Michael Turner
Immediate recommendation: Keep all spare lithium-ion and lithium-metal batteries, including portable power packs and single-cell spares, in hand luggage. Devices with batteries installed (smartphones, laptops, cameras, tablets, e-cigarettes, drones) are permitted in the aircraft hold in many cases, but carrying them in the cabin reduces fire risk and simplifies access for inspections.
Regulatory limits: Lithium-ion cells are regulated by watt-hour (Wh): ≤100 Wh – allowed without airline approval; 100–160 Wh – allowed only with advance airline approval and typically limited to two spare cells per passenger; >160 Wh – forbidden on passenger aircraft (transport only as cargo under strict rules). For lithium-metal (non-rechargeable) batteries the common threshold is ≤2 g lithium content per cell for carriage in passenger operations; higher content requires special handling.
Practical packing rules: Treat power banks as spare batteries: place them inside carry-on, protect terminals (tape exposed contacts or keep them in original packaging), switch devices fully off and prevent accidental activation, and separate loose cells in individual plastic sleeves or their original cell holders. Avoid placing power banks or loose cells inside hold baggage; many operators and security agencies explicitly ban spares in the aircraft hold.
Large or uncommon batteries: E-bike packs, industrial cells and batteries over 160 Wh must not be included in passenger cabin or the hold without explicit operator approval; shipment as cargo with declared hazardous materials documentation and packaging is usually required. Declare any oversized battery at the check-in desk and obtain written airline permission before transport.
Quick checklist: 1) Spare batteries and power packs – carry-on only. 2) Devices with installed batteries – carry in cabin when feasible; if stowed in the hold protect against activation. 3) Tape terminals and use original packaging. 4) Verify Wh rating on battery labels and request airline approval for 100–160 Wh items. 5) For >160 Wh or e-bike packs arrange cargo shipment with the carrier.
Are lithium-ion batteries allowed in hold baggage?
Spare lithium-ion cells and batteries are prohibited from hold baggage; carry spare cells and battery packs in the cabin only. Batteries installed in devices may be transported in the hold subject to airline policies, but cabin carriage is strongly recommended.
Capacity limits and approval
- Up to 100 Wh: allowed in cabin as spares without airline approval; commonly used in phones, tablets, most power banks under 27,000 mAh (at 3.7 V).
- Over 100 Wh and up to 160 Wh: allowed only with airline approval; maximum of two spare batteries per passenger; devices containing these batteries also usually require airline notification.
- Over 160 Wh: forbidden in both cabin and hold for passenger carriage; movement only as cargo under dangerous-goods regulations with shipper and carrier approvals.
- National rules (e.g., FAA) may ban spare lithium batteries from hold baggage entirely–follow the airline and departure/arrival authority rules.
Packing and handling checklist
- Convert mAh to Wh if only capacity in mAh is shown: Wh = (mAh ÷ 1000) × voltage. Example: 10,000 mAh power bank at 3.7 V → 37 Wh.
- Carry spare batteries only in carry-on; never place spare cells or power banks in the hold.
- Protect terminals against short circuits: keep batteries in original retail packaging, use insulating tape over terminals, or store each battery in individual plastic bags or cases.
- Keep devices switched off and safeguard against accidental activation (remove batteries if removable and safe to do so, or use flight mode and hard power-off where possible).
- Declare batteries that require airline approval at booking or check-in; provide Wh rating and manufacturer info when requested.
- Limit quantity: respect the two-spare-battery rule for 100–160 Wh units and the airline’s declared limits for installed batteries.
- If transporting large-capacity batteries commercially, use a licensed dangerous-goods shipper and obtain carrier acceptance; passenger channels are not suitable for >160 Wh units.
How to pack phones and tablets for hold baggage
Prefer cabin carriage; if phones and tablets must travel in the aircraft hold, power each device off completely, remove SIM and microSD cards and place them in a labeled pouch, disable biometric unlock, and wrap screens with a microfiber cloth before inserting into a padded sleeve.
Physical protection
Use a hard-sided case or a rigid insert inside the suitcase and surround devices with soft clothing to absorb shock. Place items near the center of the bag, away from edges and wheels. Add 2–3 cm of foam or bubble wrap around corners. For tablets, use a folio or hard shell that keeps front and back surfaces separated; for phones, a case with raised bezel + tempered glass reduces screen pressure. Store chargers and cables separately to avoid scratching.
