Cosori air fryers are not toxic when used normally. The cooking surfaces on current models are free of PFAS (the “forever chemicals” linked to health concerns) and BPA, and the appliances operate well below the temperatures where non-stick coatings break down into harmful fumes. That said, there are a few things worth understanding about materials, older models, and a major safety recall that had nothing to do with toxicity.
What Cosori Baskets Are Coated With
Cosori has moved toward ceramic-based non-stick coatings on its newer models. The Iconic line, for example, uses a PFAS-free ceramic coating on both the basket and crisper plate. PFAS is the broad family of synthetic chemicals (including PFOA, once used in Teflon manufacturing) that persist in the environment and have been linked to thyroid problems, immune suppression, and certain cancers with long-term exposure. A ceramic coating sidesteps that issue entirely because it’s made from inorganic minerals rather than fluoropolymers.
Some older Cosori models used PTFE-based non-stick coatings, which is the same polymer found in traditional Teflon. PTFE itself is chemically stable and considered safe at normal cooking temperatures. It only starts to decompose and release potentially harmful fumes at around 360°C (680°F), according to the German Federal Institute for Risk Assessment. Most air fryers max out between 200°C and 230°C (around 400–450°F), which leaves a wide safety margin of over 130°C. So even if you own an older PTFE-coated Cosori, overheating to the danger point isn’t realistic during normal use.
BPA and Plastic Concerns
Air fryers combine high heat with enclosed spaces, which naturally raises questions about plastic components releasing chemicals into food. Cosori addresses this in its newer designs by minimizing plastic. The Iconic model, for instance, is 96% metal by visible area and uses a stainless steel structure with tempered glass. The cooking surfaces are listed as BPA-free.
If you own an older model with more visible plastic around the basket housing or interior, the plastic components generally aren’t in direct contact with food. The basket itself sits inside a drawer, and the heating element is above, so the hottest air circulates around the metal or coated cooking surface rather than against plastic housing. Still, if plastic parts show signs of warping, discoloration, or cracking, that’s a sign to replace the unit.
The 2023 Recall Was About Fire, Not Chemicals
In 2023, roughly two million Cosori air fryers were recalled in the United States, and the scale of that recall understandably alarmed people. But the issue was electrical, not chemical. A wire connection inside the units could overheat, creating fire and burn hazards. The U.S. Consumer Product Safety Commission reported 205 incidents of the fryers catching fire, burning, melting, overheating, or smoking, along with 10 minor burn injuries and 23 cases of minor property damage.
If you’re unsure whether your specific model was part of the recall, you can check the CPSC website with your model number. The recall covered specific units manufactured during a certain period, not the entire Cosori product line.
How to Reduce Any Remaining Risk
Even though the materials are safe under normal conditions, a few habits help keep things that way:
- Don’t use metal utensils on the coating. Scratching a non-stick surface, whether ceramic or PTFE, exposes the base metal underneath and accelerates coating breakdown. Use silicone or wooden tools.
- Replace damaged baskets. If the coating is visibly chipping, peeling, or flaking, small particles can end up in your food. While swallowing a flake of PTFE or ceramic isn’t acutely toxic (it passes through your digestive system), a degraded surface no longer performs as designed.
- Don’t preheat empty for extended periods. An empty basket heats up faster than one with food in it, since food and moisture absorb thermal energy. A few minutes of preheating is fine, but leaving it running empty for 10 or 15 minutes pushes surface temperatures higher than necessary.
- Use parchment liners if you want a barrier. Perforated air fryer parchment sits between your food and the coating, reducing direct contact and making cleanup easier, which means less scrubbing that wears the surface down.
Choosing a Lower-Risk Model
If you want to avoid non-stick coatings altogether, Cosori’s Iconic line uses a stainless steel structure with ceramic-coated surfaces. For people who prefer zero coating of any kind, some brands offer fully bare stainless steel baskets, though food sticks more and cleanup takes longer. Within Cosori’s lineup, the Iconic is the most material-conscious option, combining PFAS-free ceramic, BPA-free construction, and minimal plastic.
For most people, any current Cosori model used at its intended settings poses no meaningful toxicity risk. The combination of operating temperatures well below decomposition thresholds, PFAS-free coatings on newer models, and BPA-free construction puts these appliances in line with mainstream cookware safety standards.