Can Lithium Battery on Plane Be Allowed?

The Federal Aviation Administration tracked 50 verified battery-related incidents through August 2025, averaging nearly one per week. These numbers represent more than statistics—they reflect phones catching fire in seat-back pockets, power banks igniting in overhead bins, and emergency diversions that put hundreds of passengers at risk. Understanding lithium battery regulations has shifted from a travel convenience question to a safety imperative that affects every passenger boarding commercial aircraft today.

Yes, lithium batteries are allowed on planes with specific restrictions based on battery type, size, and packaging. Devices containing lithium-ion batteries must stay in carry-on baggage where cabin crew can respond to incidents, while spare batteries require terminal protection and airline approval for larger capacities. These rules exist because lithium battery fires at 35,000 feet present unique challenges that standard aircraft fire suppression systems struggle to control.

Why Lithium Battery Rules Exist

The confined environment of an aircraft cabin amplifies risks that seem minimal on the ground. A smartphone battery that might cause minor damage in a home becomes a critical threat when 200 passengers share an aluminum tube seven miles above Earth with limited firefighting resources.

Lithium batteries power an extraordinary range of devices precisely because they pack substantial energy into compact spaces. This high energy density creates the same risk that makes them valuable—thermal runaway. When a lithium-ion cell experiences damage, manufacturing defects, or short-circuiting, it can trigger an uncontrollable chain reaction. One compromised cell heats neighboring cells, creating a cascading effect that reaches temperatures exceeding 900°F within seconds.

The January 2025 Air Busan incident at Gimhae International Airport demonstrated these dangers. Investigation results indicated that insulation breakdown inside a power bank battery stored in an overhead compartment initiated the fire. The aircraft was still on the ground, yet the blaze injured 27 people and gutted the Airbus A321. Had this occurred during flight, the consequences would have been catastrophic.

The FAA issued a renewed safety alert in September 2025 emphasizing that batteries stored in overhead bins or deep within carry-on bags may be “obscured, difficult to access, or not readily monitored.” Detection delays and restricted firefighting access increase danger exponentially. Flight crews train extensively for lithium battery fires, but their effectiveness depends on immediate detection and battery accessibility—both compromised when devices hide in checked luggage or buried carry-ons.

Current regulations emerged from hard lessons. The 2016 Samsung Galaxy Note 7 ban followed multiple incidents where the device’s battery overheated, smoked, and in some cases exploded. That singular product recall highlighted a universal truth: any lithium battery can fail, and aircraft represent the worst possible environment for that failure.

Core Rules You Must Know

Federal regulations governing lithium battery transport balance passenger convenience against documented safety risks. The Transportation Security Administration and FAA established these requirements after analyzing incident patterns and fire suppression capabilities.

Installed vs. Spare Batteries: The Critical Distinction

Devices with installed batteries—smartphones, laptops, tablets, cameras—face different rules than loose batteries. Personal electronic devices containing lithium-ion batteries can travel in either carry-on or checked baggage when certain conditions are met. The device must be completely powered off (not in sleep or hibernation mode), protected from accidental activation, and packed to prevent damage.

However, the FAA strongly recommends keeping all battery-powered devices in accessible carry-on baggage. This recommendation stems from a simple reality: cabin crew can respond to smoking devices in the cabin within seconds, whereas fires in the cargo hold often go undetected until reaching uncontrollable stages.

Spare batteries follow absolute rules. Every uninstalled lithium-ion battery, power bank, portable charger, and external battery pack must travel in carry-on baggage only. No exceptions exist for this requirement. When flying with lithium batteries as spares, passengers must keep them accessible and protect battery terminals from short circuits.

The gate-check situation creates particular confusion. When airlines check carry-on bags at the gate or planeside due to space constraints, passengers must remove all spare batteries and power banks before relinquishing their bag. These items must stay with the passenger in the aircraft cabin. Many travelers miss this requirement, creating safety risks and potential confiscation at the aircraft door.

Battery Terminal Protection Requirements

Short circuits cause more battery incidents than manufacturing defects. When battery terminals contact metal objects—keys, coins, other batteries—they can create heat buildup leading to thermal runaway. The FAA mandates terminal protection through several acceptable methods:

Batteries should remain in original retail packaging when possible. This packaging includes plastic terminal covers and insulation specifically designed to prevent short circuits. For batteries outside original packaging, covering terminals with electrical tape provides adequate protection. Placing each battery in a separate plastic bag or protective pouch also satisfies requirements. Camera battery cases designed for travel serve this purpose well.

