Beyond one-size-fits-all: Bespoke adaptations of smoking robots for accurate ENDS and HTP aerosol exposure

CORESTA PSPT Conference 2025 -- The rapidly evolving landscape of Electronic Nicotine Delivery Systems (ENDS) and Heated Tobacco Products (HTPs) presents significant challenges for aerosol testing. Device topology has shifted dramatically, from early "cigalike" designs to sophisticated pod and disposable systems, often featuring diverse mouthpiece geometries and designs driven by consumer aesthetics and mass production requirements (e.g., draft angles, compound curves) many times directly at odds with routine analytical testing. This poster highlights the limitations of universal adaptors and champions the development of bespoke solutions. We demonstrate the successful application of rapid prototyping technologies, including 3D scanning, CAD modelling, 3D printing (e.g., FDM, SLA), and custom platinum-cure silicone moulds, to create product-specific interfaces for smoking robots. These custom adaptors ensure consistent product positioning, optimal aerosol production, and minimised operator-induced variability. By addressing the unique design features of individual ENDS and HTPs, bespoke adaptations provide a more robust and reliable approach, ultimately enhancing the quality and reproducibility of aerosol-related research in the evolving nicotine product market.