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Immediate rule: all spare lithium-ion and lithium metal batteries (including power banks) must travel in your hand baggage. Devices with installed batteries are usually permitted in both cabin and hold baggage, but most carriers and regulators require spares to remain onboard with the passenger.
Hard limits: lithium-ion cells up to 100 Wh are allowed as spares only in the cabin. Cells between 100 Wh and 160 Wh require airline approval and are typically limited to two spare units per passenger. Cells above 160 Wh are not permitted on passenger aircraft except via approved cargo processes. Non-rechargeable lithium metal batteries with more than 2 g lithium content are forbidden in passenger consignments.
Packing and handling steps: keep battery terminals insulated (tape or original packaging), place each spare in individual protective sleeves or plastic bags, power devices down, prevent accidental activation (remove covers, enable flight/airplane mode), and secure items against crushing. Power banks are treated as spare batteries and must follow the same rules.
If you need to transport high-capacity packs (e.g., e-bike, professional camera packs, large UPS units), contact the airline’s cargo or dangerous-goods department before travel. Such items often require special packaging, labeling and a formal dangerous-goods declaration under IATA DGR; many carriers will refuse unapproved consignment at the airport.
Before departure, verify the carrier’s battery policy and the departure/arrival country’s rules; airline webpages and the IATA dangerous-goods guidance provide the authoritative limits and approval procedures. Keep documentation for any approved high-capacity cells and present it at check-in/security if requested.
Transporting battery-powered devices in the aircraft hold
Keep batteries and spare power packs in cabin baggage; equipment with installed lithium cells may be stowed in the aircraft hold only if the airline permits and the battery is secured against shorting and accidental activation.
Watt‑hour and lithium-content thresholds
Lithium‑ion (rechargeable): ≤100 Wh – permitted in cabin and typically allowed installed in hold; >100 Wh and ≤160 Wh – airline approval required and usually limited to two items or spare batteries per passenger; >160 Wh – not permitted on passenger aircraft. Lithium‑metal (non‑rechargeable): lithium content ≤2 g – generally allowed; >2 g – forbidden. Convert mAh to Wh: Wh = (mAh × V)/1000. Example: a 10,000 mAh power bank at 3.7 V ≈ 37 Wh.
Packing steps and practical notes
Power down devices completely and remove external memory cards. Insulate battery terminals with tape or keep cells in original packaging. Place fragile gear in a rigid case with foam; separate power banks and spare cells from other items. Label batteries >100 Wh and obtain airline approval before travel. Do not place spare batteries or portable chargers in the aircraft hold – they belong in cabin baggage. Large batteries used for e‑bikes, scooters and similar gear (over 160 Wh) are denied on passenger flights; arrange freight transport if needed. For studio lighting components such as bulbs, consult product selections like best light bulb best light bulbs for photography studio umbrellas and pack them in a dedicated, padded container to avoid impact damage and filament breakage.
Which devices are prohibited in the aircraft hold (lithium batteries, power banks, e-cigarettes)?
Do not stow spare lithium batteries, external battery packs (power banks) or vaping devices in the aircraft hold; these items are restricted to cabin baggage and subject to capacity and quantity limits.
Battery types and strict limits
– Lithium‑ion (rechargeable): spare cells/packs are forbidden in the hold. Ratings >160 Wh are prohibited on passenger aircraft. Packs between 100 Wh and 160 Wh require airline approval and are normally limited to a maximum of two spare units per passenger. Packs ≤100 Wh are allowed only in cabin and should have terminals protected.
– Lithium‑metal (primary, non‑rechargeable): cells containing more than 2 g of lithium metal per cell are banned on passenger aircraft. Spares of smaller cells remain cabin‑only.
– Power banks: treated as spare batteries. Determine watt‑hours by formula Wh = (mAh × V) / 1000 (typical nominal cell voltage 3.7 V). Example: 20,000 mAh × 3.7 V = 74 Wh. Any power bank >100 Wh needs airline approval; >160 Wh is forbidden; all power banks must travel in cabin, not the hold.
