Can you put betteries in checked luggage

Regulatory summary: International (IATA/ICAO) and U.S. (TSA) guidance treats lithium-ion and lithium-metal differently. Lithium-ion cells up to 100 Wh are permitted in the cabin and in devices; cells between 100 Wh and 160 Wh require airline approval and are limited (typically two spare units per passenger) and must remain in the cabin; cells above 160 Wh are forbidden on passenger aircraft unless shipped as cargo under special Dangerous Goods provisions. Lithium-metal (primary) cells with lithium content greater than 2 g per cell are not allowed on passenger aircraft; spare lithium-metal cells are generally prohibited from the aircraft hold and should be carried in the cabin when permitted.

Practical actions before travel: Check the capacity label (Wh); if only mAh is shown, calculate Wh = (mAh ÷ 1000) × V (for example, a 3.7 V, 2000 mAh cell = 7.4 Wh). For any battery marked 100–160 Wh, obtain written airline approval ahead of departure. Treat power banks as spare lithium-ion batteries and place them in the cabin.

Packing technique: Insulate terminals (tape or terminal covers), keep spares in original packaging or use individual plastic pouches, avoid contact between terminals, and limit the number of spares. Devices with batteries installed are usually allowed in the aircraft hold, but placing devices in the cabin reduces risk and allows crew access in an emergency. Fully enclose loose cells; do not allow loose batteries to mingle with metal objects or chargers.

Declare any nonstandard battery equipment at check-in when requested by the carrier, and follow specific airline instructions. When uncertainty exists, consult the carrier’s Dangerous Goods or battery policy and request written confirmation for batteries in the 100–160 Wh range; for large-format batteries (>160 Wh), arrange certified cargo shipment only.

Batteries in the aircraft hold: concise rules and actions

Keep spare lithium-ion cells in cabin baggage; loose spare cells and power banks are prohibited from the aircraft hold, while batteries installed inside devices may be carried in the hold if the device is completely powered off and terminals are protected against short circuit.

Capacity limits and approvals

Rechargeable lithium-ion: cells up to 100 Wh permitted without approval. Cells >100 Wh and ≤160 Wh require the carrier’s written approval and are limited (typically two spare batteries per passenger). Cells >160 Wh are forbidden on passenger aircraft. Non-rechargeable lithium metal: batteries containing more than 2 g of metallic lithium are prohibited.

Practical handling and labeling

Determine watt‑hours using Wh = V × Ah (Ah = mAh ÷ 1000). Example: a 3.7 V, 2200 mAh cell → 3.7 × 2.2 = 8.14 Wh. Typical examples: smartphone ~10–15 Wh, laptop ~40–90 Wh, 20,000 mAh power bank (3.7 V) ≈ 74 Wh. When spare cells are carried in the cabin, protect terminals with tape or original packaging, place each battery in an individual plastic pouch, and avoid loose contact with metal objects.

For devices with built-in batteries: turn off, use a protective case, and disable alarms. For power packs exceeding 100 Wh or unusual configurations, obtain airline approval before travel and declare at check‑in if requested. Follow IATA/ICAO rules and the specific carrier’s policy; local aviation authority and TSA guidance may add restrictions.

Store spare lithium‑ion cells in the cabin (carry-on); do not store loose spares in the aircraft cargo hold.

Regulatory bodies (IATA, FAA, TSA) require spare lithium‑ion batteries to be transported in the passenger cabin; cargo compartment stowage for loose spares is prohibited on passenger aircraft.

• Capacity rules:

  • ≤100 Wh: permitted in carry‑on without airline approval.
  • 100–160 Wh: airline approval required; most carriers limit to two spare batteries per passenger.
  • >160 Wh: forbidden on passenger planes (transport only via specialized cargo with dangerous‑goods procedures).

• Terminal protection and packaging:

  • Insulate terminals with tape or keep cells in original retail boxes or individual plastic pouches to prevent short circuits.
  • Keep each spare separated from metal objects and other batteries.
  • Markings: confirm Wh rating on cell label; if only mAh listed, calculate Wh = (mAh ÷ 1000) × V and carry evidence if requested.

• Installed batteries vs spares:

  • Devices with batteries installed are generally acceptable in the cabin and sometimes allowed in the cargo compartment at the airline’s discretion; however, critical electronics and power banks should be carried onboard when feasible.

• Airline approval and declaration:

  • Obtain carrier approval before travel for 100–160 Wh cells and follow any quantity limits the airline imposes.
  • Declare large capacity batteries at check‑in if requested and carry documentation showing Wh ratings.

• Practical packing recommendations:

  • Store spares in a hard-sided personal bag or pouch inside the cabin; for selection guidance see best luggage personal item.
  • For outdoor or hunting trips that require multiple batteries, choose a carry solution designed for equipment transport: best luggage for hunting trips.
  • If transporting battery‑powered cleaning or accessory tools, verify compatibility and handling recommendations alongside gear guides such as best pressure washer surface cleaners.

Quick checklist

• Keep all spare lithium‑ion cells in cabin carry‑on.
• Insulate terminals; use original packaging or individual pouches.
• Confirm Wh rating; calculate from mAh and voltage when necessary.
• Request airline approval for 100–160 Wh spares before travel.
• Do not transport spares >160 Wh on passenger aircraft.

How to pack devices with installed batteries to comply with airline and TSA rules

Place devices with built-in lithium cells in carry-on/cabin baggage, fully powered off, protected from accidental activation, and cushioned against impact.

