Can you have batteries in your carry on luggage

Allowed without airline approval: cells and rechargeable power packs rated ≤100 Wh each. Restricted: items between 100 Wh and 160 Wh require airline approval and are normally limited to two spare units per passenger. Prohibited: cells or power modules exceeding 160 Wh are not permitted in cabin or checked baggage.

Spare primary (non-rechargeable) lithium cells must meet content limits: lithium content ≤2 g per cell and ≤25 g per battery under common carrier rules. All spare cells and power banks are treated as loose power sources and therefore belong in cabin baggage only; installed cells inside electronic devices are generally accepted but carriers may impose additional restrictions for checked stowage.

Protect terminals by using original packaging, insulating caps, or non-conductive tape to prevent short circuits. Carry documentation or markings that show Wh or lithium content when seeking airline approval for items >100 Wh. Declare items that require approval at check-in and follow airline-specific limits on quantity and placement.

Follow guidance from regulatory authorities (IATA/ICAO/TSA) and consult the airline before travel when transporting unusual configurations (e.g., multiple power banks, professional-grade packs, or packs near the 160 Wh threshold).

Permitted cell types for cabin carriage by major airlines

Store all spare lithium‑ion cells in the aircraft cabin; spares are prohibited in checked baggage and must have terminals insulated or be in original packaging.

Rechargeable lithium‑ion: cells and packs with a rated energy up to 100 Wh are allowed in the cabin without airline approval. Units between 100 Wh and 160 Wh require airline approval and are normally limited to two spare units per passenger; anything above 160 Wh is banned from passenger aircraft.

Non‑rechargeable lithium‑metal: cells with lithium content ≤2.0 g are permitted in the cabin as spares; lithium‑metal cells with >2.0 g lithium are not accepted on passenger flights. Small coin/button lithium cells typically fall below the 2.0 g limit.

Alkaline, NiMH and NiCd: standard primary and rechargeable cylindrical cells (AA, AAA, etc.) installed in devices are acceptable in either checked or cabin stowage; spare packs and power banks using these chemistries should be kept in the cabin. Lead‑acid (SLA) and other large industrial cells require airline approval and are usually transported as cargo, not in passenger compartments.

Power banks and external packs: classified as spare lithium‑ion packs and therefore must travel in the cabin, be protected against short circuits, and comply with the Wh limits above. Labelled Wh or manufacturer data must be available for review; convert mAh to Wh using Wh = (mAh × V) / 1000 (example: 3.7 V × 2600 mAh = 9.62 Wh).

Major carriers’ practice (summary): American Airlines, Delta, United, British Airways, Lufthansa, Air Canada, Emirates and Qantas apply IATA/FAA rules: lithium‑ion ≤100 Wh allowed in cabin; 100–160 Wh requires approval and is limited (usually two spares); lithium‑metal ≤2 g allowed in cabin; spares are not permitted in checked baggage. Specific carrier webpages list declaration procedures and approval contacts for >100 Wh items.

Practical steps before travel: verify Wh or lithium‑content labeling, limit 100–160 Wh spares to two units with prior airline approval, insulate terminals or use original retail packaging, place all spare cells and power banks in carry‑on cabin items, and declare larger/industrial cells to the airline well ahead of departure.

How to transport spare lithium cells and power banks in cabin baggage: quantity and placement

Store spare lithium-ion cells and power banks in cabin baggage only; protect terminals (tape, original packaging or individual plastic sleeves), ensure each unit is labeled with Wh or calculated Wh, and keep all spare power sources switched off during screening and flight.

Quantity limits (clear rules and common carrier practices)

International regulations (IATA/ICAO and FAA) set Wh-based limits for rechargeable lithium packs: units ≤100 Wh require no airline approval; units 100–160 Wh require airline approval and are limited to two spare units per passenger; units >160 Wh are not permitted in passenger aircraft. Non-rechargeable lithium metal cells are generally limited to ≤2 g lithium content per cell for transport in the cabin; cells with >2 g lithium content are prohibited.

Placement and packing checklist

Place all spare cells and power packs inside hand or cabin baggage; do not stow spares in the aircraft hold. Protect exposed terminals by taping contacts, using original retail packaging, placing each unit in a separate plastic bag, or using individual sleeves. Keep spare power sources accessible for inspection; officers may request removal for screening.

Label verification: confirm Wh rating printed on the unit. If only mAh and voltage (V) are shown, calculate Wh = (mAh ÷ 1000) × V. Example: a 10,000 mAh power pack at 3.7 V → (10000 ÷ 1000) × 3.7 = 37 Wh.

If Wh or lithium content cannot be determined, treat the item as exceeding limits and consult the carrier before travel; undeclared or improperly packed spares may be denied boarding or confiscated during security checks.

Devices with installed power cells: power off, secure and present at security

Power off devices with installed power cells – use a full shutdown (no sleep/hibernate), disable alarms and wake-on notifications, and lock physical power switches to prevent accidental activation.

Prevent accidental activation and shorting

Remove external cases or accessories that press buttons; immobilize sliders and pop-up cameras; cover exposed terminals with non-conductive tape or use original terminal caps. Place each device in a hard-sided protective sleeve or individual padded pouch to avoid crushing or impact. For devices with removable cells, follow spare-cell rules rather than leaving loose inside other items.

