Hey This Leo, I am a Research & Development engineer of VAPORESSO.
Today Im gonna share another story behind developing Armour Ultra. Share the technical challenges that we’ve faced during producing the product. its quite fun, lets have a look!
1. The Challenge: Pushing Beyond Triple Protection
When we began developing Armour Ultra, the industry standard was clear — most DTL devices were already built with Triple Protection: waterproof, dustproof, and drop-resistant.
But we didn’t want to stop there. Our goal was to go beyond IP68, and achieve something that had never been done in DTL devices before — IP69K, the highest level of protection against high-temperature and high-pressure water.
That’s when the real challenge began. At first, our prototype shells couldn’t withstand 80°C high-pressure spray. The water seeped through micro gaps between the buttons and the Type-C port, causing internal circuit instability and performance failure.
Even small amounts of water vapor could damage the chipset over time.
2. The Turning Point: Engineering Without Compromise
We knew we couldn’t just “seal” the device tighter — that would make it bulky, heavy, and ruin the user experience.
So our mechanical design team spent months re-engineering the internal structure, optimizing the joint sealing ring geometry and using military-grade silicone materials.
Meanwhile, the electronics team developed a new multi-layer isolation design,
so even if moisture entered the outer layer, the chipset and power module remained completely unaffected. We also had to rethink heat dissipation.
When you make a device more sealed, it traps heat. To solve this, we built a thermal management system using aerospace-grade materials, allowing Armour Ultra to maintain both IP69K durability and stable performance.
3. The Breakthrough: Passing the Impossible Test
After six major design iterations and hundreds of hours of stress testing, we finally passed the IP69K certification.
In the final test, Armour Ultra endured: 80°C high-pressure water jets from multiple angles for several minutes, Repeated impact drops from over 1.2 meters, Continuous temperature cycling from -20°C to 70°C.
And every unit still functioned perfectly. For us engineers, that was the moment we knew —
we didn’t just make the device tougher.
We had redefined what “reliable” means for DTL vaping.
What makes Armour Ultra truly special isn’t just the Quad Protection system — it’s the balance between engineering precision and real-world reliability.
We didn’t want users to worry about where they could take their device. Whether it’s heavy rain, beach sand, or outdoor pressure washing,
Armour Ultra is ready for it all.