What doesn’t work: tossing multiple spare batteries loose into a carry-on bag, even if separated from other items. Terminal-to-terminal contact between batteries creates the same risk as terminal contact with metal objects.

Prohibited Items Without Exception

Certain lithium battery items face absolute bans from all passenger aircraft. Damaged batteries showing swelling, leaking, corrosion, or physical damage cannot travel in any baggage type. Recalled batteries and devices containing recalled batteries are prohibited unless the battery has been removed or the recall issue has been resolved. Manufacturing defects that trigger recalls often involve thermal runaway risks too severe for air transport.

Electronic cigarettes and vaping devices occupy a special category. These items must travel in carry-on baggage only and cannot be used or charged during flight. The FAA tracked numerous incidents where vaping devices in checked baggage ignited fires, leading to the absolute prohibition on checked transport.

Battery Size Limits Explained

Lithium battery capacity determines which aircraft regulations apply. The aviation industry measures lithium-ion battery capacity in watt-hours (Wh), while lithium metal batteries use grams of lithium content. Most travelers encounter only lithium-ion batteries, but understanding both measurement systems helps avoid security checkpoint surprises.

Standard Batteries (Up to 100 Wh)

The vast majority of personal electronics use batteries below 100 watt-hours. This category includes typical smartphone batteries (10-15 Wh), standard laptop batteries (40-90 Wh), tablet batteries (20-40 Wh), and camera batteries (10-20 Wh). No airline approval is required for batteries in this range, and passengers can bring reasonable quantities for personal use.

Calculating watt-hours from battery specifications requires simple multiplication. Wh equals voltage (V) multiplied by amp-hours (Ah). A 12-volt battery rated at 8 amp-hours produces 96 watt-hours (12 × 8 = 96). For batteries marked in milliamp-hours (mAh), divide by 1,000 to convert to amp-hours before multiplying. A 10,000 mAh power bank at 3.7 volts equals 37 watt-hours (10,000 ÷ 1,000 × 3.7 = 37).

Many modern lithium-ion batteries print the Wh rating directly on the battery casing, eliminating calculation needs. Look for markings like “74 Wh” or “3.7V 20,000mAh (74Wh)” on power banks and laptop batteries.

Medium Batteries (101-160 Wh)

Larger batteries serving professional equipment fall into this middle category. Extended-life laptop batteries, professional camera equipment batteries, and some portable power stations reach 101-160 watt-hours. These batteries require airline approval before travel.

Passengers can carry up to two spare batteries in this size range with airline approval. “Airline approval” means the specific carrier permits these batteries under their policies—not that individual passengers need explicit permission for each flight. Check airline websites under dangerous goods or battery policies to verify acceptance.

Installed batteries between 101-160 Wh face fewer restrictions. A laptop with a 150 Wh battery can travel in carry-on or checked baggage as long as the device is powered off and protected. However, carrying that same battery as a spare requires both airline approval and carry-on-only transport.

Large Batteries (Over 160 Wh)

Any lithium-ion battery exceeding 160 watt-hours is prohibited on passenger aircraft in all circumstances. These batteries must ship as cargo under dangerous goods regulations with specialized packaging, documentation, and handling. Professional video equipment, large power stations, and some electric vehicle batteries fall into this prohibited category.

Passengers occasionally attempt to board with batteries they believe fall under allowances when capacity actually exceeds limits. A 44,000 mAh power bank at 3.7 volts equals 162.8 Wh—over the limit despite seeming comparable to smaller power banks. TSA officers have authority to confiscate batteries that exceed restrictions, and ignorance of capacity provides no exception.

Lithium Metal Battery Limits

Non-rechargeable lithium metal batteries follow different limits measured in grams of lithium content. Batteries containing up to 2 grams of lithium per battery are permitted in carry-on baggage. This limit covers most coin cell batteries in watches, calculators, and medical devices like hearing aids. Spare lithium metal batteries also require carry-on-only transport with terminal protection.

How to Pack Safely

Proper packing prevents most battery incidents. The preparation you make at home determines whether your devices pass security screening without delays and reach your destination without causing safety concerns.

Step 1: Inventory and Inspect

List every battery-powered device and spare battery you plan to bring. Inspect each item for damage signs: swelling, dents, corrosion around terminals, unusual odors, or excessive heat when touched. Damaged batteries stay home—the risk of in-flight thermal runaway far exceeds the inconvenience of leaving a device behind. Check manufacturer recall lists if you have older devices, particularly power banks and smartphones from 2016-2020 when several major recalls occurred.