Before departure
Full device backup, export of IMEI/serial numbers, and photos of device condition reduce loss claims processing time. Note battery percentage before packing; ensure devices are fully powered off (not just sleep). Mark the external bag with contact info but not a list of contents. If selecting protective container options, consider a rigid model such as best luggage for study abraod or a padded daypack like best backpack for bike commuting.
| Item | Packing method | Notes |
|---|---|---|
| Phone | Padded sleeve → hard-sided case → center of bag | Power off, SIM/microSD removed, photo of IMEI |
| Tablet | Folio/hard shell → extra foam at corners | Screen protector, soft divider from other electronics |
| Spare battery / power bank | Carry in cabin; do not place in hold | Label capacity (Wh) and pack terminals to prevent short |
| Chargers & cables | Pack in separate pouch inside bag | Prevents abrasion and allows quick removal for checks |
Power banks and portable chargers: stowage rules for cabin and aircraft hold
Store external battery packs inside cabin baggage; do not place them in the aircraft hold.
- Regulatory basis: TSA, IATA and ICAO classify spare lithium-ion batteries (power banks/portable chargers) as carry-on items only; stowing them in the aircraft hold is prohibited by most carriers and authorities.
- Watt-hour thresholds:
- ≤100 Wh – permitted in cabin without airline approval.
- >100 Wh and ≤160 Wh – allowed only with explicit airline approval; typically limited to two units per passenger.
- >160 Wh – prohibited for passenger transport on commercial flights.
- Capacity conversion: Wh = (mAh × V) / 1000. Use the cell nominal voltage (usually 3.7 V) unless the manufacturer states otherwise.
- 5,000 mAh at 3.7 V ≈ 18.5 Wh
- 10,000 mAh at 3.7 V ≈ 37 Wh
- 20,000 mAh at 3.7 V ≈ 74 Wh
- 30,000 mAh at 3.7 V ≈ 111 Wh – airline approval required
- Packing and protection:
- Keep packs in an outer pocket of the cabin bag for quick access at security checkpoints.
- Prevent short circuits by covering exposed terminals with electrical tape, placing each unit in its own plastic sleeve, or retaining original packaging.
- Do not tape multiple units together or place loose inside checked/hold baggage.
- Labeling and declaration:
- Follow manufacturer Wh markings; if only mAh shown, perform conversion and mark the Wh value on the device or a paper note.
- Declare any unit >100 Wh to the airline during check-in to obtain required approval.
- Quantity limits and airline policies:
- Most carriers allow several units under 100 Wh per passenger but restrict higher-capacity units to one or two with approval.
- Review the specific airline’s dangerous goods section before departure; policies vary for international routes and low-cost carriers.
- Security screening and enforcement:
- Expect inspection at security; power banks discovered in the aircraft hold will normally be removed and may be confiscated or returned only to the passenger at the gate.
- Flight crews or ground staff retain final authority; compliance with airline instructions prevents delays and penalties.
When in doubt, check the device label for Wh, obtain airline approval for units between 100–160 Wh, and keep all external battery packs accessible inside cabin baggage with terminals protected.
How to protect cameras, drones and lenses in aircraft hold
Store cameras, drones and lenses inside a rigid, lockable case with at least 2.5 cm (1 in) of high-density foam on every side and custom-cut inserts to prevent shifting during transport.
Camera and lens packing
Separate bodies from lenses: remove lenses from camera bodies and fit body caps and rear lens caps to avoid mount stress. Place the body and each lens in individual foam compartments or padded wraps; do not stack items directly on top of each other.
Lens orientation and padding: keep lenses with both caps on and hoods reversed or stored separately. For telephoto lenses use a lens collar or plate and a foam cradle; support the lens at two points (mount and barrel) and surround with at least 2.5–5 cm (1–2 in) of dense foam around the ends.
Microfiber and wraps: wrap each item in lint-free microfiber or padded lens wraps before inserting into foam. Use pick-and-pluck or convoluted foam to eliminate empty spaces that allow movement.
Humidity control: place 2–4 silica gel packs (5–10 g each) inside the case for flights longer than three hours or when traveling to humid regions; resealable desiccant pouches reduce condensation risk.
