Are you allowed batteries in checked luggage

Immediate recommendation: Store all spare lithium-ion and lithium-metal power cells inside carry-on bags. Cells installed in devices can be packed in suitcases placed in the aircraft hold only when the device is powered off, terminals are protected against short circuits, and the device is prevented from accidental activation; many carriers still require cabin carriage for high-capacity units.

Regulatory limits (practical numbers): Lithium-ion cells up to 100 Wh are permitted in cabin without airline approval. Units between 100 Wh and 160 Wh require airline approval and are commonly limited to two spare units per passenger. Cells above 160 Wh are not accepted on passenger aircraft. For lithium-metal cells, single-cell lithium content must not exceed 2.0 g; cells with greater lithium content are prohibited on passenger flights.

Packing rules: Protect terminals from shorting by taping exposed contacts or keeping cells in original, non-conductive packaging. Place each spare cell in individual protective sleeves or separate compartments. Power banks and portable chargers are treated as spare cells and must travel in cabin baggage; carrying them in checked bags is routinely forbidden.

Labeling, calculations and declarations: When Wh rating is not shown, calculate energy as Wh = V × Ah. For units between 100–160 Wh obtain written airline approval before travel and declare such units at check-in. For large quantities, commercial shipments should follow dangerous-goods procedures and use approved courier or cargo services.

Operational tips: Keep device power low or removed, insulate removable cells, place devices in a hard-sided bag inside the cabin for added protection, and consult the specific airline and national aviation authority rules prior to departure for any carrier-specific restrictions.

Transport of lithium‑ion (rechargeable) cells in aircraft hold

Spare Li‑ion cells must travel in the passenger cabin; stowing loose cells in the aircraft hold is prohibited by most regulators and major carriers.

Regulatory thresholds: cells up to 100 Wh are generally permitted in the cabin. Cells from 100 Wh to 160 Wh require airline approval and are typically limited to two spare packs per passenger. Cells above 160 Wh are prohibited on passenger aircraft and may only move as cargo under dangerous‑goods procedures.

Packs installed in equipment (phones, laptops, cameras, tools) are usually accepted in both cabin and the hold, but many carriers prefer cabin carriage and some explicitly forbid specific items (power banks, e‑cigarettes) from the hold. Damaged or swollen packs must not be transported.

Watt‑hour calculation: Wh = V × Ah. Convert mAh to Ah by dividing by 1000. Example: 7.4 V × 2500 mAh → 7.4 × 2.5 = 18.5 Wh.

Packing recommendations: insulate terminals with tape or keep packs in original packaging; place each spare in individual protective pouches or sleeves; ensure devices are switched off and protected from accidental activation; avoid placing spare packs inside checked suitcases with heavy items that could cause crushing.

Check the specific carrier’s dangerous‑goods rules and the civil‑aviation authority for the departure and arrival countries before travel; when guidance differs, prioritize cabin carriage for spare packs.

Uninstalled power cells: keep in cabin, never in cargo hold

Recommendation: Store uninstalled power cells inside the passenger cabin (carry-on). Loose cells or spare power packs must not be stowed in the aircraft cargo hold.

Capacity limits and practical examples

Lithium‑ion (rechargeable) cell limits: individual cells and battery packs up to 100 Wh may be carried in the cabin without airline approval; units between 100 Wh and 160 Wh require airline approval and are limited to two spare units per passenger; units over 160 Wh are prohibited from both cabin and cargo compartments. Convert mAh to watt‑hours with Wh = (mAh × V)/1000. Examples: typical phone pack ~10–15 Wh; mainstream laptop packs ~40–100 Wh; a 20,000 mAh power bank at 3.7 V ≈ 74 Wh.

Primary lithium (non‑rechargeable) cells: primary cells with more than 2 g lithium content per cell are forbidden in transport; cells with ≤2 g lithium content should be carried only in the cabin as spare items.

Packing, marking and airline interactions

Terminal protection required: individually insulate each terminal with tape, place cells in original retail packaging or dedicated battery sleeves, or use individual plastic pouches to prevent short circuits. Keep spare cells separate from devices; avoid loose mixing with metal objects. Power banks count as spare units and must travel in carry-on; label watt‑hour rating if visible. For packs between 100–160 Wh, obtain airline approval before travel and carry any written approval documents at the gate. Damaged, swollen or recalled cells must not be transported in either cabin or cargo.

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Watt-hour (Wh) and lithium metal limits for cells placed in the aircraft hold

Keep lithium-ion packs at or below 100 Wh for routine carriage in the aircraft hold; packs rated 100–160 Wh require airline approval and are typically restricted to two units per passenger; packs above 160 Wh must be transported as cargo under special dangerous-goods procedures and are not carried on passenger aircraft in normal service.

Determine Wh from the manufacturer label or by calculation: Wh = volts (V) × ampere-hours (Ah). Example conversions: a 3.7 V, 2,000 mAh cell = 3.7 × 2.0 = 7.4 Wh; a 14.8 V, 5.0 Ah power pack = 14.8 × 5.0 = 74 Wh. When the Wh rating is absent, use stamped voltage and capacity to compute the rating for compliance checks.

Primary lithium-metal limits are expressed as grams of lithium: common regulatory thresholds permit cells containing up to 2 g lithium per cell and batteries containing up to 5 g lithium per pack for passenger aircraft carriage; higher lithium content generally requires special cargo handling, documentation and packaging, and is normally prohibited from placement in the aircraft hold on passenger flights.