Step 2: Verify Capacities

Check watt-hour ratings for all power banks and extended laptop batteries. This information appears on the battery itself, in device specifications, or on manufacturer websites. If you cannot verify capacity, assume the battery might exceed limits and contact your airline before traveling. The TSA can deny boarding to passengers carrying batteries without verifiable capacity information.

Step 3: Protect All Terminals

Cover terminals on every spare battery. Use original packaging when available—this provides optimal protection and makes security screening faster. For batteries outside original packaging, apply electrical tape to both terminals. Place each battery in an individual plastic bag or use battery storage cases. Never pack multiple unprotected batteries together, even if separated from metal objects.

Step 4: Pack Strategically

Keep all battery items in carry-on baggage. Place devices and spare batteries where you can access them quickly during security screening and during flight if issues arise. Laptop batteries installed in laptops, camera batteries installed in cameras, and similar installed batteries can remain in devices. Spare batteries must be individually protected and easily accessible.

Avoid packing batteries deep in bag interiors. If your phone or power bank begins emitting heat or smoke during flight, you need immediate access. Overhead bin storage is acceptable for installed batteries in devices, but Southwest Airlines now requires power banks to remain in plain sight if used during flight—a policy other carriers may adopt.

Step 5: Prepare for Gate Checks

If airlines might gate-check your carry-on due to full overhead bins, pack a small bag within your carry-on containing all spare batteries. When the gate agent checks your bag, remove this inner bag with your batteries and carry it onto the aircraft separately. This step prevents the dangerous situation where spare batteries enter the cargo hold inadvertently.

What Happens at Airport Security

TSA screening procedures specifically target lithium batteries due to their fire risk. Understanding these procedures reduces stress and speeds up the security process.

Security officers typically require passengers to remove laptops and large electronics from carry-on bags for separate screening. This separation allows X-ray scanners to view battery compartments without obstruction from clothing and other items. Smaller devices like phones and tablets usually remain in bags unless officers request removal.

When carrying spare batteries or power banks, keep them easily accessible. Officers may ask to inspect these items directly, particularly larger power banks that could exceed watt-hour limits. Having battery capacity information readily available—whether printed on the battery or on a manufacturer specification sheet—prevents delays.

TSA officers can ask passengers to power on any electronic device at the checkpoint. Devices with dead batteries that cannot power on may be prohibited from the aircraft. This policy helps identify potentially damaged batteries and ensures devices haven’t been modified to conceal prohibited items. Keep at least a minimal charge in all devices you plan to carry.

Questions about battery capacity arise most often with power banks. Officers can refuse boarding to passengers carrying batteries without visible capacity markings or those that obviously exceed 100 Wh without airline approval. Some power banks lack proper labeling, creating legitimate confusion. When in doubt, the officer’s decision stands—passengers can either voluntarily abandon the item or miss their flight.

International flights face additional scrutiny. Some countries impose stricter battery limits than U.S. regulations. Japan and South Korea have enhanced inspection procedures following their 2025 incidents, with some carriers prohibiting power bank charging during flights and requiring batteries to remain visible when in use.

can you bring lithium batteries on a plane through security depends on following these procedures exactly. Cooperation with TSA officers and advance preparation with proper labeling and capacity information ensure smooth screening.

Real Incidents and Lessons

Recent incidents provide concrete examples of what can go wrong and why regulations exist. These cases illustrate both failure points and effective responses.

Air Busan Flight 391 (January 2025)

On January 28, 2025, Air Busan Flight 391 sat on the runway at Gimhae International Airport preparing for departure to Hong Kong. Smoke began pouring from an overhead bin as flames engulfed the cabin. Despite rapid response from ground crews, the fire gutted the Airbus A321’s interior. Twenty-seven people suffered injuries, three seriously.

Investigation results pointed to a power bank battery stored in the overhead compartment where passengers had placed carry-on luggage. The battery’s insulation had broken down, initiating thermal runaway that spread to luggage and cabin materials before detection. Had this occurred during cruise flight, the outcome would likely have been catastrophic.

This incident prompted South Korea to implement strict new rules effective March 1, 2025. Power banks now require visible storage during operation—no more charging phones inside bags or bins. Some Asian carriers extended these restrictions, with several airlines banning charging entirely during flight.

Delta Air Lines Flight 1334 (August 2025)

Flying from Atlanta to Fort Lauderdale in August 2025, Delta Flight 1334 experienced an onboard fire when a passenger’s personal lithium-ion battery pack ignited in a backpack. The device had been tucked away in carry-on baggage, and initial detection was delayed. Once crew members identified the source, they followed trained protocols using halon fire extinguishers and water to cool the battery.

