Michael Turner
Store all spare lithium-ion and lithium-metal power cells in carry-on bags. Most carriers and aviation authorities forbid loose cells in the aircraft hold because a thermal event there is far more hazardous and harder to manage than one in the passenger cabin.
Regulatory limits: lithium-ion cells up to 100 Wh are accepted in the cabin; units between 100 Wh and 160 Wh need airline approval and are commonly limited to two per passenger; units above 160 Wh are not permitted on passenger flights. For lithium-metal cells, any cell containing more than 2 g of elemental lithium is prohibited on passenger aircraft.
Protect terminals against short circuit by keeping cells in original packaging, placing each in an individual plastic sleeve, or covering terminals with non-conductive tape. Spare power packs must remain in the cabin and never be loose inside checked suitcases. Equipment with built-in cells is generally permitted in the aircraft hold if powered off and prevented from accidental activation, but many carriers advise carrying such devices in the cabin when feasible.
Before departure, verify the airline’s policy and obtain written approval for units between 100–160 Wh. Do not transport damaged, recalled, or swollen cells. Declare high-capacity packs at the airline counter and carry documentation for any approved units.
Can I put batteries in my checked luggage?
Recommendation: Do not stow spare lithium-ion or lithium‑metal cells in the aircraft hold; carry them in the cabin and protect terminals.
Regulatory limits: spare lithium‑ion cells with energy ≤100 Wh are permitted in the cabin without airline approval; cells >100 Wh and ≤160 Wh require airline approval and are normally limited to two spare packs per passenger; cells >160 Wh are forbidden on passenger aircraft. Lithium‑metal cells are restricted by lithium content: cells containing >2 g elemental lithium are generally prohibited on passenger flights.
Installed power sources (inside cameras, laptops, e-cigarettes, etc.) are usually allowed in either cabin or hold if the device is protected against accidental activation and damage; nevertheless many carriers advise carrying devices in the cabin and some outright forbid installed high‑capacity packs in the hold–check the airline’s policy before travel.
Terminal protection: insulate exposed terminals with electrical tape or original caps, place each spare in individual plastic bags or dedicated battery cases, and prevent contact with metal objects. For installed packs, switch devices off and use hard cases for fragile gear.
How to read capacity: Wh = volts × ampere‑hours. Convert mAh to Ah by dividing by 1000. Examples: typical phone cell 3.7 V × 2.6 Ah = 9.6 Wh; common laptop pack ~56 Wh; a 20,000 mAh power bank at 3.7 V ≈ 74 Wh.
Power banks and external chargers are classified as spare lithium packs and must travel in the cabin only; they are treated like loose cells, even when carried inside a bag.
Wet (spillable) lead‑acid cells: may be accepted only when immobilised, terminals insulated and with airline approval; many carriers prohibit transport of flooded or unsealed lead‑acid types in passenger baggage.
At the airport: declare any high‑capacity packs at check‑in, carry documentation showing Wh rating if available, expect security inspection, and be prepared to move restricted items to the cabin or remove them from the journey if the carrier denies transport.
Installed energy cells inside devices – immediate recommendation
Recommendation: Devices with installed lithium-ion or lithium-metal cells are normally permitted in the aircraft hold if the device is completely powered off, protected against accidental activation, and in sound condition; any cell over 100 Wh requires airline approval and any cell over 160 Wh is prohibited on passenger flights.
Practical limits and examples
Typical ratings: smartphones ~5–15 Wh, laptops ~30–100 Wh, professional camera packs 20–200 Wh, e-bike packs frequently >160 Wh. Integrated packs up to 100 Wh are routinely accepted in both cabin and hold compartments; integrated packs between 100 Wh and 160 Wh need explicit carrier approval; integrated packs >160 Wh must travel as cargo under special handling or are declined for passenger flights.
How to confirm capacity and prepare the device
Find the cell rating on the device label or in the specification sheet. Compute watt-hours if only mAh and voltage are listed: Wh = (mAh ÷ 1000) × V. Example: 5000 mAh at 3.7 V → 18.5 Wh. For travel: power the device off, use original housings or protective cases, immobilize moving parts, cover exposed terminals with tape or terminal caps if accessible, and remove any external power packs from the device before presenting it for transport.
Do not transport devices with swollen, leaking, or otherwise damaged cells in any baggage compartment. Mobility aids, medical power packs, large e-bike accumulators and industrial packs require prior arrangement with the carrier and often special paperwork; declare these at the airline counter well before departure.
