Recommendation: Keep all mobile devices and external battery packs in cabin baggage; do not stow uninstalled batteries or power banks in the aircraft hold.
TSA and FAA rules allow devices with installed lithium‑ion cells to travel in the aircraft hold, but both agencies advise passengers to carry such items in the cabin when possible. Uninstalled lithium batteries and portable chargers are classified as spare batteries and are forbidden in checked stowage. IATA Dangerous Goods Regulations set the technical thresholds: cells up to 100 Wh are permitted in passenger baggage, batteries between 100 Wh and 160 Wh require airline approval (typically limited to two per person), and cells over 160 Wh are prohibited on passenger aircraft.
Quick arithmetic for battery capacity: Wh = V × Ah. Example: a 3.7 V, 3000 mAh pack equals approximately 11.1 Wh (3.7 × 3.0). Typical mobile device packs fall well under 100 Wh; professional camera or drone batteries may approach or exceed the 100 Wh mark – check the printed Wh rating or calculate from voltage and mAh.
Packing checklist: power the device off, remove external cases that could trap heat, place the unit in a protective compartment to prevent crushing and accidental activation, and insulate exposed terminals on spare cells with tape or store them in original retail packaging. Power banks must be carried in the cabin and count as spare lithium batteries; airlines commonly require terminal protection and limit the number per passenger.
If a battery exceeds 100 Wh, contact the airline before travel to obtain written approval and follow carrier instructions regarding declaration and placement. For routine travel with standard mobile devices and installed batteries, cabin carriage minimizes fire risk, allows crew intervention if necessary, and reduces the chance of loss or damage during handling.
Airline and TSA rules for mobile devices and lithium batteries in hold baggage
Spare lithium batteries and external power banks must travel only in cabin baggage; none should be stowed in the aircraft hold.
Regulatory limits and what requires airline approval
Lithium‑ion (rechargeable): up to 100 Wh – permitted in cabin without airline approval. Between 100 Wh and 160 Wh – allowed in cabin with airline approval (typically limited to two spare batteries); above 160 Wh – prohibited from passenger aircraft (may require special cargo procedures).
Lithium‑metal (non‑rechargeable): maximum 2 g lithium content per battery for carriage in cabin without approval. Batteries with >2 g require airline approval and are generally restricted.
Spare batteries: any battery not installed in a device (including power banks) is classified as a spare and is forbidden in the aircraft hold.
Practical handling and packing rules
Devices with installed batteries: many carriers permit stowage in the hold but recommend placement in the cabin. Devices must be powered off and protected from accidental activation (flight mode is not sufficient). If possible, remove the battery; otherwise protect power button and place device in a protective case.
Spare batteries and power banks: keep in carry‑on; insulate terminals by taping exposed contacts, using original packaging, or placing each battery in a separate plastic pouch. Limit the number of spares to the carrier’s allowance (often two for high‑capacity batteries).
Special items: e‑cigarettes/vaporizers and hoverboards are commonly prohibited in the hold (e‑cigarettes are allowed in cabin but must not be used onboard). Drone batteries follow the same Wh limits as other lithium‑ion cells and generally require airline approval if 100–160 Wh.
Wh calculation example: Wh = (mAh × V) / 1000 – a 20,000 mAh bank at 3.7 V = 74 Wh (allowed in cabin without approval).
Declare batteries that exceed standard limits at airline check‑in and obtain written approval if required. Follow the strictest rule among TSA, the departing carrier and destination country; noncompliance can result in confiscation, denied boarding or fines.
When a mobile device must travel in carry-on: prohibited scenarios and exceptions
Keep spare batteries and external battery packs in carry-on baggage only; never stow spares in the aircraft hold.
Spare lithium‑ion battery limits: batteries with a rating of ≤100 Wh are permitted in cabin without airline approval; those rated 100–160 Wh require airline approval and are normally limited to a maximum of two spare units per passenger; batteries above 160 Wh are prohibited on passenger aircraft and must be transported as cargo under dangerous‑goods procedures.
Installed batteries with high capacity: equipment that contains an internal battery rated above 100 Wh must receive airline approval before carriage in the cabin; many carriers forbid such equipment from the passenger cabin and will demand cargo shipment with proper dangerous‑goods declaration for very large packs (e.g., professional audio/video rigs, e‑bikes).
Power banks and portable chargers: treated as spare lithium batteries by regulators and carriers. Convert milliampere‑hours to watt‑hours for compliance: Wh = (mAh ÷ 1000) × V (typical nominal voltage = 3.7 V). Example: 10,000 mAh ≈ 37 Wh. If Wh exceeds 100, secure airline approval; >160 Wh not allowed in passenger carriage.
Damaged, defective or recalled batteries: swollen, punctured, leaking, charred or otherwise compromised cells are banned from both the cabin and the aircraft hold for passenger flights. Such units must not be accepted for carriage; contact the airline or manufacturer for instructions on approved hazardous‑goods shipment or safe disposal.
Medical and mobility devices – exceptions: batteries for medically necessary devices (portable oxygen concentrators, wheelchairs, mobility scooters) may be permitted with advance airline approval and documentation. Airlines typically require device and battery specifications, physician’s letter where applicable, and secured terminal protection; spare batteries for these devices often need pre‑authorization and specific packing.
