This paper was the design of aerosol generator for inhalation toxicology study of lead and evaluation with real time monitoring, and applied several engineering methodology to classical aerosol generator to cope with it's disadvantages. According to the testing conditions, source temperature 50℃ and inlet-duct band heater temperature 150℃, aerosol generation results for sodium chloride and lead acetate were as followings: CPM(Count Per Minute) for Sodium chloride that used for the testing material in aerosol generation and inhalation system was decreased in the 2nd and the 3rd hour's serial trials, but CVs(coefficient of variation) were maintained within 10%. CPMs for 5 and 2.5 gram of lead acetate that used for aerosol generation and inhalation exposure of lead showed similar results because of the sedimentation of lead acetate on piezoelectric crystal with time. For that reason, heating and mixing of nebulizing solution will be needed to generate lead aerosol with stable profile and maximum generation efficiency. Fluctuations of 10 and 5 gram lead acetate were low but 2.5gram was high. However, CVs for 10, 5, and 2.5gram lead acetate were within 10%. Considering the theoretical efficiencies for sodium chloride and lead acetate, 5gram sodium chloride and 2.5gram lead acetate were appropriate choice. Aerosol generation characteristics for two materials with 1 hour interval were different with respect to the fluctuation of CPM and the decrease to 10gram in it's material. For that reason, sodium chloride can not be used to estimate the aerosol generation and it's related parts for lead acetate. According to the testing conditions, source temperature 20, 50, 70℃, and inlet-duct band heater temperature 20, 50, 100, 150, 200℃, aerosol generation results for sodium chloride and lead acetate were as followings: Excluding inlet-duct band temperature 200℃, maximum CPM for sodium chloride was manifested in source temperature 70℃ with each inlet-duct band temperature conditions. We suggest that this condition was the optimum in the design of aerosol generator, inhalation system, and the testing. Maximum CPMs for 10, 5, and 2.5gram sodium chloride were from source temperature 70℃ and inlet-duct band temperature 20℃. Excluding inlet-duct band temperature 50, 200℃, maximum CPMs for lead acetate were indicated in source temperature 50℃ with each inlet-duct band temperature conditions. We suggest that this condition was the optimum in the design of aerosol generator, inhalation system, and the testing for lead inhalation study. Source and inlet-duct band temperatures for 10, 5, 2.5gram lead acetate were 50 and 100℃, 50 and 100℃, 50 and 150℃, respectively. In conclusion, considering above 2 paragraphs of results for aerosol generation, 5gram efficiencies for sodium chloride, lead acetate were higher than 2.5gram's. If inlet-duct band temperature was same, aerosol generation was increased with increase of source temperature. To get maximum aerosol generation will be the conditions that set the appropriate inlet-duel band temperature for each materials and increase the source temperature.