Michael Turner
Safety regulation: Lithium-ion cells can short and ignite under pressure or impact, so IATA and most airlines prohibit spare lithium-ion batteries in the checked hold. Standard limits: up to 100 Wh per battery allowed without airline approval; 100–160 Wh allowed only with airline approval; >160 Wh are not permitted on passenger aircraft. For non-rechargeable lithium-metal cells, many carriers follow a 2 g lithium-per-cell guideline for cabin carriage – verify your airline if a battery approaches that threshold.
Packing technique: Power banks and spare cells must be carried in cabin baggage and kept in original packaging or with terminals taped. Remove external batteries from devices when possible, power items fully off (not just sleep mode), and place each device in a padded compartment to prevent crushing and connector shorting. Keep chargers and a short cable with the device to prevent rummaging through other bags at the gate.
Security screening: Expect to present laptops, tablets and cameras separately at the X-ray lane unless your checkpoint uses a CT scanner or you have expedited screening (e.g., TSA PreCheck). Presenting these items in their own tray reduces secondary inspection rates and speeds throughput; label or show device Wh ratings if asked. Convert mAh to Wh using Wh = (mAh × V) / 1000 – use 3.7 V when voltage is not printed.
Risk reduction: Storing large devices in the cabin lowers the chance of loss, theft and mechanical damage; checked baggage is exposed to handling, temperature swings and pressure differentials. Back up and encrypt sensitive data before travel, carry a phone charger and an external battery within allowed limits, and keep serial numbers or photos of high-value gear in a separate place for claims.
Practical checklist: 1) Verify battery Wh on each device and power bank; 2) Keep spare batteries and power banks in cabin; 3) Pad and switch off devices; 4) Be ready to remove devices at security unless directed otherwise; 5) Check your airline’s written policy for batteries over 100 Wh and for any country-specific restrictions.
Which devices airlines prohibit from checked baggage
Recommendation: Do not pack spare batteries, power banks, vaping equipment, self-balancing scooters, electric bicycle packs or recalled/damaged battery items in checked baggage; these items are either strictly forbidden or heavily restricted and must be carried in the cabin or shipped as regulated cargo.
- Spare lithium-ion batteries (uninstalled): Forbidden in checked baggage. Batteries up to 100 Wh are normally allowed only in carry-on; batteries between 100 Wh and 160 Wh require airline approval and are limited to two spares per passenger; batteries over 160 Wh are not permitted on passenger aircraft.
- Spare lithium-metal (non-rechargeable) batteries: Not allowed in checked baggage. Single-cell lithium-metal with ≤2 g lithium content are generally permitted in carry-on; above 2 g requires airline/authority approval and is typically prohibited in passenger compartments.
- Power banks and portable chargers: Classified as spare batteries – must be carried in the cabin. Packing them in checked baggage is prohibited by most carriers and regulatory bodies.
- Vaping devices and e-cigarettes: Must not be stowed in checked baggage. Carriage rules require these items to remain in the passenger compartment and be powered off; spare cartridges and liquid often have additional limits.
- Hoverboards and self-balancing scooters: Widely banned from both checked and carry-on on many airlines due to high fire risk from built-in lithium batteries; many carriers refuse to transport them at all.
- Electric bicycles, scooters with external battery packs: Battery packs usually exceed passenger-aircraft limits and are prohibited in checked baggage; transport typically requires approved cargo shipment under dangerous-goods procedures.
- Large battery packs in musical instruments, medical devices, drones: Removable spares follow the spare-battery rules above. Permanently installed batteries often have separate limits – verify with the carrier and carry relevant medical documentation if applicable.
- Recalled, damaged or defective batteries: Prohibited from checked baggage and often from passenger aircraft entirely; require special handling and hazardous-goods shipping arrangements.
How to identify and comply:
- Check battery rating on the cell or pack: Wh = (mAh ÷ 1000) × V. If voltage is not shown, use nominal 3.7 V for many consumer cells to estimate Wh.
- Labelled examples: typical smartphone battery ≈ 10–15 Wh; laptop packs ≈ 30–100 Wh; common power bank (10,000 mAh at 3.7 V) ≈ 37 Wh.
- Protect terminals (tape exposed contacts or keep in original packaging) and ensure devices are powered off.
- Confirm carrier policy and applicable national rules (IATA Dangerous Goods Regulations, FAA/TSA or local civil-aviation authority) before travel.
How battery type and watt-hour rating determine carry-on rules
Carry spare lithium-ion and lithium-metal cells in the cabin; do not pack loose batteries in checked baggage.
