Can you put power tools in your checked luggage

Recommendation: Do not load battery-operated drills, saws or similar workshop devices into the aircraft hold unless internal batteries are removed, spare lithium cells are carried in the cabin, battery terminals are insulated, and the airline has given explicit approval for any high-capacity cells.

Regulatory baseline: International Air Transport Association Dangerous Goods Regulations and FAA/TSA guidance treat lithium batteries as dangerous goods. Installed lithium-ion cells up to 100 Wh are generally permitted inside carried equipment, but spare cells must remain in the cabin. Cells between 100–160 Wh require airline approval; cells above 160 Wh are typically forbidden on passenger flights.

Practical steps for compliance: remove all batteries from portable workshop equipment; place removed cells in individual insulating pouches or original packaging; cover terminals with tape or use terminal caps; secure devices in a hard-sided case to prevent movement and accidental activation; lock or disable triggers (zip ties, trigger blocks). If only milliamp-hours (mAh) and voltage (V) are printed on a cell, calculate watt-hours: Wh = (mAh ÷ 1000) × V – for example, a 3000 mAh, 18 V pack equals 54 Wh.

Combustion and gas-driven gear: remove and purge any fuel; no liquid gasoline or fuel-soaked components are allowed in airline baggage. Compressed-gas cartridges, aerosol lubricants and sealed gas canisters are forbidden in both hold and cabin unless specifically approved under dangerous-goods provisions.

Before travel: inspect battery labels, document Wh ratings when possible, notify the airline at booking for any items with cells between 100–160 Wh, and retain manufacturer packaging or certification for unusual batteries. When in doubt, transport high-capacity cells as carry-on with the terminals insulated and the airline informed.

Transporting motorized equipment in hold baggage

Keep spare lithium batteries in the cabin; stowed baggage must not contain loose cells or packs.

Regulatory limits and airline rules

• Lithium-ion: cells/packs up to 100 Wh are allowed in carry-on; 100–160 Wh require airline approval and are limited to two spare packs per passenger; >160 Wh are forbidden on passenger aircraft.
• Lithium metal (non-rechargeable): maximum lithium content 2 g per cell; higher-content cells are prohibited.
• Devices with batteries installed are often permitted in hold baggage, but some carriers mandate cabin carriage for all battery-powered equipment–verify with the airline before travel.
• Spare batteries (not installed in a device) must travel in the cabin at all times; they are not permitted in stowed suitcases.

Packing checklist for drills, saws, grinders and similar items

• Remove removable batteries and carry them in the cabin with terminals insulated (tape terminals or use original retail packaging).
• If batteries are non-removable, ensure the device is completely powered off and any activation mechanism is blocked (trigger lock, tape over switch).
• Empty all fuel reservoirs; petrol, diesel and any flammable liquids or aerosols are prohibited in hold bags.
• Secure sharp edges and rotating parts with guards or heavy padding; place the unit in a hard-sided case if possible.
• Label batteries above 100 Wh with the Wh rating and keep documentation of airline approval for 100–160 Wh items.
• Place heavy equipment at the center of the suitcase surrounded by soft items to reduce shifting and impact damage.

Failure to follow these rules may lead to removal of items at security, flight delays or fines; always check the specific carrier and departure/arrival country regulations before travel.

Airline and TSA rules for battery-operated equipment

Recommendation: Carry all spare lithium batteries and battery packs inside cabin baggage; spare lithium cells are prohibited in the aircraft hold. Devices with installed lithium-ion cells may travel in the cabin or the hold depending on carrier policy, but spare batteries must remain in carry-on. Capacity limits: up to 100 Wh per cell or battery allowed without airline approval; 100–160 Wh requires airline approval and most carriers limit spares in that range to two per passenger; greater than 160 Wh is not permitted on passenger aircraft. Non-rechargeable lithium (lithium metal) units with lithium content over 2 g are forbidden; units at or below 2 g are accepted in the cabin only.

Terminal protection and packaging

Insulate battery terminals by taping exposed contacts or using original manufacturer packaging; place each spare in individual plastic sleeves or a protective pouch to prevent short circuits. Do not stow loose spare cells in the aircraft hold. Devices should be switched off and any activation mechanisms blocked (for example remove batteries or secure triggers) to prevent accidental operation during transit.

Airline declarations and special chemistries

Declare batteries larger than 100 Wh at the airline counter when handing over baggage and obtain written approval when required. Sealed lead-acid (SLA), wet-cell, and fuel-containing equipment often require prior airline authorization or are prohibited for passenger carriage; arrange cargo shipment with hazardous-materials documentation if needed. For unrelated packing choices, see best color for outdoor patio umbrella.

