Lithium-ion and lithium-metal batteries are classified as hazardous materials by aviation safety regulators like the FAA and TSA. Because of their potential to overheat and cause cargo fires, strict packing regulations apply.
The rule for lithium batteries comes down to one question: can your device go in checked luggage? Some lithium battery devices can, some can’t, and loose batteries follow their own set of rules. Here’s the clear breakdown so you know where to pack what.
Spare Batteries vs. Batteries in Devices
The rules differ significantly depending on whether a battery is loose (spare) or inside a device:
- Spare Lithium Batteries: Must go in carry-on baggage only. Spare battery terminals must be protected from short circuits (e.g. by taping terminals or packing in individual plastic pouches).
- Batteries Installed in Devices: Laptops, phones, and tablets with built-in batteries are allowed in both carry-on and checked luggage. However, safety agencies strongly recommend carry-on packing.
[!WARNING] Loose power banks, external battery chargers, and spare lithium cells are strictly prohibited in checked baggage. If checked at the ticket counter, security staff will remove them from your luggage.
Capacity Limits (Watt-Hours)
FAA rules specify limits based on the battery capacity measured in Watt-hours (Wh):
- Under 100 Wh: Allowed without quantity limits (this covers most laptops, phones, camera batteries, and standard power banks).
- 100 to 160 Wh: Requires airline approval before boarding. Limited to two spare batteries per passenger.
- Over 160 Wh: Strictly prohibited on passenger flights. This applies to large electric vehicle batteries, hoverboards, and large solar generator packs.
Safety Tips for Packing Batteries
- Keep Power Banks in Cabin: Never pack portable power banks in luggage that you check at the ticket counter or gate.
- Prevent Accidental Activation: Turn devices containing batteries (like electric toothbrushes or laptops) completely off. Do not leave them in sleep or standby mode.
- Tape Terminals: Protect spare battery connection terminals with electrical tape or place them in individual zip baggies.