Pocketable devices, vaping items and packaging rules
– Vaping devices (e‑cigarettes) and cartridges must not be placed in the hold. Devices must be switched off, protected from accidental activation, and kept in cabin baggage. E‑liquid cartridges in hand baggage must comply with liquid restrictions at departure and transfer airports (commonly ≤100 ml per container in a transparent bag); some states prohibit vaping imports–verify destination laws.
– For all spare batteries: tape exposed terminals or use original packaging/insulating caps; keep each spare separated from metal objects. Airlines and security may inspect and confiscate non‑compliant items; fines or travel delays are possible.
– Airline and national rules differ: always check carrier policy and destination regulations for exceptions. For a related reference on employer/insurance listings and payout rankings see best paying umbrella company.
How to pack laptops, tablets and cameras to minimize damage
Place laptops, tablets and cameras inside a rigid, lockable hard case with a minimum of 2.5 cm (1 in) of high‑density closed‑cell foam padding on every side.
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Remove and stow small parts:
- Detach straps, external grips, lens hoods and lenses with collars; store each item in separate padded pouches.
- Keep memory cards, USB drives and SIMs in a labeled, hard plastic case inside your carry-on or on-person storage when possible; do not leave loose pieces around the main compartment.
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Screen and lens protection:
- Apply a tempered glass protector to tablet and laptop screens before travel.
- Cover camera lenses with front and rear caps and wrap lenses in a microfiber cloth, then place in a padded lens pouch.
- Add one layer of anti‑static bubble wrap (8–12 mm bubbles) around screens and lenses; secure with painter’s tape (no adhesive on surfaces).
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Layering and placement:
- Center devices in the case so at least 5–7 cm of padding separates them from all outer walls.
- Surround the hard case with soft garments (fleece, wool) rather than items with zips or buttons.
- Avoid placing heavy objects above or directly adjacent to the device compartment.
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Immobilize with custom inserts:
- Use pick‑and‑pluck polyethylene foam or cut-to-shape EVA inserts to cradle gear and eliminate movement.
- For mixed kits, use dividers that keep bodies, lenses and chargers in separate tightly‑fitting cells.
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Exterior protection and sealing:
- Choose a hard-shell suitcase or case rated for impact; close and lock zippers with TSA‑approved locks.
- Wrap the case in a weatherproof cover if moisture is a concern; include silica gel packs to reduce humidity inside the case.
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Weight distribution and orientation:
- Place the heaviest protected items closest to the wheel/base area of the suitcase to reduce crushing risk.
- Keep hinge/port areas of laptops and tablets cushioned–use foam blocks to prevent direct pressure on screens or ports.
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Documentation and verification:
- Photograph gear and note serial numbers before departure for insurance or damage claims.
- Inspect devices immediately upon retrieval and document any dents, cracks or functional failures within 24 hours.
Materials checklist: hard case with foam inserts, neoprene sleeve (3–5 mm) for laptops/tablets, microfiber cloths, tempered glass protectors, 8–12 mm bubble wrap, polyethylene or EVA foam, silica gel packets, small hard plastic cases for cards/USBs.
Where to store spare batteries and removable lithium cells – cabin rules and exceptions
Store all spare lithium-ion and lithium-metal cells in your cabin bag; never place spare cells in the aircraft hold.
Watt‑hour and lithium-content limits
Lithium‑ion: batteries rated 100 Wh or less are allowed in the cabin without airline approval. Batteries rated above 100 Wh and up to 160 Wh require airline approval and are limited to two spare batteries per passenger. Batteries over 160 Wh are prohibited on passenger aircraft and must be shipped as cargo under dangerous‑goods regulations.
Lithium‑metal (primary) cells: most passenger rules permit cells with up to 2 g lithium content per cell and up to 5 g lithium content per battery assembly; verify markings and airline policy before travel.
Safe storage, terminal protection and special cases
Protect terminals against short circuits: keep batteries in original retail packaging, use purpose-made plastic battery cases, or individually tape terminals and place cells in separate resealable plastic bags. Do not pack loose spares with keys, coins, or other metal objects.
Power banks and external battery packs are treated as spare lithium‑ion batteries: they must travel in the cabin and have terminals protected. Convert mAh to Wh using Wh = (mAh × V) / 1000 (example: a 10,000 mAh bank at 3.7 V = 37 Wh).
