Michael Turner
Recommendation: Store all vaping units and spare lithium batteries inside carry-on baggage. Devices must be switched off and protected against accidental activation; spare cells should be kept in dedicated battery cases or have terminals taped to prevent short circuits.
Regulatory specifics: US Transportation Security Administration and European aviation authorities permit vaping devices in cabin baggage only and prohibit them in checked baggage. Lithium-ion batteries up to 100 Wh are allowed without airline approval; batteries between 100–160 Wh require airline authorization; batteries over 160 Wh are not permitted. To convert capacity: Wh = (mAh × V) / 1000 – for example, a 2500 mAh cell at 3.7 V equals ~9.25 Wh.
Liquid nicotine solutions follow standard liquid rules for cabin carriage: individual containers no larger than 100 ml (3.4 oz), all containers placed within a single resealable clear plastic bag (typically 1 litre / quart-sized). Use or charging of vape devices aboard aircraft is prohibited and may incur penalties; in-flight power outlets should not be used to charge spare batteries.
Quick pre-flight checklist: secure devices in a hard case, remove or empty tanks to reduce leakage, keep spare batteries in original or insulated packaging, ensure capacity markings are visible, declare items at security if requested and review the specific airline and destination country rules before departure.
Electronic vaping devices in cabin baggage: rules and practical steps
Store vaping devices in cabin baggage only; most airlines ban placement in checked baggage due to lithium battery fire risk.
Lithium battery limits: cells up to 100 Wh are generally permitted in the cabin without approval; batteries between 100 Wh and 160 Wh require airline approval; batteries over 160 Wh are forbidden on passenger aircraft.
Spare batteries must be carried in the cabin and protected against short-circuit (original packaging or a dedicated battery case). Insulate terminals with tape or use terminal covers. Airlines may limit quantity of spare cells–confirm with the carrier before travel.
E-liquid containers in cabin baggage must follow the standard liquids rule: individual containers no larger than 100 ml, all fitting inside a single 1‑liter resealable clear bag. Tanks attached to devices count as liquids during security screening; larger bottles should be transferred to checked baggage only if the carrier and destination permit.
Deactivate devices: power off, engage any lock feature, and where possible remove batteries. Place devices in a protective pouch to prevent accidental activation and damage during screening and stowage.
Security screening may require devices to be presented separately and powered on to demonstrate functionality. Refusal to comply, possession of prohibited models, or entry into jurisdictions that ban vaping may result in confiscation, fines, or denial of boarding.
Policy variation across carriers and countries is significant; passengers must verify airline rules and destination regulations (some jurisdictions prohibit possession or import of vaping products) before travel.
Which vape device types and spare lithium battery rules apply to carry-on
Recommendation: Place all vaping devices, power banks and spare lithium-ion cells in carry-on; remove removable cells from mods and pack them individually protected against short circuits.
Device types: Pod systems and single-piece devices with non-removable batteries are permitted in cabin carriage when powered off and protected; box mods and mechanical rigs with removable cells require those cells to be carried separately in protective cases.
Watt‑hour limits: Cells ≤100 Wh: permitted in cabin without airline approval (terminal insulation required). Cells >100 Wh and ≤160 Wh: allowed only with airline approval and normally limited to two spares per passenger. Cells >160 Wh: prohibited as carry-on and checked.
How to calculate Wh: Wh = (mAh ÷ 1000) × nominal voltage. Example: a 3.7 V, 3000 mAh 18650 cell = (3000/1000)×3.7 = 11.1 Wh.
Packing technique: Use retail packaging, individual plastic battery cases or insulating caps; tape exposed terminals or cover with non-conductive material; avoid loose batteries in pockets or pouches. Store devices with tanks emptied or locked to prevent activation.
Power banks and chargers: Treated as spare batteries; show Wh rating on the unit or packaging. If rating not printed, calculate and label. Airlines frequently enforce limits per unit and per passenger.
Practical tip: Keep spare cells in a hard protective case inside a main tote or cabin bag that fits airline size limits – see best leather tote bags for travel for sturdy options. For metal cases or external gear cleaned before travel, product recommendations include best bottled pressure wash for house exterior.
How to pack e-liquid in carry-on baggage: allowed volumes, secure containers and leak prevention
Pack e-liquid only in containers of 100 ml (3.4 fl oz) or smaller and place all such containers inside a single clear resealable 1 litre (quart) plastic bag; bottles exceeding 100 ml belong in checked baggage or must be purchased in a tamper-evident duty‑free bag with receipt for onward travel.
Allowed volumes and exceptions
- Standard limit: each container ≤100 ml (3.4 fl oz); total volume limited by the 1 L transparent bag size (EU/UK/US/IATA guidance).
- Practical examples: up to ten 10 ml bottles, or three 100 ml bottles if they physically fit within the 1 L bag.
