This outbreak, later named EVALI, was primarily linked to vape products containing THC and vitamin E acetate—a substance often used to dilute THC oils.
Vitamin E acetate was found to interfere with lung function when inhaled, causing a wave of severe respiratory illnesses. The CDC confirmed that EVALI led to over 50 deaths nationwide and thousands of hospitalizations due to life-threatening lung damage.

Legal Action and Growing Litigation

Due to the health risks associated with vape pens—especially those involving THC and modified devices—a growing number of lawsuits have been filed across the country. Individuals who developed lung injuries or experienced physical harm after using e-cigarettes may be eligible to seek compensation through legal action.
Many law firms handling vape-related cases offer free consultations and operate on a contingency basis, meaning they collect legal fees only if a settlement or verdict is secured in favor of the client.