Filling Disposable Vapes vs 510 Cartridges: What’s Different, What’s the Same
Whether you’re upgrading your process, expanding into filling disposable vapes, or trying to run both formats on the same line, understanding the differences between these devices will help you choose the right vape cartridge filling machine and build a smoother, more efficient production workflow.
Understanding Filling Disposable Vapes and 510 Cartridges
Aspect | 510 Cartridges | Disposable Vapes |
Device format | Standardized 510-thread carts with separate batteries | All-in-one devices with built-in battery and tank |
Filling complexity | Generally easier, more standardized fill ports | More variation in design, ports, and internal space |
Fill head compatibility | Many filling machines are originally designed for 510 carts | Requires adjustable or specialized heads to match different disposable designs |
Dose volume | Commonly fixed volumes (e.g. 0.5 g, 1.0 g) | Can vary more by brand and model, sometimes smaller chambers |
Dosing precision needs | High – but small errors are more forgiving in larger tanks | Very high – small overfills can easily cause leaks or failures |
Workflow impact | Established workflows, predictable handling and capping | May need different handling, QC steps, and changeover procedures |
Hardware failure risk | Often user-swappable if a cart fails | If the disposable fails, the whole device is usually waste |
Brand use case | Flexible for users who already own batteries | Convenient, grab-and-go option that many consumers prefer |
As the cannabis vape market matures, most producers eventually run into the same crossroads: keep focusing on classic 510-thread cartridges, pivot toward disposable vapes, or build a setup that can handle both. It’s more than a packaging decision. The direction you choose will influence which vape cartridge filling machine you buy, how your production line is laid out, how your oils behave during filling, and how consistent your products feel to customers.
On the surface, disposables and 510 cartridges aren’t that different. In both cases you’re trying to get the right amount of oil into a small device, keep temperatures in the right range, seal everything cleanly, and make sure your extract plays nicely with the hardware. Whether you’re running distillate, CBD, live resin, or rosin, the fundamentals stay the same: accurate fills, repeatable results, and as few leaks, clogs, or failures as possible.
The differences show up once you look at them from a production point of view. 510 cartridges tend to follow more standard dimensions and fill-port designs, so they’re relatively predictable for most vape cartridge filling machines. Disposable vapes are much more variable: chamber depth, airflow paths, battery placement, and fill-port style can change dramatically from one model to the next.
Those design differences affect things like:
• how easily oil flows into the device
• which type of fill head and tooling you need
• how you dial in temperature and dosing settings
• how quickly your team can switch between formats
• where and how you build in quality checks
As your operation scales, these details start to matter a lot. They influence operator efficiency, scrap rates, consistency across batches, and how quickly you can respond to new product trends. That’s why many brands now treat filling as a strategic decision rather than a simple task: choosing the right vape cartridge filling machine is a big part of how well you’ll keep up as the market shifts further toward disposables.
Fill Head Types and Compatibility in a Vape Cartridge Filling Machine
When it comes to filling machines, the “fill head” – the interface between the oil reservoir and the device – is a critical component. With 510 cartridges, you usually have a relatively standardized body, a specific thread type, known fill ports, and predictable tolerances.
With disposable vapes, however, variation increases: internal structure may differ, the built-in battery’s size and shape can shrink or reshape the oil chamber, filling ports may be non-standard, and the device may not behave like a traditional “cart” at all.
Reddit users highlight some of the differences:
“I had a 1g Diamond Extracts DVP and it was great… although I had to recharge it more often.”
“Almost everything [brand] makes tastes like burning rubber… Hitting this disposable is like hitting a clogged pen.”
From a filling machine perspective, if you’re filling disposables, you must ensure the fill head is flexible – able to adapt to different formats, different depths, and different sealing styles. A machine built only for 510 threads may struggle with variations in device height, filling port geometry, or airflow constraints.
Dosing Adjustments and Precision in Vape Cartridge Filling Machines
Regardless of device type, accurate dosing is fundamental. However, dose precision becomes even more critical when switching between formats. Disposables tend to be more compact, sometimes with smaller chambers or shorter oil paths, so even small dosing errors can lead to over-fill, under-fill, or leaks.
Reddit discussions around carts vs disposables point to hardware failure, clogged devices, or poor flavor when fill volume or device compatibility is off.
To avoid these issues, producers need to account for several variables that directly affect fill accuracy:
Oil viscosity: Thick distillate flows more slowly and may require higher temperatures or adjusted pump settings.
Device port geometry: A narrow or recessed fill port can introduce back-pressure or trap air.
Device height/depth: A shallow reservoir means the same volume that fits a 510 cart may overflow a disposable.
Repeatability: A dosing deviation as small as 0.02 g becomes extremely costly and inconsistent when multiplied across thousands of units.
This is exactly where a high-precision system makes a real impact. Equipment like Longwill’s vape cartridge filling machine is engineered to handle these differences with stable multi-zone heating, fine dosing control, and adjustable filling profiles for various hardware types. Whether you’re filling a large 510 glass tank or a compact disposable chamber, these machines help maintain predictable flow, accurate volume, and consistent product quality.
Workflow Considerations When Using a Vape Cartridge Filling Machine
Your production workflow can change significantly once disposable devices enter the mix. Here are a few important differences to keep in mind:
Format switching frequency: If your team frequently switches between 510 cartridges and disposables, you’ll need equipment that allows quick, simple changeovers without slowing down the line.
Supply chain & device sourcing: Disposables often involve additional assembly steps — such as managing built-in batteries or airflow vents — which adds complexity to your QC process and parts sourcing.
Cleaning & maintenance: Some disposable designs include integrated components that make cleaning or maintaining your filling equipment a bit more challenging, especially when switching between different oil types.
Output expectations: A machine that fills 510 cartridges at a certain rate may run more slowly with disposables due to differences in device geometry, fill-port style, or airflow resistance. Throughput often drops unless the machine is properly set up for both formats.
Quality control and data capture: This becomes even more important with disposable devices. Tracking fill weight, leak rate, and device failure helps identify issues early. Reddit users highlight how many disposables can fail early or deliver poor taste due to hardware issues, underscoring the need for strong QC practices.
By understanding these workflow differences, brands can better prepare their production lines, reduce inefficiencies, and ensure consistent results when working with both 510 carts and disposables.
Read more:
https://longwillmachinery.com/Blog/how-to-prevent-leaks-in-your-disposable-vape-production.html
https://longwillmachinery.com/Blog/how-cartridge-filling-machines-can-transform-your-business.html
Conclusion
As the industry grows more competitive — and consumer demand leans further toward disposables — the producers who succeed will be those who understand the nuances between formats and invest in equipment that can adapt with them. Whether you’re running 510 cartridges, disposables, or both, choosing the right vape cartridge filling machine and dialing in your process will directly affect your efficiency, consistency, and product reliability.