Final checklist: verify Wh rating, obtain airline approval for 100–160 Wh units, keep the device powered down and protected, carry small valuable devices in cabin when feasible, and never accept transport of defective cells.
Spare lithium-ion and lithium metal cells in the aircraft hold
Do not stow spare lithium-ion or lithium metal cells in the aircraft hold; they must travel in the cabin (carry-on) only.
Rechargeable lithium-ion cells or packs: individual units up to 100 Wh are allowed in the cabin without airline approval. Units greater than 100 Wh but not exceeding 160 Wh require airline approval and are limited to two spare units per passenger. Units above 160 Wh are prohibited on passenger aircraft.
Primary lithium (non-rechargeable) cells: carriage in the cabin is permitted only when lithium content does not exceed 2 g per cell and 5 g per pack; any cell or pack exceeding these limits is forbidden on passenger aircraft.
Terminal protection and storage: each spare cell or pack must have terminals insulated (tape over terminals, original retail packaging, individual plastic sleeves or a dedicated protective case). Do not store loose spares together; prevent metal contact between terminals.
Power banks and external chargers are treated as spare lithium-ion packs and must remain in the cabin. Convert mAh to Wh using Wh = (mAh × V) / 1000; for a 3.7 V nominal cell, 100 Wh ≈ 27,000 mAh and 160 Wh ≈ 43,200 mAh.
Airline and national rules vary: notify the airline at booking or the ticket counter if carrying high-capacity spares or packs requiring approval. When in doubt, arrange transport via approved cargo/dangerous-goods carriers rather than the passenger cabin or aircraft hold.
Non-compliance risks removal of the items, travel disruption and possible fines; declare large-capacity spares in advance to avoid confiscation at the gate.
Watt‑hour, cell‑count and quantity limits for lithium cells in the aircraft hold
Keep all spare lithium‑ion and lithium‑metal cells in the cabin; spare cells are not permitted in the aircraft hold.
- Lithium‑ion (rechargeable) – general thresholds
- ≤ 100 Wh per pack: no airline approval required for installed packs; removable spare packs must travel in the cabin only.
- 100–160 Wh per pack: airline approval required; maximum two spare packs per passenger allowed in the cabin (in addition to packs installed in equipment).
- > 160 Wh per pack: forbidden on passenger aircraft (cargo transport only under dangerous‑goods procedures).
- Lithium‑metal (non‑rechargeable) – lithium content
- ≤ 2.0 g lithium per cell: permitted when installed in equipment; spare cells must be carried in the cabin.
- > 2.0 g lithium per cell: not allowed on passenger aircraft.
- Per‑passenger quantity rules
- Packs ≤ 100 Wh: no specific numeric limit in IATA provisions beyond “for personal use”, but airlines may set tighter limits–check carrier policy.
- Packs 100–160 Wh: limited to two spare packs per passenger (airline approval required).
- All spare packs/cells must be individually protected against short circuit (tape terminals, original packaging, or insulated pouches).
- Labeling and documentation
- Packs >100 Wh must show a Wh rating on the pack or device label; airlines will require approval for such items.
- When watt‑hour is not printed: calculate Wh = volts × ampere‑hours (Wh = V × Ah). For mAh use Wh = V × (mAh/1000). Example: 3.7 V, 2500 mAh → 3.7 × 2.5 = 9.25 Wh.
- Packing and protection
- Spare packs/cells must be carried in the cabin, terminals insulated, and each item protected from damage or contact with metal objects.
- Power‑banks are treated as spare lithium‑ion packs and must remain in the cabin; they count toward the per‑passenger limits by Wh rating.
Always verify the carrier’s dangerous‑goods policy before travel: some airlines restrict quantity or require prior approval even for items within the standard IATA limits.
How should cells be prepared, insulated and packaged for stowage in the aircraft hold?
Insulate exposed terminals with non-conductive tape (Kapton, PVC or electrical tape) and house each cell in its own retail or sealed plastic pouch before placing into a rigid container.
For removable power cells: remove from devices, cap terminals or apply tape, insert into individual poly bags or original packaging, then place those packages inside a hard-sided box or a dedicated protective case. Add at least 2–3 cm of cushioning (foam, clothing, bubble wrap) around each package to prevent shifting and impact.