Rule summary by battery chemistry and Wh
Lithium-ion (rechargeable): ≤100 Wh – allowed in the cabin without airline approval. 100–160 Wh – allowed only with airline approval and generally limited to two spare units per passenger; terminals must be protected. >160 Wh – not permitted on passenger aircraft except under special cargo/DG approvals. Lithium-metal (non-rechargeable): cells with lithium content ≤2 g are permitted in the cabin (installed or extra); cells with >2 g lithium are prohibited on passenger aircraft.
How to calculate and apply Wh limits
Use Wh = V × Ah (amp-hours). If only mAh is printed, convert: Ah = mAh / 1000. Examples: a typical smartphone cell ~3.7 V × 2.7 Ah = ~10 Wh; common laptop packs are 11.1 V × 5 Ah = ~55.5 Wh; large power banks often list Wh directly – many fall between 20–100 Wh. Power banks are classified as spare batteries and must travel in the cabin.
Packaging and labeling: protect terminals (tape, original box, or individual plastic sleeves), keep batteries in carry-on, and keep devices powered off. Batteries rated 100–160 Wh should carry a manufacturer Wh marking and, where required by the carrier, written approval. When in doubt about a specific pack or high-capacity battery, contact the airline’s dangerous-goods contact before travel.
Packing laptops and tablets for security checks and in-flight use
At security checkpoints
Keep each laptop or tablet in a slim, easily removable sleeve at the top of your cabin bag so it can be extracted quickly. Remove rigid cases, detachable keyboards and folio covers before placing devices in the screening tray; foldable covers that expose the screen should be opened. Place one device per bin, screen facing up; separate chargers and long cables into a small pouch and either place that in a different tray or lay it beside the device so X‑ray operators can view connectors clearly. Holders of expedited screening (for example TSA PreCheck) should follow checkpoint signage and officer directions, since some lanes allow devices to remain inside bags.
Keep devices charged and able to power on for inspection–airports commonly request boot-up if identity or security checks require device verification. A charged battery and a visible boot/lock screen speeds secondary checks; devices that fail to power on may be subjected to additional screening or, in some cases, denied boarding.
Protect data privacy during screening: use a screen lock, disable automatic unlock (biometrics or saved PIN if convenient), and avoid unlocking or entering passwords in screening lanes. If an officer requests additional inspection, present only what is asked; don’t hand over passwords unless legally compelled.
During the flight
Stow larger laptops in a padded sleeve under the seat in front of you if allowed by cabin stowage rules; many carriers require laptops to be fully stowed (not on tray tables) during taxi, takeoff and landing, while smaller tablets and e‑readers are often permitted in use. When using a laptop at cruise, place it on the tray table and keep elbows and personal items clear to avoid accidental damage; use a slipproof pad or a lightweight lap desk for stability on narrow seats. Close and secure the device before any expected turbulence.
Use a hard or semi‑hard case for transit within the cabin to protect against knocks when removing or replacing the device, and fit a thin privacy screen film when working with sensitive material. Pack a compact cable organizer, a microfiber cloth, and an external mouse or foldable keyboard if you rely on frequent in‑flight productivity; keep all accessories accessible in an external compartment for rapid retrieval at security or during boarding.
Rules for spare lithium batteries and power banks in carry-on
Keep all spare lithium-ion and lithium metal batteries, including portable chargers, in carry-on; do not place them in checked baggage.
Capacity and approval rules
Follow watt-hour (Wh) ratings for rechargeable cells and grams (g) of lithium for primary cells when checking allowances with the carrier.
| Battery category | Rating | Airline approval | Typical allowance | Placement |
|---|---|---|---|---|
| Rechargeable (lithium‑ion) | < 100 Wh | No approval | Personal-use quantities (check carrier limits) | Carry-on allowed; checked prohibited |
| Rechargeable (lithium‑ion) | 100–160 Wh | Required | Usually up to 2 spare cells with approval | Carry-on with approval; checked prohibited |
| Rechargeable (lithium‑ion) | > 160 Wh | Prohibited | Not accepted | Not permitted in either compartment |
| Primary (lithium metal) | Measured by grams of lithium | Small cells typically allowed; larger cells may require approval | Most carriers permit cells with ≤2 g Li; check for higher limits | Carry-on preferred; checked often restricted |
Practical packing steps and documentation
Label or keep original packaging for batteries with printed Wh; for marked mAh, convert using Wh = (mAh × V)/1000 and write the result on the battery or pouch.
