Flying With Lithium Batteries: Your Essential Guide

Yes, you can fly with lithium batteries, but there are specific regulations you must follow. Small lithium batteries inside devices like phones and laptops are generally permitted in carry-on luggage. However, spare batteries must be properly protected and carried in your cabin baggage, never in checked luggage.

This comprehensive guide covers everything you need to know about flying with lithium batteries in 2025.

Why The Rules Exist: Understanding The Safety Concerns

Lithium batteries power nearly all our portable electronics, from smartphones and laptops to cameras and portable chargers. While these energy-dense power sources have revolutionized mobile technology, they also present unique safety challenges, especially in an aircraft’s confined environment.

The Science Behind Lithium Battery Risks

Lithium batteries store significant energy in a compact form. When damaged or improperly handled, they can experience what engineers call “thermal runaway”—a chain reaction where the battery temperature rises rapidly, potentially leading to:

• Fire that can reach temperatures of over 1,000°F (538°C).
• Release of toxic gases.
• There is an explosion risk if the battery casing ruptures.
• Fires that cannot be extinguished with conventional methods.

Real-world incident: In 2016, a passenger’s e-cigarette battery caught fire in the overhead bin of a Delta flight. Fortunately, crew members were able to extinguish it quickly, but this incident highlights why proper battery handling is crucial.

Why Carry-On Is Safer Than Checked Baggage

Aviation safety experts require spare lithium batteries to be carried in the cabin for three critical reasons:

1. Immediate detection: Cabin fires can be spotted and addressed immediately
2. Access to fire extinguishers: Crew members have specialized equipment to handle battery fires
3. Pressure and temperature monitoring: The cabin environment is more controlled than the cargo holds

Who Makes The Rules For Flying With Lithium Batteries?

International organizations, national aviation authorities, and individual Airlines establish the rules.

1. International Civil Aviation Organization (ICAO)

The ICAO, the International Civil Aviation Organization, is like the United Nations for airplanes! It’s a special part of the UN that helps all countries agree on making flying safe and organized.

2. TSA Guidelines

In the US, the Transportation Security Administration (TSA) is your first point of contact at security checkpoints. Their website guides what’s allowed in carry-on and checked baggage, including lithium batteries.

3. FAA Regulations

The Federal Aviation Administration (FAA) sets broader safety standards for US air travel. Their guidelines form the foundation for many Airline-specific policies concerning lithium batteries.

4. IATA Standards

Globally, the International Air Transport Association (IATA) provides guidelines that Airlines adopt for safely transporting various items, including lithium batteries.

5. DOT Oversight

The Department of Transportation (DOT) also has rules for moving dangerous stuff, including lithium batteries.

Flying with Lithium Batteries as a Passenger

It can be confusing to know the rules for flying with lithium batteries. Safety groups like the TSA in the US and IATA worldwide make most of the rules. Airlines also have their own extra rules you need to follow.

1. Carry-on vs. Checked Baggage

Carry-on Baggage

Spare lithium batteries, including power banks and spare batteries for laptops and cameras, must typically be carried in carry-on luggage. This requirement allows for more quickly managing in-cabin battery fires.

Checked Baggage

Devices containing lithium-ion batteries might be allowed if powered off and adequately protected, though it’s recommended that they be carried onboard.

Comprehensive Lithium Battery Regulations for Air Travel

Source: TSA and IATA guidelines, with airline-specific policies. (May 2025)

2. Lithium Metal Batteries

Generally, non-rechargeable batteries have stricter limits and must be carried onboard.

3. Battery Capacity Limits

Lithium-ion battery capacity is measured in Watt-hours (Wh), while lithium metal batteries are measured by lithium content (grams):

• Small Batteries (Under 100 Wh or ≤ 2 grams of lithium) are generally allowed in carry-on bags.
• Medium Batteries (101–160 Wh or 2–8 grams lithium) are allowed with Airline approval, but passengers are limited to two spare batteries per passenger.
• Large Batteries (Over 160 Wh or > 8 grams of lithium) are prohibited on passenger flights and must be shipped as cargo under dangerous goods regulations.

How to get airline approval for batteries?

Typically, Airline approval is required only for:

• Spare lithium-ion batteries rated between 101 Wh and 160 Wh.
• Spare lithium metal batteries containing 2–8 grams of lithium.

Batteries installed in devices generally do not need pre-approval if they fall.

1. Contact the Airline Directly

Contact the Airline well in advance—ideally when booking your ticket or as soon as you know you’ll carry these batteries.