For cells installed in equipment: fully power the device off, block the power switch with tape or a zip-tie to prevent accidental activation, immobilize the device inside the case so it cannot move, and cover exposed connectors with non-conductive caps or tape.
Avoid any contact between cell terminals and metal objects (coins, keys, zippers). Do not allow cells to contact each other – use individual compartments or separators. Keep chemical labels and manufacturer documentation accessible in case inspection is required.
Store rechargeable lithium cells at a partial state of charge (~30–50%) for longer trips; fully charged cells increase thermal runaway risk. Do not place cells near sharp objects, heavy tools, or heat sources inside the suitcase or container.
| Action | How to do it | Notes |
|---|---|---|
| Terminal protection | Cover with non-conductive tape or use plastic end caps | Prevents short circuits during handling |
| Individual packaging | Original retail box, sealed plastic pouch, or foam-cut compartment | Stops contact between cells and cushions against impact |
| External containment | Hard-sided container or protective case inside the suitcase | Reduces crushing and abrasion risk |
| Device safety | Power off, secure switch, pad around device to prevent movement | Prevents accidental activation and connector damage |
| Placement in bag | Central compartment surrounded by soft items, away from metal | Minimizes crush and penetration risk |
| Fire mitigation | Use a certified fire-resistant pouch or place items in a separate hard container | May slow propagation long enough for crew response; check carrier rules |
| Documentation | Keep manufacturer specs and any required paperwork accessible | Useful for inspections or if carrier requests additional information |
When airlines, TSA or international rules require declaration or prohibit power cells in the aircraft hold
Declare rechargeable lithium‑ion cells above 100 Wh and lithium‑metal cells containing more than 2 g of elemental lithium to the carrier; spare, uninstalled cells are not permitted in the aircraft hold and must remain in cabin baggage.
Hard thresholds and what triggers mandatory declaration
– Rechargeable lithium‑ion: ≤100 Wh – generally allowed in devices and as spares in the cabin only; >100 Wh and ≤160 Wh – written airline approval required and normally limited to two spare units per passenger; >160 Wh – forbidden on passenger aircraft.
– Lithium‑metal (non‑rechargeable): cells with ≤2 g elemental lithium – permitted in cabin (spares should be carried in cabin); >2 g – prohibited on passenger aircraft and must be declared if proposed on a cargo-only shipment (subject to dangerous‑goods rules and carrier acceptance).
– Power banks and portable chargers are classified as spare lithium‑ion cells: treat them under the same Wh limits and cabin‑only rule.
How and when to declare, and documentation to carry
– Contact the airline well before departure (many require advance approval at least 48 hours). Approval must be explicit; verbal promises at the gate are unreliable.
– At check‑in/security present the device label showing Wh or the manufacturer specification sheet; if Wh is not printed, calculate Wh = volts × ampere‑hours (e.g., 3.7 V × 3.0 Ah = 11.1 Wh).
– If approval is granted, keep written confirmation (email or courier form) with the device and show it on request to airline or security personnel.
– Noncompliance risks equipment confiscation, denied boarding, fines and possible reporting to local aviation authorities.
Packing and handling notes: disable power switches, insulate terminals (tape or original covers), store each spare cell in individual protective pouches, and keep spares in the cabin at all times. For a compact cabin solution, consider a dedicated carry item such as this best small backpack for everyday use to keep cells accessible and separate from other gear.
If transporting devices with integrated power sources such as aquarium equipment, verify manufacturer ratings before travel; examples of device types to check include heaters and specialized pumps – see a representative product spec here: best aquarium heater for 125 gallon tank. For bulky items or non‑battery heavy packing considerations, use appropriate containment (avoid loose fill like sand inside soft bags) and consult guidance on suitable ballast or base materials: best sand for patio umbrella base.
FAQ:
Can I pack a power bank or spare lithium batteries in my checked luggage?
No. Spare lithium batteries and power banks must travel in the cabin, not in checked baggage. Airline and international aviation rules treat lithium batteries as a fire hazard because they can short-circuit or overheat; keeping them in the passenger compartment makes it possible for crew to respond quickly if a problem starts. Small rechargeable lithium-ion batteries up to 100 Wh are allowed as spares in carry-on only; those between 100 Wh and 160 Wh generally require airline approval and are still carried in the cabin, and batteries over 160 Wh are not permitted on passenger aircraft. Protect terminals against short circuits (tape exposed contacts or keep each battery in its original packaging), and check with your airline before you fly.