The pilots declared an emergency and diverted to Fort Myers, where all 191 passengers safely evacuated. The incident demonstrated both the risk of batteries deep in bags and the importance of cabin crew access. Had this battery been in checked luggage, the fire would have spread unchecked in the cargo hold.

Key Lessons from 2025 Incidents

These incidents and the 50 total verified cases through August 2025 reveal common failure patterns. Many incidents involve power banks rather than batteries installed in devices. Counterfeit or low-quality batteries show higher failure rates than name-brand products. Physical damage to batteries—even minor dents or drops—increases thermal runaway risk substantially.

Overhead bin storage creates detection delays that allow small problems to become emergencies. Charging devices during flight, particularly vapes and e-cigarettes, contributed to multiple 2025 incidents. The common thread: batteries outside direct passenger supervision or deep in inaccessible storage pose the greatest risks.

The lesson for travelers is straightforward: lithium batteries on planes require active attention. Keep power banks and spare batteries where you can monitor them. Use only manufacturer-approved chargers and avoid charging devices in overhead bins or under seats where early warning signs like unusual heat might go unnoticed.

2025 Regulatory Updates

Aviation authorities worldwide continue updating battery transport rules based on incident data and emerging technologies. Several 2025 changes affect passenger travel.

IATA Packaging Requirements (January 2025)

The International Air Transport Association introduced enhanced packaging requirements effective January 2025 for certain battery shipments. While these primarily affect commercial battery transport, the principles inform passenger guidance. The new 3-meter stack test requirement for non-UN specification packaging aims to ensure batteries can withstand typical transport stresses.

Passengers see indirect effects through stricter airline policies on battery labeling and capacity verification. Some carriers now require visible capacity markings on all power banks, refusing items that lack proper labels even if the battery likely falls within limits.

Country-Specific Enhanced Restrictions

South Korea’s March 2025 power bank visibility requirement represents the strictest passenger-facing change. Passengers boarding flights in South Korea must keep portable chargers visible at all times during use. Charging devices in bags or overhead compartments is prohibited. These rules apply to all passengers departing Korean airports, regardless of destination or nationality.

Several other Asian carriers implemented similar policies voluntarily. Singapore Airlines, Cathay Pacific, and Thai Airways now restrict power bank use in-flight, requiring passengers to obtain crew permission before charging devices. Some airlines limit the number of power banks per passenger beyond FAA requirements.

FAA Safety Alert (September 2025)

The FAA’s September 2025 safety alert didn’t change rules but emphasized existing guidance with renewed urgency. The alert encouraged airlines to “consider the hazard posed by the stowage of lithium batteries in areas not visible or easily accessible.” Southwest Airlines responded by becoming the first major U.S. carrier to require in-use power banks to remain in plain sight—a policy other carriers may adopt.

This alert followed the uptick in incidents and specifically addressed the challenge of batteries in overhead bins. While not mandating changes, the alert signals potential future restrictions if incident rates don’t decline.

Variations by Carrier and Country

Regulations establish minimum safety standards, but individual airlines and countries can impose stricter rules. Always verify specific airline policies before flying, particularly for international travel. Middle Eastern carriers often have enhanced restrictions on lithium batteries on flights. Australian authorities enforce strict capacity verification. Chinese airlines may limit spare battery quantities below FAA maximums.

lithium batteries on airplanes remain subject to evolving rules as authorities balance safety against passenger needs. Staying informed of current regulations specific to your route prevents surprises at boarding.

Frequently Asked Questions

Can you fly with lithium batteries in checked luggage?

Spare lithium batteries and power banks cannot travel in checked luggage under any circumstances. Devices with installed batteries can be checked if completely powered off and protected from damage, though airlines recommend carrying them on board instead for safety monitoring.

How many power banks can I bring on a plane?

Standard power banks under 100 Wh have no quantity limit for personal use, though batteries cannot be for commercial distribution. Power banks between 101-160 Wh are limited to two spare batteries per person with airline approval. Power banks exceeding 160 Wh are prohibited entirely.

What size lithium battery is allowed on planes?

Lithium-ion batteries up to 100 watt-hours require no special approval. Batteries from 101-160 Wh need airline approval and are limited to two spare batteries. Batteries exceeding 160 Wh cannot fly on passenger aircraft. For lithium metal batteries, up to 2 grams of lithium content is permitted.

Do laptop batteries need to be removed for air travel?