2. Multiple Contact Methods

3. Provide Necessary Information

Have these details ready:

1. Flight or booking reference.
2. Battery type (lithium-ion or lithium metal).
3. Wh rating (for lithium-ion) or lithium content (for lithium metal).
4. Intended use (e.g., laptop, camera, medical device).
5. Number of batteries.
6. Whether batteries are spare or installed in devices.

4. Follow the Airline’s Instructions

The Airline may:

• Add a notation to your reservation.
• Send written approval or confirmation.
• Provide packing and presentation guidelines for security checks.

5. Be Prepared at the Airport

• Keep written approval readily accessible.
• Ensure batteries are packed to prevent short circuits.
• Be prepared to display battery ratings and approvals at security.

Personal experience: “When traveling with my professional camera equipment, I always bring printed approval emails from the airline. During a recent international flight, security questioned my spare batteries, but having the airline’s written approval immediately resolved the issue.” – Sherjeel Sajid.

6. Important Considerations

• Act Early: Last-minute requests may not be accommodated.
• Policy Variance: Approval with one Airline doesn’t transfer to another.
• No Guarantees: The Final allowance rests with the Airline.
• Medical Devices: Separate approvals may apply—notify the Airline.

Protection Against Short Circuits: Practical Methods

Preventing short circuits is critical for battery safety. Here are effective methods to protect your batteries:

1. Commercial Battery Cases

Invest in purpose-designed battery cases that provide individual compartments and protection. These typically cost $10-30 but offer excellent protection.

2. DIY Protection Methods

• Electrical tape method: Cover both terminals completely with non-conductive tape.
• Original packaging: Use the original packaging for your batteries.
• Individual plastic bags: Place each battery in a separate zip-top bag.
• Terminal caps: Use plastic caps designed to cover battery contacts.

3. What To Avoid

• Never do these things: Store batteries loose with metal objects (keys, coins, etc).
• Pack multiple unprotected batteries together.
• Use damaged batteries or those showing signs of swelling.
• Attempt to charge batteries during flight.

Specific Device Regulations: Beyond Basic Batteries

1. E-cigarettes And Vaping Devices

These devices pose unique risks and have caused numerous incidents:

• Must be carried in the cabin (never in checked luggage).
• Must be completely powered off (not just in sleep mode).
• Cannot be charged during flight.
• It should be stored to prevent accidental activation.

2. Smart Luggage with Batteries

Smart luggage with tracking, charging, or motorized features requires special handling:

• Removable batteries: These must be taken out and carried inside the plane.
• Non-removable batteries: The Entire luggage cannot be checked and may be prohibited entirely.
• Airline policies vary widely: Some airlines have banned all smart luggage.

3. Mobility Devices And Medical Equipment

For wheelchairs, CPAP machines, and other medical devices:

• Advance notification: Contact the airline at least 48 hours in advance.
• Documentation: Bring medical necessity documentation.
• Special allowances: Medical devices often have different watt-hour limits.
• Backup batteries: Consider bringing spares (within limits) for essential medical equipment.

International Travel Considerations

Regulations can vary significantly between countries. When traveling internationally:

• Research destination country rules: Some countries have stricter limits.
• Consider transit countries: Your connecting flights may have different rules.
• Language barriers: Bring printed documentation in English and the local languages.
• Customs declarations: Some countries require a declaration of high-capacity batteries.

Shipping Lithium Batteries as Cargo

Shipping lithium batteries involves stringent regulations outlined primarily by the IATA Dangerous Goods Regulations (DGR), dependent on several factors:

• Battery Type: Lithium-ion vs. lithium metal.
• State of Charge (SoC): Typically limited to 30% maximum for loose batteries.
• Packaging: Requires specific UN-certified packaging.
• Marking and Labeling: Clear marking and labeling per IATA requirements.
• Documentation: Accurate declarations and documentation.
• Quantity and Weight Limits: Depending on battery type and configuration.
• Mode of Transport: Different rules apply for cargo vs. passenger aircraft.
• Training: Personnel must undergo specific dangerous goods handling training.

Key Takeaways for Travelers

Always verify the specific lithium battery regulations with your Airline before traveling. Airline rules can be stricter than general guidelines. Visit your Airline’s website or contact customer service to avoid potential issues.

Understanding and adhering to these rules allows you to travel safely and efficiently with your lithium-powered devices, avoiding delays or confiscation at security checkpoints.

Conclusion

Flying with lithium batteries is generally permitted following the established safety guidelines.

1. Know your batteries: Understand their capacity and classification.
2. Pack properly: Keep spares in carry-on, protected against short circuits.
3. Check with your airline: Verify specific policies, especially for larger batteries.
4. Stay informed: Regulations evolve, so check for updates before each trip.
5. Prioritize safety: These rules exist to protect everyone on board.

FAQs: Flying With Lithium Batteries