Transporting lithium-ion batteries: carry-on vs. hold limits

Always transport lithium-ion cells in carry-on baggage; spare packs are prohibited in the aircraft hold.

• Watt-hour thresholds:
  • ≤100 Wh – allowed in carry-on without airline approval; batteries installed in devices may travel in hold or cabin.
  • 100–160 Wh – airline approval required; usually limited to two spare batteries carried in cabin.
  • >160 Wh – not permitted on passenger aircraft except via special approval and as cargo under dangerous-goods procedures.
• Lithium metal (non-rechargeable): maximum lithium content 2 g permitted in cabin; >2 g requires airline and dangerous-goods approval.
• Labeling and calculation:
  • Wh rating must be printed on the cell or pack for batteries >100 Wh. If missing, airline may refuse carriage.
  • Calculate Wh = V × Ah (example: 14.4 V × 2.5 Ah = 36 Wh).

Packing and handling steps

1. Place all spare batteries and portable chargers in carry-on only; keep installed cells inside devices where feasible.
2. Insulate terminals: tape exposed contacts or use original caps; place each spare in a separate plastic bag or protective pouch to prevent short circuits.
3. Prevent accidental activation: devices with on/off switches should be powered off and protected against movement that could turn them on.
4. Declare higher-capacity items: notify airline/dangerous-goods officer when carrying 100–160 Wh packs or multiple spares; obtain written approval if required.
5. For items >160 Wh, arrange shipment as dangerous goods via cargo channels with appropriate documentation and packaging compliant with IATA/ICAO.

Drone packs frequently exceed 100 Wh – consult are drones considered aircraft for related classification and extra constraints.

If uncertainty exists about a specific cell or quantity, contact the airline’s hazardous-materials or technical support before travel; carriers will refuse undeclared or improperly prepared batteries at the gate.

Preparing corded and non-battery equipment for airline hold

Strip removable parts, drain all fluids, immobilize moving components, and pack each item inside a hard-sided case with at least 2.5 cm (1 in) of foam on every face.

Corded electrical devices

Coil power cords neatly and secure with reusable cable ties; protect plugs with foam or molded recesses to prevent bending. Remove detachable accessories (bits, blades, sanding discs, chuck keys) and place them in a separate, clearly labeled pouch inside the case; sharp items must have blade guards or be sheathed. For drills and saws, lock the trigger mechanically or tape it closed with high-quality PVC electrical tape to prevent accidental activation. Use anti-static bags for circuit boards and place silica gel desiccant packets to limit condensation. Recommended case types: ATA/ISO-rated hard cases (Pelican-style) with custom-cut foam inserts or layered EPE foam; internal compartments should keep heavy components from shifting.

Mark the exterior with weight (kg and lb) and a brief content list; include a signed inventory and serial numbers inside the case for customs and claims. For items exceeding typical airline size or weight limits, arrange freight or dedicated courier service instead – compare options at best luggage shipping companies.

Gas-powered, fuel-residual, and manual items

Remove all fuel and run engines until dry; disconnect spark plugs and, where possible, remove the ignition fuse or kill switch to prevent start-up. Allow a minimum 24 hours of air-drying after draining to reduce vapour risk. Empty separate fuel containers must be carried off-aircraft by ground transport or shipped via authorized hazardous-goods carriers. For manual implements and items with cutting edges, apply thin machine oil to ferrous metals to inhibit corrosion, wrap in oil-resistant paper, then cushion with foam; secure blades with guards and additional taping.

For heavy or oddly shaped equipment, distribute mass close to the case wheels to meet carrier handling norms and keep individual case weight at or below common airline limits (23 kg / 50 lb standard; many carriers allow up to 32 kg / 70 lb for excess-fee checked pieces). Use reinforced corners, internal bracing, and tamper-evident seals; employ TSA-approved locks on cases subject to U.S. inspection. Photograph packed items before dispatch and retain purchase/ownership documents accessible in the top compartment for inspection purposes.

Packaging and Securing Equipment to Prevent Accidental Activation and Damage

Recommendation: Render triggers and switches inoperable with a certified trigger lock or by threading a heavy‑duty nylon cable tie through the trigger guard; immobilize chucks, rotating spindles and sliding levers with clamps or locking pins, then enclose equipment inside a rigid, crush‑resistant case with at least 25 mm (1″) of closed‑cell foam on all faces.

Case selection: choose hard‑shell models (examples: Pelican, SKB, Nanuk) with customizable foam inserts, pressure‑equalization valve and stainless steel hasps for padlocks. Interior cutouts should limit movement to under 5 mm when subjected to a 1 m drop test; use double‑wall corrugated cartons only for items already boxed inside a rigid case.

