As competition in the e-cigarette industry heats up, the performance and reliability of core components like MEMS silicon microphones have become critical. A minor flaw can lead to massive quality control failures, resulting in huge financial losses and recalls. This was recently highlighted when a leading company faced supply disruptions because its chips were outsourced, creating a production bottleneck that competitors are watching closely.
In this high-stakes market, a few key players are leading the charge. MEMSensing and Dawei currently dominate, holding the first and second positions in shipment volume, respectively, with AAC also being a significant manufacturer. But what does it take to succeed in this demanding sector? Industry experts agree that to achieve large-scale production of silicon microphones, a manufacturer must master five core elements.
This post will break down those five pillars of success and explore the current market landscape, including key product innovations and the intense competition among top suppliers.

5 Keys to Dominating the Silicon Mic Market

For a silicon microphone manufacturer to reliably ship at scale, they need more than just a good product. They require a deep, integrated approach covering everything from initial design to final production.

1. Develop a Vaping-Specific Sensor

The environment inside an e-cigarette is harsh. The microphone’s sensor is exposed to e-liquid leaks, condensation, vapor, and extreme temperature fluctuations. A standard sensor won’t survive long under these conditions. Therefore, manufacturers must engineer custom sensors specifically designed to withstand the unique challenges of a vaping device.

2. Design a Perfectly Matched ASIC

An Application-Specific Integrated Circuit (ASIC) must be designed to precisely complement the custom sensor. This involves tailoring the ASIC’s functions to meet market demands while perfectly aligning with the sensor’s physical and electrical properties. It’s a delicate balancing act between functionality and performance.

3. Master Stable Packaging and Testing

Both the sensor and the ASIC are semiconductor products. The MEMS packaging workshop must maintain a static cleanroom environment of at least Class 1000 to prevent dust particles from contaminating the wafers. The packaging process itself is highly demanding, requiring precision equipment and skilled technicians to ensure consistent product quality and stability.

4. Own Your Production Capacity

To guarantee quality and supply, silicon microphone manufacturers must have their own large-scale packaging and testing production lines. Outsourcing these critical steps can easily lead to quality control issues and unpredictable production capacity, creating significant risks for their clients.

5. Achieve Market-Validated Scale

Success isn’t just about having the right tech; it’s about proving it in the real world. A manufacturer needs to pass the rigorous testing and trial production phases of multiple top-tier e-cigarette brands. The true mark of a reliable supplier is the ability to sustain monthly shipments of over five million units for at least six months.
Many new companies are trying to enter the e-cigarette silicon microphone market. However, most lack the deep technical expertise, rely on outsourced sensors and ASICs, and don’t have their own packaging facilities. This makes it difficult for them to scale production quickly and exposes them to significant quality risks and potential liabilities.

The Current Market Landscape

The competition among the top players is fierce, with each vying for market share through different strategies and technological innovations.

2718: The Workhorse of the Industry

Currently, the most widely used model in the e-cigarette market is the 2718 silicon microphone. MEMSensing, Dawei, and AAC are the top three suppliers of this model.
In terms of sensitivity control, MEMSensing primarily ships its products in sorted batches, such as (100-200) Pa and (150-250) Pa. In contrast, Dawei offers more precise control, delivering products with an activation pressure tolerance of ±30 Pa based on specific customer needs. Recently, Dawei even customized and delivered a batch with an activation pressure of (50±20) Pa for a leading company with special structural requirements.

F6 Silicon Mic: Innovation to Meet Market Needs

To accommodate the airflow structures of older projects and address the shortcomings of traditional electret microphones, MEMSensing developed a solution that packages a 2718 silicon microphone inside an F6 housing. While this met a market need, it came with higher costs and a potential risk of air leakage.
Seizing this opportunity, Dawei is set to launch a one-piece molded F6 silicon microphone by the end of 2024. This new design is compatible with both wire-soldering and surface-mount applications. Thanks to its superior performance and cost advantages, it is already being shipped to several major companies, marking a significant development in the market.

Power Silicon Mics: Overcoming Technical Barriers

Power silicon microphones are considered a major technical hurdle in the industry due to their extremely high requirements for chip design and packaging technology. Top manufacturers began tackling this challenge six years ago.
As of now, Dawei is the only manufacturer to have achieved mass production of power silicon microphones. Their products, which are currently being shipped to multiple leading brands, can handle a maximum load of 25W. Other manufacturers are working hard to catch up and overcome this technical barrier.

Who Will Win the Vape Tech Race?

The MEMS silicon microphone is a core component that sits at the heart of modern e-cigarettes. The ongoing battle for technological supremacy and supply chain dominance will ultimately shape the future of the market. As numerous companies compete for the top spot, the winners will be those who can deliver consistent innovation and a stable supply. The race is on, and the entire industry is watching to see who will emerge victorious.