Michael Turner
Immediate rule: portable lights with installed batteries are generally permitted in hold baggage if cell terminals are protected against short circuits. Spare lithium-ion or lithium-metal cells are prohibited from the hold and must be carried in the aircraft cabin. Alkaline, NiMH and other non-lithium cells are usually acceptable anywhere, provided terminals are insulated.
Battery limits and approvals: lithium-ion cells up to 100 Wh are normally allowed without airline approval; cells between 100 Wh and 160 Wh require explicit airline authorization and are typically limited to two spares per passenger in the cabin; cells above 160 Wh are forbidden on passenger aircraft. For lithium-metal (primary) cells, a 2 g elemental lithium content threshold applies – cells exceeding that limit are not permitted.
Practical measures: remove spare cells from the device if possible, tape exposed terminals or place each cell in original packaging or individual plastic sleeves, store spares inside carry-on only, and avoid transporting liquid fuel reservoirs or refillable fuel cartridges. Confirm carrier-specific policies and destination rules before departure and declare any unusual power sources at check-in desk.
Allowed status by battery type: alkaline, NiMH and lithium-ion
Alkaline cells: permitted installed in devices in both carry-on and hold baggage; spare alkaline cells may be transported in either cabin if terminals are insulated (tape, original packaging or individual plastic sleeves). No airline approval required and no watt‑hour marking needed for standard AA/AAA cells.
NiMH (nickel‑metal hydride) rechargeable cells: treated like alkaline for transport purposes – installed or spare NiMH batteries are allowed in carry-on and hold baggage. Store spares in retail packaging or a dedicated battery case, tape exposed terminals, and avoid loose contact with metal objects.
Lithium‑ion batteries: installed in devices are generally allowed in both carry-on and hold baggage, but spare lithium‑ion cells/batteries are forbidden in hold baggage and must be carried in the cabin. Capacity rules: ≤100 Wh – normally permitted without airline approval; >100 Wh up to 160 Wh – airline approval required and typically a maximum of two spare batteries per passenger; >160 Wh – not permitted on passenger aircraft. Use the label if available; otherwise calculate Wh = V × Ah (example: 3.7 V × 2.6 Ah = 9.62 Wh).
Practical measures for all types: insulate terminals (non‑conductive caps or high‑adhesion tape), keep spares in original packaging or separate protective cases, limit the number of spare lithium‑ion units to airline limits, and carry any required airline approval documentation for batteries >100 Wh. For unrelated DIY guidance see how to cut dog ear fence boards.
Rules for spare batteries: packing, terminal protection and placement
Recommendation: Store spare cells in carry-on containers with all terminals insulated and items isolated from metal contacts.
- Terminal protection methods
- Use original retail packaging whenever available.
- Apply non-conductive tape (PVC electrical tape) to fully cover positive and negative terminals; partial coverage is insufficient.
- Place cells in individual plastic sleeves, heat-shrink caps or purpose-made battery cases that prevent contact between terminals.
- Do not use conductive materials (aluminium foil, loose metal) for protection.
- Containment and placement inside carry-on
- Use a hard-sided battery case or compartmentalised box to prevent movement and crushing.
- Keep batteries away from loose metal objects: coins, keys, jewellery, pens and multitools.
- Arrange batteries in separate pockets or resealable polymer bags so terminals cannot touch each other or other conductive items.
- Position battery containers near the centre of the cabin bag, cushioned by clothing or soft items to reduce impact forces.
- For high-energy or multiple spares, distribute them across different compartments to minimise thermal accumulation.
- Handling damaged or malfunctioning cells
- Do not transport bulging, cracked, leaking or smoking batteries.
- Place suspect cells in a non-flammable, non-conductive container (glass jar or plastic tub) and notify airline personnel at check-in or the gate.
- Documentation, declaration and quantity limits
- For commercial quantities or uncommon battery ratings, obtain carrier approval and retain manufacturer specifications or datasheets.
- Follow IATA/ICAO guidance for shipments requiring special handling; undeclared bulk shipments risk refusal.
- Keep the number of spares limited to operational needs; large accumulations require prior approval from the carrier.
- Security screening and inspection
- Keep battery containers accessible for X‑ray or manual inspection; items may be removed from devices during screening.
- Labelled or original packaging speeds inspection; loose, unprotected cells increase likelihood of additional checks.
Summary actions: insulate terminals fully, use individual compartments or sealed sleeves, isolate from metal objects, keep spares in carry-on carriage, and obtain airline approval for large or unusual consignments.
How to prepare a torch with non-removable batteries for hold baggage
Immediate actions
Disable the power switch and prevent accidental activation by wrapping the switch area with two layers of high-adhesion electrical tape (3M Scotch 33 or equivalent) and securing with a cable tie through any lanyard or bezel hole to immobilize moving parts.