- Duty‑free exception: sealed tamper‑evident bags (STEB) with proof of purchase may permit items >100 ml through security for some itineraries; retain receipt and keep the STEB sealed for connecting flights.
- Local legal restrictions: several countries restrict import/possession of nicotine liquids or cap bottle size (e.g., Australia requires prescription for nicotine e‑liquid imports; some Asian countries prohibit vaping products). Verify destination and transit regulations before travel.
Secure containers and leak‑prevention measures
- Use original, labelled bottles with childproof caps whenever possible; original packaging often reduces inspection delays.
- Prefer rigid PET or LDPE travel bottles with PTFE-lined screw caps; avoid thin, flexible containers that can burst under pressure or when squeezed.
- Apply secondary sealing: wrap the cap threads with a thin layer of plastic wrap or use a silicone travel cap plus a strip of tape over the cap to prevent back‑pressure leaks.
- Double-bagging: place each bottle in a small zip-lock bag, then insert all into the required 1 L clear bag together with an absorbent paper towel or small cloth to soak any accidental spills.
- Rigid protective case: store the 1 L bag inside a hard-sided toiletry case or a padded container to prevent crushing and accidental opening during handling.
- Fill level: leave minimal airspace inside bottles (do not overfill) to reduce pressure changes causing leakage; for bottles with droppers, ensure dropper stem sits flush and cap is fastened fully.
- Temperature and pressure: cabin is pressurized, but temperature fluctuations in checked compartments are greater–if transporting larger volumes, checked baggage is preferable only when local law permits.
- Labeling and documentation: keep bottles labelled with ingredient and nicotine strength; carry receipts for duty‑free purchases and any required prescriptions or permits for nicotine products.
Pre‑flight checklist: confirm destination and transit rules, transfer e‑liquid only into compliant bottles, seal caps with tape or wrap, double‑bag with an absorbent layer, store the sealed 1 L bag inside a rigid case, and retain purchase receipts or prescriptions where applicable.
What happens at security screening and how to present devices and batteries
Power devices off, engage a lock mode if available, secure spare lithium cells in protective cases with terminals insulated, and place device plus spares in an easily accessible pocket or tray for inspection.
At the security checkpoint
Expect an instruction to place electronic devices and batteries in a separate screening tray similar to laptops. Devices with tanks or cartridges should be presented upright and accessible; officers may ask to inspect tanks, cartridges or pod cartridges visually and by X‑ray. If an alarm occurs, security staff will perform secondary screening (manual inspection, fingerprint/trace swab or hand search).
Battery preparation and limits
Lithium‑ion cells: up to 100 Wh allowed in cabin without airline approval; 100–160 Wh allowed only with airline approval (maximum two spare cells in that range); >160 Wh prohibited. Lithium‑metal cells: maximum lithium content 2 g per cell. Spare cells must remain in the cabin compartment and not be stowed in checked baggage. Terminals must be insulated (tape, original packaging or dedicated plastic case) to prevent short circuits.
If staff request device activation to verify functionality, produce a demonstration promptly; if activation is impossible (battery removed or device locked), expect extended inspection or temporary seizure until cleared. Non‑compliance or presentation that raises safety concerns may result in confiscation, denial of carriage or a fine under local regulations. Airline or airport-specific restrictions supersede these guidelines, so confirm rules with the carrier and departure airport before travel.
Quick checklist for checking airline and country-specific carry-on rules before travel
Verify airline and every transit/arrival country’s policies at least 72 hours before departure and again 24 hours prior.
Airline policy URL: Locate the exact webpage for restricted items or carry-on/checked baggage rules, copy the full URL, take screenshots and print a PDF with flight number and date visible.
All flight segments: Check rules for the operating carrier on each leg, including codeshares and regional partners; policies may differ between the marketing carrier and the operator.
Customs and import regulations: Consult official customs websites for the destination and transit countries for import bans, quantity limits, age restrictions and prescription requirements for nicotine-containing products; save the relevant customs page or guidance as evidence.
Airport and security pages: Review departure, transit and arrival airport security pages for presentation procedures and any terminal-specific restrictions; note whether documentation must be shown at screening or check‑in.
Contact and written confirmation: Phone the airline’s customer service and request written confirmation by email when policy wording is unclear; log agent name, time and case/reference number and keep the message accessible offline.
Embassy or consulate check: For countries with strict or unclear legislation, request official guidance from the relevant embassy or consulate; obtain a short written statement when possible.
Supporting documents to carry: Keep purchase receipts, manufacturer manuals, a medical prescription or doctor’s note if applicable, and printed policy excerpts together in an easily accessible folder.
Transit-specific actions: Verify whether transit airport security or customs enforces stricter rules than origin or destination; if transit rules conflict with the carrier, obtain airline confirmation on handling during transfer.
Last-minute recheck: Revisit airline and official government pages at online check-in and again before airport arrival; if any policy updates appear, seek immediate written clarification from the carrier.