Examples: 3000 mAh at 3.7 V → 11.1 Wh; 20,000 mAh power bank at 3.7 V → 74 Wh.
Protect terminals: use original covers, store each spare in individual plastic sleeves or terminal-tape to prevent short circuits.
Limit quantity to what is reasonable for personal use and check the carrier’s policy before travel; declare batteries that require airline approval at check-in.
Place batteries and power banks in an easily accessible compartment of your cabin bag or backpack to present at security. For compact, organised transport consider a protected organizer or a best ultramarathon backpack.
Assessing theft and damage risks when checked
Keep portable gear worth over $500 in carry-on; if that isn’t practicable, declare value with the carrier and buy supplemental insurance that covers full replacement cost.
File a Property Irregularity Report (PIR) at the airline’s desk immediately on arrival for stolen or visibly damaged items; submit a written damage claim within 7 days and a delay claim within 21 days under the Montreal Convention (damage limits default to 1,288 SDR per passenger unless excess valuation was purchased).
Protect against impact and compression: place each item in a rigid, hard-sided case or custom-cut foam with at least 20–30 mm of dense padding on every face, then position the case centrally inside the checked bag surrounded by soft clothing. Use layered protection (padded sleeve → hard case → suitcase) rather than a single thin cover.
Prevent theft during transfers: minimize connections and avoid multiple handlers by choosing nonstop routes when possible; conceal valuables inside internal zip pockets and avoid outer compartments; add a tamper-evident cable tie or numbered seal and keep photos of seals for proof of tampering.
Documentation that speeds recovery and claims: photograph items (serial numbers, IMEI, accessories, exterior condition) before travel, keep original receipts, record manufacturer model numbers, and email copies to yourself. Place a paper inventory and a GPS/Bluetooth tracker inside the packed case to locate a missing bag quickly.
Choose protective hardware: select cases rated for airline travel (hard-shell, locking clasps, reinforced corners) and consider gear cases tested to MIL-STD shock criteria when available. Secure loose parts (antennas, tripods, detachable screens) inside the case with straps or foam cutouts to prevent point-load damage.
When filing a damage or theft claim, retain all travel documents, boarding passes and baggage tags; request written confirmation of the PIR number; follow airline timelines exactly and escalate to the national enforcement body or small-claims court if the carrier refuses reasonable compensation after providing evidence.
What to do when airlines request gate-checking of devices
Act immediately: If the carrier requires gate-check, keep removable batteries and external storage on your person, power units fully off (no sleep mode), photograph serial numbers and current condition, and insist on a gate-check tag plus a written receipt before handing over any item.
Step 1 – Secure data: Back up to cloud and to an external drive, encrypt sensitive files, log out of financial apps, and disable auto-login. Remove SIM and microSD cards and carry them on board in a labeled protective case.
Step 2 – Protect the hardware: Place each item in a hard-shell or heavily padded case with at least 10 mm of foam or a padded sleeve; add bubble wrap around corners; surround the case with clothing inside the checked bag to absorb shocks.
Step 3 – Mark and document: Photograph the item from multiple angles, capture serial/IMEI numbers, note scratches or dents, keep photos timestamped, and attach a visible name tag with phone number to the case. Photograph the gate-check tag and retain that image and the paper stub.
Step 4 – Reduce theft and misuse risk: Remove detachable peripherals (dongles, styluses), disable biometric unlock if concerned, set a strong passcode, enable remote-tracking/remote-wipe services (e.g., Find My, Android Device Manager) and register serial numbers with the manufacturer.
Step 5 – Handle mechanical drives: If the item contains a mechanical hard drive, consider carrying it on instead, or remove the drive and pack it in anti-static foam inside your person-carried pouch.
Step 6 – At the gate: Watch staff tag and transfer the item; ask where it will be stowed (cargo hold vs. aircraft closet) and request a placard if placed in the hold. Keep the gate-check receipt until final delivery; confirm the airline’s claim procedure and deadlines before leaving the terminal.
Step 7 – If damage or loss occurs: Report immediately at the airline’s baggage/service desk and file a Property Irregularity Report (PIR) on site; photograph damage, keep all tags and boarding passes, and submit written claims per carrier rules (file damage reports at the airport and follow up promptly; many carriers require initial reporting before leaving the airport and have short statutory deadlines).
Practical packing choices: Opt for a rigid, impact-resistant checked bag for gate-checked items – see best luggage for a month in europe – and store wrapped items centrally, away from wheels. For guidance on bulky outdoor equipment consult best cordless lawn mowers for medium gardens.
