Michael Turner
Regulatory snapshot: international standards (ICAO/IATA) and major aviation authorities require spare power cells and portable chargers to be transported in-cabin. Cells installed inside devices may be placed in checked stowage or kept onboard, provided terminals are insulated and devices are powered off.
Watt-hour limits: rechargeable lithium-ion packs ≤100 Wh are normally permitted in-cabin without prior approval. Packs >100 Wh and ≤160 Wh require explicit airline approval and are typically limited to two units per passenger. Any pack >160 Wh is not permitted on passenger aircraft. For primary (non-rechargeable) lithium metal cells, the limit is 2 g of lithium content; above that threshold transport is forbidden.
How to verify rating: use the formula Wh = V × Ah printed on the label. Example: a 3.7 V cell rated 2 Ah equals 7.4 Wh. If a label is missing, consult the manufacturer’s specifications or product documentation before travel.
Packing rules: protect terminals by taping exposed contacts, keeping items in original packaging, or placing each unit in an individual plastic pouch. Avoid loose placement inside checked stowage for spares; stow spare cells only in-cabin and separate from metal objects and other conductive materials.
Power banks and spare chargers: treated as spare lithium-ion packs and subject to the same Wh thresholds and approval requirements. Presentation at security or check-in may be required if capacity approaches the 100–160 Wh band.
Practical steps before departure: verify airline policy for limits and approval procedures, retain product labels or spec sheets showing Wh or lithium content, declare packs that fall into the 100–160 Wh range during booking or at check-in, and place all spares in an accessible in-cabin bag for inspection.
Spare lithium‑ion cells and packs – watt‑hour limits and per‑passenger counts
Keep spare lithium‑ion cells and packs in cabin baggage; spares are prohibited in checked baggage.
Watt‑hour thresholds: up to 100 Wh – allowed without airline approval; 100–160 Wh – airline approval required and limited to two spare packs per passenger; above 160 Wh – forbidden on passenger aircraft (may be shipped as cargo under special dangerous‑goods procedures).
Terminal protection and packaging: protect terminals (tape over contacts or keep in original retail packaging), place each spare in its own protective sleeve or plastic bag to prevent short circuits, and keep spares accessible in cabin baggage for crew inspection.
Watt‑hour calculation: Wh = (V × mAh) / 1000. Examples: a 3.7 V, 3,000 mAh cell ≈ 11.1 Wh; a 3.7 V, 10,000 mAh power bank ≈ 37 Wh; many laptop packs fall between 50–99 Wh.
Installed cells vs. spares: cells or packs installed in equipment are generally permitted in the cabin even if over 100 Wh (100–160 Wh devices usually need airline approval and may be limited to two spare packs in addition to the installed unit). Multiple devices with installed packs are commonly accepted for personal use but carriers can set tighter limits.
Labels showing the Wh rating are required or strongly relied upon; if the rating is missing, airlines may refuse transport or require manufacturer documentation. Airline policies vary – confirm the carrier’s dangerous‑goods rules before travel and declare large or high‑capacity packs at check‑in when approval is required.
How to pack and protect cell terminals for onboard screening
Apply non-conductive coverage to all exposed terminals: wrap each terminal with two layers of Kapton or PVC electrical tape, overlapping edges by 5–10 mm so no metal remains visible.
Terminal covering methods
Kapton or PVC electrical tape – two full wraps per terminal, smooth edges to avoid peeling. Heat-shrink tubing – cut to cover the terminal plus 5–10 mm of adjacent casing, apply with a heat gun for a snug seal. Manufacturer terminal caps or silicone end-caps – use original caps when available. Commercial terminal protectors and rigid plastic holders – recommended for coin cells and small cylindrical cells. For coin/flat cells, tape both faces and place each cell in an individual rigid compartment or blister pack.
Packing and screening handling
Keep installed power cells inside the device unless screening personnel request removal; mark devices as powered off. Store spare cells individually in hard plastic cases or original retail packaging; then place those cases inside a clear resealable bag or a dedicated padded pouch. Prevent terminal-to-metal contact by separating cells from keys, coins, chargers and other conductive items with non-conductive dividers (cardboard, closed-cell foam). Immobilize loose packs with cable ties or foam blocks to stop movement during screening. For packs with exposed bus bars or terminals, combine insulating tape with custom-molded foam inserts or shrink-wrap and enclose in a rigid box. Do not pack swollen, damaged or leaking cells in cabin baggage; follow airline or regulator instructions for disposal or special handling.