Drone-specific steps
Propeller management: remove propellers and store them flat between foam layers or in a rigid prop protector; loose props increase the chance of punctures and scratches.
Gimbal and camera protection: lock or clamp the gimbal and secure the camera with foam wedges to prevent movement. If a manufacturer gimbal lock exists, use it plus extra padding on both sides of the gimbal assembly.
Battery handling: remove batteries and follow airline or authority guidance regarding battery carriage; store battery contacts covered and isolated in protective sleeves or original packaging if transported outside the case.
Case selection and security: choose IP-rated, crush-tested hard cases with customizable foam (examples: Pelican-type or equivalent). Use TSA-approved locks where inspections are possible; mark the case as fragile and centre gear away from edges and wheels.
Documentation and insurance: photograph contents with serial numbers before transit, keep copies of invoices, and declare high-value items to the insurer or airline if coverage is required.
What to do with spare batteries and loose cells
Keep spare lithium batteries and loose cells in cabin baggage; insulate terminals and store each cell separately in non-conductive holders or original packaging.
Packing and protection
Cover exposed terminals with electrical tape or use purpose-made terminal caps; place batteries in individual plastic pouches or dedicated battery cases to prevent contact with metal objects (keys, coins). For cylindrical cells (AA/AAA/18650) use plastic tubes or a commercial battery case. Do not bundle loose cells together in a single pocket. Label high-capacity cells with their Wh rating if label available.
Regulatory thresholds and quantities
Lithium‑ion: batteries up to 100 Wh are normally permitted in cabin baggage without airline approval; batteries between 100 Wh and 160 Wh require airline approval and are usually limited to two spare units per passenger. Lithium‑metal (primary) cells: individual cells with more than 2 g lithium content are prohibited on passenger aircraft. Alkaline, NiMH and NiCd cells are generally acceptable but still require terminal protection.
For commercial quantities or large numbers intended for sale/use away from personal use, shipper-approved packing and dangerous-goods documentation are required; contact the airline or a certified shipper before travel. Do not transport swollen, punctured, cracked or leaking cells by air; place such items in a fire-resistant container and hand over to an appropriate hazardous‑waste facility. Store lithium batteries at about 30–50% state of charge for longer trips when possible.
Airline handling of damaged electronics in hold baggage and filing a claim
Report visible damage at the airline’s baggage service desk at the carousel and obtain a Property Irregularity Report (PIR) before leaving the airport.
Airline staff will log the incident, photograph the damaged item and the bag, keep the baggage tag, and issue a PIR number that becomes the primary reference for any claim.
For international travel governed by the Montreal Convention, a written complaint for damaged items must be submitted within 7 days of receipt; delayed arrival claims use a 21-day window. Liability for international carriage is limited to 1,131 Special Drawing Rights (SDR) per passenger – roughly $1,500–$1,700 depending on exchange rates.
Domestic carrier requirements vary by airline and jurisdiction; many carriers demand an on‑site report at the airport and a written claim within the timeframe specified in the contract of carriage. Review the carrier’s published baggage damage policy immediately after reporting.
Required documentation: PIR number, boarding pass, bag tag, high-resolution photographs of the item and its packaging, original purchase invoices, serial numbers or IMEI (for phones), repair or replacement estimates from licensed technicians, and proof of insurance if applicable.
Do not discard the damaged device, packaging, or any loose components until the airline completes its inspection or specifically authorizes disposal; carriers often require physical inspection before issuing compensation.
Typical remedies include payment for repairs, cash reimbursement reflecting depreciation, or replacement up to the liability limit. High-value electronics frequently fall outside standard hold-baggage protection; for such items, declared-value coverage or third-party insurance should be arranged before travel.
If a claim is denied or stalled, request the carrier’s written denial explaining the grounds; obtain independent repair estimates and, if applicable, an expert report attributing damage to baggage handling machinery (see how can a fault help trap oil). Escalation paths include the airline’s customer relations office, national aviation consumer protection body (for example, U.S. DOT), and small-claims court. Under the Montreal Convention, legal action must begin within two years from the date of arrival or from the date on which the aircraft should have arrived.
Expect an initial airline response within several weeks; follow up using the PIR number and keep a chronological record of all correspondence, claim reference numbers and contact names to support any further escalation or judicial filing.