Padding specifics: use closed‑cell polyethylene or cross‑linked EVA foam. Recommended thickness: 25–50 mm around main bodies, 75 mm for protruding edges or blades. Wrap cables and loose accessories in microfibre pouches or 10–15 mm soft foam; fill all voids with foam blocks or minimum three layers of 3/16″ bubble wrap to prevent compression and shear during handling.

Immobilization inside the container: secure implements with at least two straps (nylon ratchet or industrial Velcro) oriented along perpendicular axes for long items; use foam wedges and corner blocks to prevent torque migration. Apply tamper‑evident seals to all case latches and attach an internal tamper tag stating which switches were disabled.

Switch and actuator protection: install non‑invasive rigid guards over exposed switches (polycarbonate or thin aluminium plate) fixed with removable screws or heavy‑duty tape; avoid permanent modification. For cutting or abrasive attachments, use molded guards or a plywood shield at least 6 mm thick, then pad the guard perimeter with foam to absorb impacts.

Handling and identification: affix shock/tilt indicators (ShockWatch, TiltWatch) to the exterior and label the package with “Heavy” and “This Side Up” where applicable. When placed inside general baggage, position the rigid case at the center surrounded by soft clothing to add 25–50 mm of cushioning; keep bag weight within typical carrier limits (common thresholds: 23 kg/50 lb economy, 32 kg/70 lb higher tiers) to reduce forced handling and seam stress. Use TSA‑approved locks on cases if inspection access may be required.

Declare electrically driven equipment and spare lithium batteries at the security checkpoint and to customs officials before screening

Present items and spare cells openly at the security line and on the customs declaration form; keep invoices, serial numbers, and manufacturer battery specifications ready for inspection.

At security screening

Notify the screening officer immediately when battery-powered devices or loose cells are inside baggage destined for inspection. Remove devices and spare cells on request and place them in bin(s) for X-ray examination; accept manual inspection if requested. For damaged, swollen, or leaking cells, place the item in a sealed plastic bag and inform staff so hazmat procedures can be followed; handling by regular screening staff is not acceptable for compromised cells.

Carry printed technical data when available: manufacturer model, cell chemistry, nominal voltage, and watt-hour or cell weight. Provide MSDS or manufacturer documentation on demand; security staff will reference UN numbers (common entries: UN3480, UN3481 for rechargeable lithium-ion; UN3090, UN3091 for lithium metal) during hazardous‑materials assessment.

At customs and when crossing borders

Declare large numbers of devices or commercial inventory on the customs declaration and supply commercial invoices and an itemized packing list. For temporary importation for work assignments, present an ATA Carnet or temporary import permit to avoid duties. High-volume consignments often trigger additional inspection, potential import licensing, and different duty classification than single personal items.

When exporting batteries that are hazardous for transport, check export control and dangerous-goods reporting requirements before arrival at the airport. Non-declared hazardous items risk seizure, civil penalties, and shipment refusal; organize documentation ahead of travel to prevent delays or penalties.

When checking is prohibited: shipping options and practical alternatives

Arrange shipment through a hazardous‑materials certified freight carrier or a cargo‑only forwarder whenever airline hold carriage is refused. Use carriers’ Dangerous Goods desks for classification and booking; declare batteries as UN3481 (packed with equipment) or UN3480 (battery only) when applicable and request written confirmation of acceptance before handing over the parcel.

Recommended shipping routes and carriers

Prefer ground freight (LTL) or specialist road couriers for domestic moves; major carriers offering hazardous‑goods services include FedEx Freight, UPS Freight and DHL Dangerous Goods divisions. For international moves, select a freight forwarder experienced with IATA/ICAO, IMDG and 49 CFR requirements so consignments travel via approved cargo aircraft or sea freight rather than passenger aircraft.

Practical packing, documentation and handling steps

Step sequence: remove detachable batteries and label Watt‑hour or cell information; insulate terminals with non‑conductive tape; immobilize items to prevent switch activation; use inner packaging to separate cells from metal objects; place assembly into a rigid outer crate with at least 10 cm of cushioning. Include the manufacturer’s MSDS, a commercial invoice with HS code 8507.60 (electric accumulators, where applicable), and any carrier‑specific Dangerous Goods paperwork or shipper’s declaration.

Purchase carrier‑approved inner packs for spare cells when available and buy cargo insurance with declared value covering theft and damage. Request signature on delivery and track via the carrier’s DG tracking channel. For pickups, confirm the driver is authorized to accept hazardous shipments.

Alternatives when shipment is impractical: rent equivalent equipment from national chains (Home Depot Tool Rental, Sunbelt Rentals, Herc Rentals), order replacement units at destination for short stays and return later, or hire a local contractor to perform the job. For time-sensitive moves within a region, consider dedicated same‑day courier or freight‑truck services that will transport crated equipment by road without hazardous‑air restrictions.