Cover external charging ports, exposed contacts and any metal fasteners with non-conductive tape (Kapton, PVC or vinyl electrical tape); ensure all adhesive covers sit flush and cannot peel off during transit.
Packaging, placement and paperwork
Place the torch inside a rigid container (hard case or tool box) with minimum 2 cm of padding on all sides (closed-cell foam, bubble wrap or tightly folded clothes) to prevent crushing and reorientation. Position the case centrally in the hold bag, surrounded by soft items and away from heavy tools, batteries, or sharp objects.
Verify internal battery watt-hour rating; calculate Wh as (mAh ÷ 1000) × nominal voltage. Example: 3500 mAh at 3.7 V → 12.95 Wh. If the internal cell rating exceeds airline limits (typically 100 Wh per battery for transport in hold under approval rules), obtain airline approval and keep manufacturer specification or datasheet with the item at check-in.
Label the exterior of the rigid container with a plain statement of internal battery chemistry and Wh (e.g., “Li‑ion 12.95 Wh”) when requested by the carrier or security. At check-in, declare any device with internal cells above allowed thresholds so ground staff can advise on acceptance or additional documentation.
Airline and country variations: checking carrier policies and international restrictions
Confirm carrier policy before travel: consult the airline’s dangerous-goods, batteries and portable electronic-device pages plus the national aviation authority guidance for departure, transit and arrival jurisdictions.
Search airline resources for keywords: “dangerous goods”, “batteries”, “portable electronic devices”, “spare battery”, “power bank” and “hold baggage rules”. If online guidance is ambiguous, request written confirmation by email from the carrier’s customer-support or cargo/dangerous-goods team and keep the reply as proof.
Key items to verify on carrier and national pages
1) Whether devices with installed batteries are permitted in the aircraft hold versus cabin and any conditions for each placement. 2) Whether spare batteries, battery packs or external chargers are allowed in the cabin only or prohibited entirely. 3) Requirements for written airline approval, labels, or documentation for high-capacity batteries or exceptions. 4) Transit-country restrictions that differ from the departure carrier (some authorities apply stricter limits for transits or forbids certain battery types outright). 5) Local enforcement practices (some airports enforce stricter screening/manual inspection protocols resulting in confiscation or refusal to board).
Practical steps for multi-leg and international itineraries
When itineraries include multiple carriers or international connections, follow the most restrictive rule among all involved carriers and civil aviation authorities; obtain written approvals from each carrier if an exception is needed. Present documentation at check-in and security checkpoints. For items not eligible for carriage under passenger regulations, arrange shipment through approved cargo channels with a freight forwarder experienced in dangerous-goods declarations. Non-compliance risks device or battery seizure, travel delays, fines and refusal to transport–carry airline approvals and official references while traveling.
When to keep a handheld torch in the cabin or stow it in the aircraft hold
Recommendation: keep any handheld lighting device in the cabin if it contains lithium-ion cells, if spare lithium batteries are present, or if the battery capacity exceeds 100 Wh; stow in the aircraft hold only when the unit uses non-lithium cells (alkaline or NiMH), has no spare batteries, and the carrier’s policy explicitly allows hold storage.
Rules-based triggers for cabin carriage
Hard thresholds and operational rules that require cabin carriage: lithium-ion batteries up to 100 Wh are permitted in the cabin; batteries between 100 Wh and 160 Wh require airline approval and are generally limited to two spare units per passenger and kept in the cabin; batteries above 160 Wh are prohibited from passenger transport. Spare lithium batteries (uninstalled) must be carried in the cabin with terminals insulated; they are not permitted in the aircraft hold. Devices with built-in lithium chemistry that cannot be removed should also be carried in the cabin when rated above 100 Wh or when airline guidance specifies.
Practical decision checklist
Step 1 – Identify chemistry: alkaline or NiMH (AA/AAA) → stow in hold acceptable in most cases; lithium-ion → prefer cabin. Step 2 – Calculate capacity: Wh = (mAh/1000) × nominal voltage (e.g., 18650 ≈ 3000 mAh × 3.7 V ≈ 11.1 Wh; 26,000 mAh power bank ≈ 96.2 Wh). Step 3 – Count spares: any spare lithium cells → cabin only; tape terminals or use original packaging. Step 4 – Check device battery type label and carrier policy for 100–160 Wh approvals. Step 5 – Consider accessibility and safety: cabin storage allows crew access in case of smoke, visible damage, or heat; aircraft hold storage makes incident detection and mitigation slower and increases fire risk for lithium devices.
Examples: small torches using single AA/NiMH (≈1.2 V × 2000 mAh → ~2.4 Wh) may be stowed in the hold where permitted; tactical units using multiple high-capacity 18650/21700 cells typically remain in the cabin due to lithium chemistry and the possibility of spare cells. For travel convenience, carry compact items such as a travel umbrella and small torch together in the cabin – see best umbrella in germany and best mens automatic umbrella.