Power banks and portable USB chargers in hand baggage
Store portable power banks and USB chargers exclusively in hand baggage; do not place them in checked baggage or the aircraft hold.
Keep units powered off, protected against accidental activation and accessible for inspection. Use original cases or insulating tape over exposed terminals and place each unit in a separate pouch or pocket to prevent contact with metallic objects.
High-power models with built-in AC outlets, removable cells or aftermarket modifications require prior approval from the operator and presentation of manufacturer specifications at check-in. Airlines may refuse boarding for units without clear markings or technical data.
Devices showing swelling, heat damage, leakage, corrosion or evidence of repair must be removed from transport and handed to ground staff or disposed of via an approved collection point; such items are not accepted for air transport in any compartment.
In-flight use of portable USB chargers is generally permitted but subject to crew instruction and local airline policy. Monitor for overheating, smoke or unusual odor and disconnect immediately if any abnormality appears.
Keep product labels, model numbers and specification sheets readily available for screening staff; photograph or print manufacturer data when original packaging is not present.
| Device type | Allowed in cabin | Allowed in checked hold | Approval | Action if damaged |
|---|---|---|---|---|
| USB-only power bank (portable charger) | Yes (hand baggage) | No | May require approval for high-power/AC-capable models | Remove from transport; hand to ground staff |
| Power bank with AC outlet or inverter | Yes with prior airline approval | No | Approval typically required; present specs | Do not transport; surrender before boarding |
| Integrated power source inside consumer device (phone, tablet, laptop) | Yes (recommended) | Often permitted but cabin storage preferred | No for standard devices; confirm for larger equipment | Power down and isolate; follow crew/ground staff instructions |
Limits for lithium metal (non‑rechargeable) cells and packs in cabin
Only primary lithium metal cells with ≤2 g lithium content per cell and primary lithium metal packs with ≤5 g lithium content per pack are acceptable in hand baggage when installed in devices; units exceeding these limits must be transported as regulated dangerous goods via cargo with prior operator approval.
Classification: UN3090 applies to lithium metal cells, UN3091 to lithium metal packs. Transport regulations require the lithium content (in grams) to be marked or documented; carriers and security may request proof of the per‑cell or per‑pack lithium mass. Loose primary cells or packs that exceed the 2 g/5 g thresholds are not allowed on passenger aircraft under ordinary passenger provisions.
If a unit surpasses the 2 g (cell) or 5 g (pack) limits, arrange shipment under the applicable dangerous‑goods procedures – do not attempt to move such items in hand carriage or checked items without advance acceptance by the airline and proper cargo paperwork. Verify operator policies before travel, retain manufacturer specifications showing lithium content, and segregate incompatible devices to avoid mixed‑hazard consignments.
Which power sources must be placed in checked baggage and which are prohibited from the aircraft
Recommendation: keep all spare lithium‑ion cells and portable power packs in the cabin; only installed, non‑spare power sources with airline approval may be stowed in checked baggage, while high‑energy and damaged cells are forbidden aboard.
Lithium‑ion (rechargeable): cells above 160 Wh are not permitted on passenger aircraft in either checked or cabin spaces. Units between 100 Wh and 160 Wh require airline approval and are usually limited to two per passenger and carried in the cabin. Spare lithium‑ion cells and portable USB power packs must never be placed in checked baggage; treat them as cabin items with terminal protection.
Lithium‑metal (non‑rechargeable): cells with more than 2 grams of elemental lithium are forbidden on passenger aircraft. Cells with ≤2 g lithium may be transported if installed in equipment or, for spares, only under specific airline rules and typically in the cabin with terminal insulation.
Wet lead‑acid and flooded automotive cells: loose automotive or large lead‑acid units are generally prohibited in checked baggage unless specifically accepted by the airline with written approval and compliant packaging. Mobility‑device batteries (sealed, non‑spillable) are often permitted when installed in the device and when terminals are protected and airline notified; documentation and special handling may be required.