Mobility-aid batteries: removable batteries should be transported in the cabin if possible; if removal is impossible, notify the carrier before departure. The carrier may require disconnection, terminal insulation and special stowage or acceptance under specific procedures.
Defective, damaged, swollen, leaking or recalled cells are not permitted on passenger flights in either the cabin or the hold. Such batteries must be handled via approved cargo dangerous‑goods procedures and only after consulting the airline or the manufacturer.
Quick checklist: keep spares in the cabin, check Wh or lithium-content markings, obtain airline approval for 100–160 Wh units, insulate terminals, and notify the carrier for mobility-aid or damaged batteries.
How to verify airline and international regulations before departure processing (TSA, IATA, carrier policies)
Before handing devices to the airline, consult three authoritative sources: the U.S. Transportation Security Administration (for U.S. segments), the IATA Dangerous Goods Regulations (DGR) for international standards, and the specific operator’s dangerous‑goods / baggage policy page.
Actionable verification steps
1) Open the IATA DGR summary (iata.org → Programs → Cargo → DGR) and search for lithium battery passenger rules. General guidance used by most carriers: lithium‑ion batteries up to 100 Wh are normally permitted in the cabin; batteries between 100–160 Wh usually require airline approval (often limited to two spare or replacement batteries per passenger); batteries above 160 Wh are not allowed on passenger aircraft.
2) For flights involving the United States, consult TSA Hazardous Materials pages (tsa.gov → Travel → Hazardous Materials). TSA guidance classifies power banks and spare lithium cells as forbidden in aircraft hold and requires they remain with the passenger in the cabin.
3) Open the operating carrier’s official website and locate “dangerous goods,” “battery policy” or “special baggage” pages. Look for: stated Wh limits, number of permitted spare batteries, approval procedures, and any route‑specific prohibitions. If policy language is ambiguous, proceed to step 4.
4) Contact the airline’s customer service or dangerous‑goods desk by phone or email before departure. Provide device model, battery type, and Wh rating; request written confirmation or an approval reference number for batteries between 100–160 Wh or for multiple spare units.
5) For itineraries with multiple airlines or code‑shares, repeat checks for each operator and for aviation authorities of transit/arrival countries (e.g., EASA member states, UK CAA, CAAC). Operator policies and national rules may be stricter than IATA minimums.
Documentation and quick technical checks
Keep the following with you: battery datasheets or manufacturer specification pages, screenshots or printouts of airline approval, and serial numbers for large batteries. Verify Wh on the battery label; if only mAh and voltage are shown, calculate Wh = V × Ah (example: 3.7 V × 2,600 mAh = 3.7 × 2.6 Ah = 9.62 Wh). Present these documents at the ticket counter if asked.
Declare these battery-powered items at bag drop and during security screening
Declare spare batteries, power banks, medical batteries, damaged cells and any non-standard battery installations to the agent at bag drop and to the security officer before screening.
What exactly to report
- Spare lithium-ion packs (state Wh rating): standard 160 Wh prohibited for passengers – specify quantity and Wh per cell.
- Spare lithium metal (non-rechargeable) cells: state lithium content in grams (limit usually ≤2 g per cell for passenger transport).
- Power banks and portable chargers: declare capacity in Wh or mAh+V; most airports prohibit them in the aircraft hold and require placement in cabin baggage/onboard for inspection.
- Battery-powered mobility aids and mobility device batteries: present battery specification sheet, airline approval paperwork and confirm terminals are insulated or battery disconnected following carrier rules.
- Professional gear with large packs (film, broadcast, industrial tools, drones): declare quantity, Wh per pack and whether spares are carried separately.
- Devices with visibly damaged, swollen or previously overheated batteries: state damage and request manual inspection; such items are frequently refused if battery integrity is compromised.
- Prototypes, custom assemblies or unpackaged cells intended for shipment or research: provide MSDS, manufacturer data sheet and airline/cargo acceptance confirmation at bag drop.
Documents and evidence to have ready
- Battery labels showing Wh (or mAh and voltage). If only mAh and V shown, compute Wh = (mAh × V) / 1000 and present the calculation.
- Airline written approval (email/printed) for packs 100–160 Wh or for multiple large batteries.
- MSDS or technical datasheet for bulk shipments, prototypes or powders associated with battery systems.