Terminal protection and handling: all spare batteries and power banks must have exposed terminals insulated (tape or terminal caps), be individually packaged or in original retail packaging, and kept separate from conductive items. Loose spare cells inside checked bags are forbidden; carry them in the cabin in a dedicated pouch or plastic bag.
Immediate actions before travel: verify battery Wh printed on the unit or convert mAh→Wh; obtain written airline approval for 100–160 Wh units; remove and insulate removable batteries when requested; refuse transport of batteries showing physical damage; keep documentation for medical devices readily available for inspection.
How to prepare a mobile device for stowage in the aircraft hold: power state, battery handling, and packaging
Power the device off completely; disable alarms, scheduled starts and any wake-on-motion or accessory-trigger features; set battery level to roughly 30–50% before stowage.
Power state and settings
Full shutdown is preferable to flight-mode because shutdown prevents accidental activation, background processes and thermal load. Remove any external power packs or charging cases that could activate while compressed. Disable fingerprint/face unlock and remove auto-backup schedules that could attempt network access during transit.
Battery handling and packaging
Removable lithium-ion cells: remove from the handset if possible, cover exposed terminals with non-conductive tape, place each cell in its own plastic pouch or original manufacturer box and then inside a hard protective container. Non-removable battery devices: leave powered off and place inside a rigid case that resists crushing and puncture. Surround the device with soft padding (folded garments or bubble wrap) at least 2–3 cm thick on all sides and position centrally inside the suitcase or bag away from sharp metal objects, heavy tools and items that can shift.
Do not stow visibly swollen, dented or heat-discolored batteries in the hold; hand such items to airline or ground staff for inspection. Label the outer bag with contact details and ensure all ports are covered to prevent short circuits. For packing accessories and durable protective gear comparisons, see best fully automatic washing machine for hard water.
Packing tips to minimize fire and physical damage in hold baggage
Store the device at the geometric center of the suitcase with a minimum of 2–3 cm of non-conductive padding on every side to reduce compression and heat transfer.
Place the gadget inside a rigid container such as a molded EVA case or small hard box, then nest that container between soft garments (sweaters, towels) rather than beneath heavy items like shoes, toiletry bottles or books to avoid point loads and crushing.
Eliminate movement: use internal compression straps, packing cubes, or foam inserts so the item cannot slide or rotate during conveyor and cart handling; voids should be filled with soft items rather than air.
Keep electronics separate from sharp or metallic objects (keys, razors, metal tools, pens) and from pressurized or flammable goods (aerosols, loose toiletries). If toiletries are present, seal them in secondary plastic bags and locate them away from the protected container.
Use a fire-resistant pouch or FAA-listed containment bag for devices with swollen or previously damaged batteries; store spare power banks and loose batteries in hand baggage when airline policy allows, and never mix loose cells with metal items in the same pocket.
Reduce corrosion and abrasion by inserting 1–2 silica gel packets, wrapping screens in a microfiber cloth, and placing corner protection (foam wedges) around edges. Add a visible fragile label and choose a hard-shell suitcase or model with an internal electronics compartment – see best luggage for european train travel for suitable designs.
What to do after loss, damage, or a battery incident in hold baggage
Report the incident at the airline arrival counter immediately and obtain a written Property Irregularity Report (PIR) with a reference number.
Immediate safety actions after a battery thermal event
- Move the affected bag away from people and flammable material; alert ground staff or cabin crew and airport emergency responders.
- If smoke or flame is present, allow trained responders to extinguish; do not attempt to extinguish a lithium battery fire with water unless directed by responders.
- Do not power on, charge, or attempt to repair the damaged device or battery; remove nearby combustible items if this can be done without risk.
- Photograph the damaged device, surrounding contents and exterior of the bag from several angles before handing over to airline or emergency crews, if safe to do so.
- Collect contact details of airline staff, on-scene responders and incident-report numbers; request a copy of any official safety or fire reports generated at the scene.
Claims, evidence preservation, and next steps
- Preserve all physical evidence: retain the damaged device, battery (if possible), original packaging, damaged items, boarding pass and bag tag until claim resolution.
- Document identification data: record device IMEI/serial number, purchase receipt, warranty information and any cloud-backed device identifiers (Find My Device, iCloud, etc.).
- File formal claims with the airline and any travel insurer. For international carriage governed by the Montreal Convention: damage claims normally must be submitted within 7 days from receipt of the item; delay claims within 21 days. Include PIR, photos, receipts and repair estimates.
- If theft is suspected, obtain a police report and provide the report number to airline claims and insurers.
- Use remote-management services (Find My Device, iCloud, Google Find My Device) to lock, locate, or erase device data as needed; record timestamps of any remote actions.
- Contact the device manufacturer for guidance on inspecting, repairing, or recycling a damaged battery; many manufacturers offer take-back for hazardous batteries.
- For incidents within the United States, report battery fires or serious safety incidents to TSA (see tsa.gov/contact) and retain any incident reference for claims.
- Keep originals of all correspondence, repair invoices, quotes and settlement offers; request a written claim reference and expected handling timeline from the airline.
- Do not dispose of a visibly damaged battery in regular trash; arrange hazardous-waste disposal through airport environmental services or a certified battery-recycling facility.
- If injury or significant property damage occurred, obtain medical and repair records and include those documents in any legal, insurer or regulatory reports.
Maintain copies of all documentation until claim closure and final reimbursement or repair is received; retain the damaged item for inspection if requested by the airline, insurer or manufacturer.