Damaged, defective, recalled or thermally unstable cells: shipment on passenger aircraft is prohibited in both checked and cabin stowage. Suspected swollen, leaking, or heat‑damaged units must be transported as cargo under dangerous‑goods procedures or disposed of per manufacturer guidance.
Items commonly misrouted: e‑cigarette devices, spare camera cells, power banks and spare lithium packs must not be checked; place inside carry‑on. Large ebike or motorcycle battery packs are treated as dangerous goods and are almost always forbidden on passenger flights–use specialized cargo services.
If an item must be stowed in checked baggage with airline approval, secure terminals, insulate against short circuit, pad against impact, and declare at check‑in. For heavy or awkward equipment that may require checked acceptance, select robust transport options such as best luggage for young adults or best foldable duffel bag for travel, and separate supplements or powders from power sources when possible–see which is better whey protein or weight gainer.
Action checklist before presenting items for checked acceptance: obtain airline written approval for non‑standard cells; ensure Wh or lithium content markings are visible; protect terminals; declare at check‑in; if denied, arrange cargo shipment through a certified dangerous‑goods carrier.
How to transport large power packs (e‑bike, mobility aid) and request airline approval
Obtain written airline approval at least 72 hours before departure for any large lithium power pack intended to travel on board; many carriers refuse acceptance at airport without prior authorization.
Required documentation and details to provide
- Flight number, date and passenger name.
- Device type (e‑bike, mobility aid) and whether the power pack is installed or removable.
- Technical data: watt‑hour (Wh) rating, nominal voltage (V), ampere‑hours (Ah), cell chemistry (Li‑ion or Li‑metal), cell count and serial number(s).
- Regulatory identifiers: UN numbers (UN3480/UN3481 for lithium‑ion; UN3090/UN3091 for lithium metal) where applicable.
- Safety Data Sheet (SDS/MSDS) and manufacturer declaration or technical specification sheet.
- Clear photographs of the power pack label, full device, and any external damage or modifications.
- Description of proposed stowage (cabin stowage request or checked hold handling) and packaging/containment method if removed from the device.
- Contact phone number and local time zone for queries; attach any previous airline approval reference if available.
Step‑by‑step request process
- Locate the carrier’s Dangerous Goods Acceptance (DGA) contact or Special Assistance/Dangerous Goods team; use email plus a daytime phone number. For major airlines this contact appears on the official website under “special items” or “dangerous goods.”
- Submit the full document package: SDS, technical data, photos and the exact Wh rating. State whether the energy unit will remain installed or be removed and how it will be secured during transport.
- Ask for written confirmation with a reference number and any special handling instructions (e.g., reduced state of charge, approved packaging, on‑site inspection requirement, fee or collection point at the airport).
- Print the approval and present it at airport check‑in and security screening. Expect an on‑site inspection; staff may require the device to be powered off and terminals isolated and may retest the label information.
- If approval is denied, arrange transport via a certified dangerous‑goods freight forwarder or ship by ground/sea using an approved DG service provider; do not attempt to present the item at the airport without alternative arrangements.
Sample email body (replace bracketed fields):
Subject: Request for approval to transport large lithium power pack – Flight [XX123] on [YYYY‑MM‑DD] Passenger: [Full name] Contact: [+Country Phone] Device: [e‑bike / mobility aid] – power pack [installed / removed] Specification: [Wh], [V], [Ah], chemistry: [Li‑ion or Li‑metal], serial: [numbers] UN number (if known): [UN3480 / UN3481 / UN3090 / UN3091] Attachments: SDS, manufacturer spec sheet, photos of label and device Requested handling: [stowage preference] Please confirm acceptance in writing and provide any packing or SoC requirements and reference number.
- Keep approvals and documents printed and accessible; some airports enforce carrier‑specific procedures at security checkpoints.
- Modifications to the device or uncertified aftermarket cells often cause refusal; include evidence of factory specification where possible.
- Service animals or mobility‑aid assistance programs at the airline may have separate coordination channels; when applicable, notify both Special Assistance and Dangerous Goods teams.
