An article for insertion into an apparatus for heating an aerosol generating material to aerosolize at least one component of the aerosol generating material includes an aerosol generating material and a downstream portion downstream of the aerosol generating material. The downstream portion has at least one ventilation area and a first air flow path is defined in which air drawn through the article at its downstream end passes through the aerosol generating material, and a second air flow path is defined in which air drawn through the article at its downstream end is drawn into the article through the at least one ventilation area in the downstream portion. The resistance to draw of the second air flow path is greater than the resistance to draw of the first air flow path. An article is also provided in which an aerosol generating material is wrapped by a wrapper having a level of permeability greater than about 2000 Coresta Units. An article is also described having a ventilation level of between 40% and 60% ventilation. A system and a method for forming an article are also described.

A unitary aerosol-generating component including at least two portions having different aerosol-generating materials. There is also provided a process for preparing a unitary aerosol-generating component including at least two having different aerosol-generating materials, wherein an additive manufacturing process is used to form the portions. Also provided is a delivery system including a unitary aerosol-generating component as described herein.

A system for preparing an aerosol-generating component customized by a user including an apparatus for using one or more feedstock materials in an additive manufacturing process, wherein the one or more feedstock material is selected and formed into an aerosolizable substrate by the additive manufacturing process in accordance with instructions provided by the user. There is also provided a process for producing a customized aerosol-generating component, the process including forming one or more feedstock materials into the aerosol-generating component by an additive manufacturing process in accordance with instructions provided by the user.

Electrically heated cigarettes used in an electrical smoking system include a flavoring-release additive and sorbent effective to remove one or more gas-phase constituents of mainstream tobacco smoke. The flavoring-release additive includes gamma cyclodextrin and at least one flavoring. Flavoring is released in a cigarette upon the flavoring-release additive reaching at least a minimum temperature during smoking. The flavoring-release additive can have various forms including, for example, powder and films.

Electrically heated cigarettes used in an electrical smoking system include a flavoring-release additive and sorbent effective to remove one or more gas-phase constituents of mainstream tobacco smoke. The flavoring-release additive includes gamma cyclodextrin and at least one flavoring. Flavoring is released in a cigarette upon the flavoring-release additive reaching at least a minimum temperature during smoking. The flavoring-release additive can have various forms including, for example, powder and films.

A flavor generating segment includes a first flavor generating member and a second flavor generating member, wherein: at least either of the first and the second flavor generating members includes a plurality of stacked flavor generating sheets and has, between at least a pair of the neighboring flavor generating sheets, a non-contact part in which the flavor generating sheets do not come into contact with each other; and principal surfaces of the flavor generating sheets face the other flavor generating member, as well as a flavor generating article and a flavor inhalation system equipped therewith. The flavor generating segment gives a good smoking flavor.

A method of making an amorphous solid is provided. The method comprises: (a) forming a slurry comprising: 0.5-60 wt % of a gelling agent; 5-80 wt % of an aerosol forming material; and 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry; (c) setting the slurry to form a gel; and (d) drying the gel to form an amorphous solid; wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes. Amorphous solids provided by the method, articles comprising the amorphous solids, and non-combustible aerosol provision systems comprising the articles are also provided.

A method of making an amorphous solid is provided. The method comprises: (a) forming a slurry comprising: 0.5-60 wt % of a gelling agent; and 5-80 wt % of an aerosol forming material; 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry using a stencil; (c) setting the slurry to form a gel; and (d) drying the gel to form an amorphous solid. Amorphous solids provided by the method, articles comprising the amorphous solids, and non-combustible aerosol provision systems comprising the articles are also provided.

An amorphous solid and related method of making including (a) forming a slurry having 0.5-60 wt % of a gelling agent; 5-80 wt % of an aerosol forming material; and 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry on a support material, wherein the slurry has a bottom surface proximal to the support material, and a top surface opposite the bottom surface; (c) setting the slurry to form a gel with bottom and top surfaces corresponding to the bottom and top surfaces of the slurry; and (d) drying the gel to form an amorphous solid; wherein the drying includes a first period of supplying heat to the bottom surface of the gel and a second period of supplying heat to the top surface of the gel.

An amorphous solid and related methods of making an amorphous solid including: (a) forming a slurry having: 0.5-60 wt % of a gelling agent; 5-80 wt % of an aerosol forming material; and 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry; (c) applying a setting agent to a surface of the slurry so that the slurry sets to form a gel; and (d) drying the gel to form an amorphous solid; wherein the amorphous solid has a substantially constant concentration of setting agent throughout.