Labels and packaging: units >100 Wh should display the Wh rating and manufacturer/model where required; shipments moved under cargo provisions require UN numbers (UN 3480/3481 for lithium-ion, UN 3090/3091 for lithium-metal), state/airline acceptance and appropriate dangerous‑goods labels. Terminals must be protected against short circuit (tape, original packaging, terminal covers), devices must be rendered inoperative, and airline approval must be obtained for any unit that exceeds the 100 Wh threshold.

Preparing devices with installed power cells for aircraft hold

For devices with internal power cells destined for the aircraft hold, follow these packing steps:

1. Power off completely and remove external power cords, wall plugs and portable chargers from the device.
2. Disable any auto‑power or wake functions (alarm clocks, quick‑start, scheduled power events) to prevent accidental activation.
3. Prevent accidental switching by taping main power buttons or using a physical band/zip tie across toggle switches; avoid adhesive on device screens or vents.
4. Cover exposed terminals or contacts with non‑conductive tape or terminal caps; if terminal protection exists in original packaging, use it.
5. Use original manufacturer packaging when available; otherwise place the device in a hard protective case or wrap in at least two layers of foam or bubble wrap.
6. Center the protected device inside a hard‑sided bag or suitcase, with minimum one layer of soft items (clothing, foam) on all sides to reduce crushing and shock.
7. Segregate from metal objects, tools and loose coins to eliminate risk of short circuits; place device inside a sealed pouch if small conductive items are present.
8. Avoid packing next to sharp or heavy objects that could puncture the casing or deform the cell under pressure.
9. Keep vents and cooling paths unobstructed; do not fully seal thermal vents with tape or thick insulation that could trap heat.
10. Label fragile contents on the outer bag and place the packed device where handlers are less likely to stack heavy items above it.

Quick checklist

• Device powered off
• External chargers removed
• Switches taped or secured
• Terminals insulated
• Placed in hard case or original box
• Centered and padded inside suitcase

Packing materials recommended

• Hard protective case or rigid box
• Closed‑cell foam, bubble wrap or dedicated inserts
• Non‑conductive tape (electrical tape) or terminal caps
• Zip ties or bands for securing switches
• Sealable plastic pouch for isolation from metal objects

When removable cells exist, remove them and transport via cabin carriage where regulations require; consult carrier or official guidance for any additional documentation or labeling requirements before placing a device in the aircraft hold.

Which disposable cells (alkaline, NiMH, zinc‑air) may be stowed in the aircraft hold and how to pack them

Place alkaline, NiMH and zinc‑air cells inside devices whenever feasible; if packed in a suitcase for stowage in the aircraft hold, insulate terminals, prevent short circuits and protect against crushing or impact.

Packing rules: keep cells in original retail packaging or in a rigid container; tape exposed terminals (especially 9V and snap‑top types) with non‑conductive tape; separate cells from metal objects and tools using plastic bags or individual compartments; pad devices containing cells to avoid pressure on the power sources; do not mix corroded or leaking cells with good ones; store zinc‑air cells in sealed blister packs until activation to avoid loss of capacity and venting.

Type‑specific guidance: AA/AAA/C/D alkaline – no special energy declarations required; treat like dry cells, tape terminals if loose. NiMH (rechargeable) – safe for stowage but ensure devices are switched off and terminals cannot contact conductive materials; avoid partial disassembly that exposes contacts. Zinc‑air (hearing‑aid) – keep in manufacturer blister packs; do not remove the tab until ready to use; if loose, place each cell in its own sealed bag and pad to prevent crushing.

Regulatory note: conventional dry and nickel‑metal hydride cells carry no watt‑hour or lithium metal restrictions applied to lithium chemistries, but airline operators may set their own limits or packaging requirements – check carrier policy before travel. For safer transit, choose a suitcase with rigid compartments or dedicated electronics pockets; see best luggage for students traveling abroad for suitable options. Pack small accessories and fragile items in separate pockets (an umbrella with wind resistance can protect contents from sudden opening inside a bag) – more on protection at best outdoor umbrella to withstand wind.

How to declare damaged, recalled or high-capacity power packs to the airline before bag drop

Contact the carrier at least 72 hours before departure and request written special approval; attach clear photos, manufacturer recall notice, the pack label with voltage and Wh rating, chemistry (Li‑ion or Li‑metal), serial numbers and a damage description.

Documentation to submit

Technical data: total watt‑hours per pack and per cell, nominal voltage, mAh. Use formula Wh = (mAh/1000) × V (example: 2,500 mAh × 3.7 V = 9.25 Wh).

Identification: model number, serial number(s), proof of purchase or repair/inspection report, manufacturer recall reference or safety bulletin number.

Evidence of condition: high-resolution photos from multiple angles showing dents, swelling, burn marks or recall labels; short video if thermal event suspected.

Quantity and status: exact count, whether installed in a device or carried as spare packs, and whether any packs have been modified or repackaged.

Packing, arrival and alternatives

Until written approval is received, do not place damaged or recalled cells into passenger cabin or hold. If carrier grants transport under special conditions, present the printed approval at bag drop and to security staff; follow the operator’s handling instructions.

For approved transport: insulate terminals with non-conductive tape or terminal caps, place each pack in individual plastic bags and then inside a rigid protective case, and ensure devices remain powered off with protection against accidental activation.

If transport by passenger aircraft is declined, arrange freight shipment under dangerous goods procedures with a certified cargo operator or the manufacturer’s recall support; provide the same documentation and request a dangerous goods acceptance certificate.

Sample subject line for email to carrier: “Special approval request – recalled/damaged Li‑ion packs, flight [flight number], date [DD‑MM‑YYYY]”.