Security screening and documentation

Present devices separately at the checkpoint when requested; security staff may require a power-on demonstration to verify functionality. Devices that fail to power may undergo enhanced inspection or be denied carriage on the aircraft. Devices with installed lithium-ion ratings ≤100 Wh are normally acceptable in the passenger cabin, 100–160 Wh require airline approval, and >160 Wh are restricted from passenger transport – carry manufacturer label or datasheet and any airline approvals for devices in the 100–160 Wh range.

Store devices in an easily accessible compartment of hand-held cabin baggage to allow rapid removal at screening and quick isolation if a thermal event occurs. For containment and post-incident odor/smoke control guidance, see how to make a carbon air scrubber.

How to calculate watt-hours (Wh) and apply airline, ICAO and FAA limits

Calculate Wh with the formula Wh = V × Ah. When capacity is listed in mAh use Wh = (mAh ÷ 1000) × V.

If voltage is not printed, assume nominal cell voltage 3.7 V for most Li‑ion/Li‑poly cells; some high-density cells use 3.6 V or 3.85 V – use the exact label value when available.

Quick examples: 3.7 V × 2200 mAh → (2200 ÷ 1000) × 3.7 = 8.14 Wh. A power pack rated 10,000 mAh at 5 V output → (10,000 ÷ 1000) × 5 = 50 Wh. If a power bank lists mAh without voltage, convert using 3.7 V unless the manufacturer specifies otherwise.

Common conversion targets (using 3.7 V): 10,000 mAh = 37 Wh; 20,000 mAh = 74 Wh; 27,000 mAh ≈ 100 Wh; 30,000 mAh ≈ 111 Wh; 43,000 mAh ≈ 159 Wh.

ICAO/IATA/FAA thresholds for Li‑ion cells and packs: ≤100 Wh – permitted onboard without airline approval; >100 Wh and ≤160 Wh – airline approval required, quantity often limited (airlines typically limit to two spare packs per passenger); >160 Wh – forbidden on passenger aircraft and must be shipped only under cargo regulations.

Primary lithium (metal) rules use lithium content, not Wh: cells with lithium content ≤2.0 g per cell are allowed; cells or batteries with >2.0 g lithium are prohibited for passenger transport.

Practical steps: inspect device/pack label for Wh or voltage+mAh, perform the Wh calculation, compare to the 100 Wh and 160 Wh thresholds, and request airline approval in advance for items between 100–160 Wh. Packs exceeding 160 Wh require specialized cargo handling and dangerous-goods paperwork.

For small portable power packs choose a slim protective case that meets onboard size constraints; consider models that fit inside a messenger-style bag such as best messenger bag for magic the gathering cards. For wet-weather protection of accessories consult best umbrellas wind resis.

How to package cells: terminal protection, labeling and handling damaged cells

Insulate terminals completely with non-conductive caps or full-wrap tape, place each cell in an individual polyethylene pouch or retail sleeve, and secure all pouches inside a rigid, impact-resistant container with internal separators.

• Terminal protection

  • Use manufacturer-supplied plastic terminal caps whenever available; otherwise use Kapton or high-quality PVC heat-shrink tubing sized to cover the entire terminal and any exposed metal.
  • For cylindrical cells (e.g., 18650): install tip caps or slide each cell into a dedicated plastic tube; add tape only if caps or tubing are not available.
  • For flat pouch or prismatic cells: fold tabs inward (if possible) and apply full-surface Kapton or electrical tape; avoid leaving any part of a terminal exposed.
  • Avoid metallic or conductive anti‑static bags for loose cells–use plain polyethylene or other non‑conductive bags so terminals cannot short.

• Internal packaging and containment

  • Place each insulated cell in a separate soft pouch or compartment; never allow contact between terminals of different cells or with metal objects (keys, coins, tools).
  • Use a rigid outer container (hard plastic case or cardboard box with rigid inserts). Fill voids with non-conductive foam or dense packing to prevent movement and crushing.
  • For multi‑cell packs, keep the original manufacturer pack or use designed cell holders that prevent compression and lateral movement.
  • Label internal divisions to indicate positive/negative orientation if multiple cells are stacked to avoid accidental reassembly errors.

• Marking and documentation

  • Affix a clear, legible sticker on the outer container stating cell chemistry (e.g., “Lithium‑ion cells”), total nominal voltage and Wh for the entire shipment when required by carrier/shipper policies.
  • For small consumer cells (<100 Wh nominal per cell), include a brief note stating “Terminals insulated” to assist security screening officers.
  • When shipping under dangerous‑goods procedures, apply the UN and handling labels specified by the shipper; follow carrier-specific placarding and paperwork requirements.

• Damaged, swollen, leaking or heat‑affected cells

  • Do not attempt to recharge, puncture, disassemble or compress compromised cells.
  • Immediately isolate the affected cell in a non‑conductive, sealable plastic bag; place that bag inside a rigid, non‑combustible container (metal tin or heavy plastic box) lined with sand or vermiculite to absorb leaking electrolyte.
  • If leakage is present, avoid skin contact and ventilate the area; use nitrile gloves and safety goggles when handling.
  • Do not place damaged cells in passenger baggage; arrange transport via approved hazardous‑materials channels or deliver to an authorized recycling/repair facility following carrier and local hazardous‑waste rules.
  • In the event of smoke, flame or thermal runaway: evacuate the vicinity, alert ground staff or emergency services, and use a Class D extinguisher or large quantities of sand/earth. ABC dry‑chemical extinguishers may suppress flames but will not stop internal cell reactions.

Keep records of brand, model, nominal voltage and Wh for all packs when preparing for inspection or compliance checks; retain original packaging and manufacturer documentation where possible.