- Medical letter for implantable devices or essential portable medical aids that contain batteries.
- Evidence of proper terminal protection (tape, capped terminals) for spare cells.
Conversion example: 10,000 mAh at 3.7 V → (10000 × 3.7) / 1000 = 37 Wh. Present both original label and the arithmetic if Wh is not printed.
- At bag drop: state aloud what you have – e.g., “Spare lithium-ion batteries: three units, 45 Wh each; one power bank 20,000 mAh (74 Wh).”
- Hand over documentation and, if requested, remove items from packing for security inspection; keep spares separated and with terminals protected.
- At the security checkpoint: declare medical or implanted battery devices before placing trays through X-ray; request manual search if the device cannot be powered off.
- If agent requests, transfer approval email or MSDS to their device or provide printed copies; do not conceal items – full disclosure reduces the chance of seizure or travel delays.
Sample phrasing for bag drop: “I have spare lithium-ion batteries – three at 45 Wh each – and one power bank of 74 Wh; I have airline approval (presenting email).” Sample for security: “This is a medical device with an internal battery; it cannot be powered off, please advise on manual inspection.”
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How to document and claim loss or damage of devices from hold baggage
Report the damaged or missing device at the airline’s baggage desk immediately and obtain a written Property Irregularity Report (PIR) with a reference number before leaving the airport terminal.
Actions to complete at the airport: present boarding pass and baggage tag stub; insist on a printed PIR; photograph the damaged item and the external bag and tag; keep the original packing materials and any torn baggage pieces.
Required evidence to assemble for the carrier claim: PIR number, boarding pass, baggage tag, timestamped photos showing pre‑ and post‑flight condition (closeups of serial numbers, cracks, watermarks), original purchase receipt or invoice, device serial/IMEI number, and any repair quotations from a certified technician.
Deadlines and legal limits: submit a written claim to the carrier within 7 days from date of receipt of damaged property; for delayed deliveries, submit within 21 days from the date the bag was made available; for international carriage the Montreal Convention limits airline liability for loss or damage to checked items to 1,288 SDR per passenger unless a higher value was declared and additional charge paid at ticketing.
If theft is suspected, file a local police report at the arrival airport and attach the police reference to your carrier claim; many airlines require a police report for content-theft compensation.
When filing the claim online or by email, include the PIR reference, flight number, date, passenger name and contact details, itemized list of damaged/missing items with serial numbers and values, and attach photos, receipts and repair estimates. Ask the carrier for a claim reference and expected response timeframe in writing.
| Document | Why | Where to obtain |
|---|---|---|
| Property Irregularity Report (PIR) | Carrier official record; required to start a claim | Airline baggage desk at arrival |
| Boarding pass and baggage tag stub | Proof of carriage and item association | Passenger keeps; obtain tag stub at drop-off |
| Photos (timestamps preferred) | Visual proof of condition and packaging | Smartphone or camera at airport and after unpacking |
| Purchase receipts / invoices | Proof of value for reimbursement | Retailer, bank records, emailed receipts |
| Device serial number / IMEI | Identification; prevents fraudulent claims | Device label, original box, system settings |
| Repair estimate or technician report | Supports damage valuation | Authorized service centre or certified repair shop |
| Police report (if theft) | Often required for content-theft claims | Local law-enforcement at arrival |
If the carrier’s settlement is below expected value: request a written explanation of the calculation, reference the Montreal Convention limit (1,288 SDR) for international flights, and provide evidence of declared excess valuation if you paid for higher coverage at ticketing. If unsatisfied, escalate to the national civil aviation authority or an independent small-claims forum; include all prior correspondence and claim references.
Sample claim email body (concise): Subject: Claim – PIR [PIR number] – Flight [Airline/Number] – Date [DD/MM/YYYY]. Passenger: [Name]; Contact: [phone/email]; Description: [device make/model, serial]; Damage/loss summary: [one sentence]; Attachments: PIR, boarding pass, baggage tag, photos, receipt, repair estimate, police report (if any). Request: reimbursement or repair authorization and expected response date.
Check whether travel insurance or the payment card used to buy the ticket provides contents cover; submit the carrier’s claim outcome and the same evidence to the insurer for parallel recovery.
