I also have had this issue.
I have been using the same cart for a week and a half, and while I thought I had been aligning it correctly there is always the chance I missed on ocassion.
I admit that using the same cart for a week and half straight is perhaps a BIT much, but I wanted to see how they would hold up. (I did wash the filler every few refills)
My 510 atty is also a "high bridge" type, Using stock 3.7v manual batteries.
Obviously I am not a fan of inhaling burnt plastic either, so I trimmed off the affected section with a box cutter, about a dimes thickness of material. I havent used it as long now as I had originally to replicate the ammount of use/abuse yet to see if this is enough clearance to not melt it over time. I did note that the divot in the filler material after removal is much less pronounced (deep) than it was before, but still there for wicking. It is working the same as an uncut cart however.
Before discovering this, when refilling my cart I would have the filler matierial even with the edge of the cart, and upon removal of the cart after use the filler would be pushed back into the cart (from being pressed against the high bridge (wick?).
I PM'd a few kind people here and was told that this generally is a non issue with the Low Bridge atty's, which I will need to try just for this if my trimming experiment ends up in more (slight) melting.
Unless the low bridge atty's eleminate this, I would hope to see a metal cart design come out in the future.
I know the pic is not HQ, but hopefully clear enough that you can see the deformation of the melted area on the cut off section.
Top = new cart.
Bottom - trimmed cart.
Right = cut off section with the melted part (divot) on top.
Sorry, I wasn't able to borrow Bandit's awesome camera, and mad skillz to take the pic.![]()



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I stopped using them in the first week of vaping , that was in January. Just get yourself sealed batteries and drip drip drip !!! and if you must use carts get a model that uses cartomizers .


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