Power down completely; disable timers, alarms and any “wake on” settings. Disconnect external chargers, remove memory cards if recommended by manufacturer, and stow charging cables separately to avoid pressing buttons during transit.

Use hard-shell or padded cases for phones, tablets, laptops, cameras and other battery-containing equipment. Surround each item with soft material (clothing, foam sleeves) so the device cannot shift or be crushed. Keep devices in dedicated compartments rather than loose among hard objects.

Check cell ratings before travel: lithium‑ion cells up to 100 Wh are permitted in the cabin without airline approval; cells between 100 Wh and 160 Wh require airline approval (usually limited to two installed or spare batteries per passenger); cells above 160 Wh are prohibited from carriage. For lithium metal (non‑rechargeable), batteries with >2 g lithium content typically require airline approval. Convert mAh to Wh when only capacity is listed: Wh = (mAh ÷ 1000) × V. Example: 5000 mAh at 3.7 V = 18.5 Wh.

Keep devices accessible for screening and present manufacturer labels or specification sheets when staff request verification of Wh or lithium content. For devices with removable battery compartments that expose terminals or spring contacts, cover exposed contacts with non-conductive tape or place the device inside a protective sleeve to reduce short‑circuit risk.

Do not transport devices that show swelling, leakage, burn marks or heat generation. Isolate any damaged item in a non-flammable container and notify airline or security personnel before travel; many carriers will refuse transport of compromised cells.

For large-capacity equipment (power tools, professional camera packs, mobility aids) obtain written airline approval in advance and carry proof (email or paper authorization) onboard. Retain original packaging labels for high‑Watt‑hour cells when possible to speed inspections.

What battery capacities (Wh or mAh) trigger airline approval or restrictions

Any lithium‑ion cell or pack over 100 Wh requires airline approval; units above 160 Wh are not permitted for passenger transport without special cargo arrangements.

Threshold summary: ≤100 Wh – generally allowed in cabin without prior approval; 100 Wh < = pack ≤160 Wh – airline approval required and quantity usually limited (commonly up to two spare packs per passenger); >160 Wh – prohibited on passenger aircraft (may be shipped only as regulated cargo with a dangerous goods permit).

Calculate Wh when only mAh is listed: Wh = (mAh × V) / 1000. Example conversions for common nominal voltages: at 3.6 V, 100 Wh ≈ 27,778 mAh and 160 Wh ≈ 44,444 mAh; at 3.7 V, 100 Wh ≈ 27,027 mAh and 160 Wh ≈ 43,243 mAh. Practical examples: a 3,000 mAh phone cell at 3.85 V ≈ 11.6 Wh; a typical laptop pack at 56 Wh falls well under the 100 Wh threshold.

Lithium‑metal (non‑rechargeable) cells follow a different limit: more than 2 g of elemental lithium per cell is forbidden on passenger aircraft. Verify manufacturer specifications for gram lithium content when dealing with primary (non‑rechargeable) cells.

If a device or power bank lacks a Wh label, request official specs from the manufacturer or use the mAh×V formula. For packs falling into the 100–160 Wh band, obtain written airline approval before travel and confirm allowable quantity; for packs exceeding 160 Wh, arrange transportation only as approved dangerous goods cargo.

How to protect terminals and reduce fire risk when placing batteries in hold baggage

Insulate every terminal with high-adhesion electrical tape or purpose-made insulating caps, then enclose each cell or battery pack in a rigid, non-conductive container to prevent short circuits and mechanical damage.

Terminal protection – materials and technique

Tape: Use PVC electrical tape (rated ≥80°C) or polyimide (Kapton) tape (rated ≥200°C). Cover the entire positive and negative terminals with at least 5–10 mm overlap onto the cell casing. Avoid single narrow strips; apply two perpendicular wraps for redundancy.

Heat-shrink: Apply adhesive-lined heat-shrink tubing (2:1 or 3:1 ratio) sized to cover the terminal and extend 3–5 mm onto the insulated sleeve or case. Shrink with a heat gun until snug; no exposed metal should remain.

Insulating caps: Use molded plastic or silicone terminal caps sized to the terminal diameter. Caps are preferable for cylindrical cells (18650, 21700) and external battery posts; secure with tape if loose.

Containment and packing methods

Individual separation: Place each insulated cell or pack into its own non-conductive sleeve or pouch (polyethylene or polypropylene). Then put sleeves into a rigid plastic battery case or hard-sided box with individual compartments to prevent contact between cells and other metal objects.

Cushioning and location: Surround the battery case with at least 10–20 mm of closed-cell foam to absorb impact. Position the case in the center of the hold bag or aircraft hold compartment, away from heavy items (tools, chargers) that could shift and crush the container.

Fire containment: Use a certified flame-retardant LiPo/battery safety bag for high-energy cells (RC packs, drone batteries). Those bags are designed to contain venting and flames; place the bag inside the rigid case for dual protection.

Damaged or swollen cells: Never transport cells that exhibit swelling, leakage, burn marks or strong odors. If a cell shows these signs, follow manufacturer and carrier hazardous-material instructions for disposal before travel.

Additional safeguards: Remove batteries from devices with exposed metal contacts; fully power down devices and use terminal covers or tape over device contacts. Keep batteries of different chemistries and states of charge separated to avoid internal shorting or thermal propagation.

Video: