From what I've seen so far, air popped corn seems to give my pouch less problems than when I cook it with oil. On a 1 to 10 scale of 1 being uncomfortable and 10 as comfortable as it gets with a pouch, I'd give oil popcorn a 4 and air popped corn an 8. Although perhaps oil popcorn can be improved by using different kinds of oil. I mainly use olive and canola.
Replies sorted oldest to newest
Oops sorry I didn't mention microwave popcorn too. But that comes in many different shapes and forms. I guess it's not much different than hot air popcorn though when it comes to effecting your pouch. I'm just not much of a microwave fan.
I think most microwave popcorn contain oil. For me, I see no difference. I don't eat too much at a time (maybe a few cups) because the hulls are sort of irritating. Plus, they get stuck under my gums.
Jan 
I could live on popcorn and many times it is dinner! Thank God my pouch feels the same way!
I could come close to living on popcorn if it was just air popped. It still annoys my pouch like any other food but the annoyance level still isn't too bad compared to other foods I can think of. It just doesn't taste as good as the oil popped corn too. There's always the question of what do you add to it too, such as salt, butter, I can't believe it's not butter, and whatever else. I guess you could go completely nuts and create your own caramel corn.