Laptop batteries installed in laptops do not need removal for air travel. The laptop can travel in carry-on or checked baggage when powered off. Spare laptop batteries must travel in carry-on baggage only with terminal protection and airline approval if exceeding 100 Wh capacity.

Are lithium batteries allowed in international flights?

lithium batteries on flights are generally allowed internationally with the same basic restrictions as U.S. domestic travel, though some countries impose additional requirements. Japan, South Korea, China, and several other nations have enhanced inspection procedures or stricter limits. Always check both airline and destination country regulations before international travel.

What happens if my power bank exceeds 160 Wh?

Power banks and batteries exceeding 160 watt-hours cannot travel on passenger aircraft under any circumstances. These batteries must ship separately as cargo under dangerous goods regulations. TSA officers will confiscate oversized batteries at security checkpoints. Calculate capacity before traveling to avoid confiscation.

Can I charge my devices during the flight?

Charging personal electronics during flight is generally permitted using aircraft power outlets or USB ports when available. However, several airlines now restrict or prohibit charging power banks during flight following 2025 incidents. Vaping devices and e-cigarettes cannot be charged during flight under any circumstances.

What should I do if my battery starts overheating on a plane?

Immediately alert flight attendants if any device or battery shows signs of overheating, swelling, smoking, or unusual odor. Do not attempt to handle the device yourself beyond moving it away from flammable materials if safe to do so. Cabin crew receive specialized training for battery fire incidents and have equipment to contain thermal runaway. Never drop a device—alert crew to retrieve it from under or between seats to avoid damage that could trigger thermal runaway.

Are camera batteries subject to the same rules as power banks?

Camera batteries follow identical rules based on capacity. Batteries installed in cameras can travel in either carry-on or checked baggage. Spare camera batteries must travel in carry-on only with protected terminals. Most camera batteries fall under 100 Wh and require no special approval, but professional video equipment sometimes uses larger batteries requiring airline approval.

How do I know the watt-hour rating of my battery?

Many modern batteries print watt-hour ratings directly on the casing. Look for markings like “74 Wh” or calculations showing voltage and amp-hours. If not marked, check manufacturer specifications online or calculate using the formula: Wh = Voltage (V) × Amp-hours (Ah). For milliamp-hours, divide by 1,000 before multiplying. When capacity cannot be verified, airlines or TSA may refuse the battery.

What is thermal runaway and why does it matter on planes?

Thermal runaway occurs when a lithium battery overheats uncontrollably, causing a chain reaction where damaged cells heat adjacent cells to temperatures exceeding 900°F. This can cause smoke, fire, and explosive reactions. In aircraft environments, thermal runaway is especially dangerous because fires spread quickly in confined spaces, and cargo hold fires often go undetected until reaching uncontrollable stages. Cabin placement allows immediate crew response.

Do all airlines follow the same battery rules?

FAA and TSA regulations set minimum standards for U.S. carriers, but airlines can implement stricter policies. International carriers follow IATA guidelines but may add restrictions based on their country’s regulations. Southwest requires in-use power banks to be visible. Some Asian carriers prohibit charging during flight. Always check your specific airline’s policy before traveling, especially for international flights.

Key Takeaways

Incident rates are rising: The FAA tracked 50 verified lithium battery incidents through August 2025, averaging nearly one per week and highlighting the growing scope of the safety challenge facing aviation authorities
Spare batteries must stay accessible: All uninstalled lithium-ion batteries, power banks, and portable chargers must travel in carry-on baggage only where cabin crew can respond immediately to thermal runaway incidents
Size determines requirements: Batteries under 100 Wh require no approval, 101-160 Wh need airline permission with a two-battery limit, and anything exceeding 160 Wh cannot fly on passenger aircraft
Terminal protection is mandatory: All spare batteries require covered terminals using original packaging, electrical tape, or protective cases to prevent short circuits that can trigger thermal runaway
2025 brought stricter enforcement: South Korea’s new visibility requirements and enhanced airline policies reflect increasing regulatory attention following the Air Busan and Delta incidents

References

Federal Aviation Administration – Lithium Batteries in Baggage (2025) – https://www.faa.gov/newsroom/lithium-batteries-baggage
Transportation Security Administration – Lithium Batteries Guidelines (2025) – https://www.tsa.gov/travel/security-screening/whatcanibring/items/lithium-batteries-more-100-watt-hours
UL Standards & Engagement – Fly Safe: How to Pack and Travel With Lithium-Ion Batteries (May 2025) – https://ulse.org/insight/ul-standards-engagement-aviation-safety-fly-safe-how-pack-lithium-ion-batteries/
CNN – FAA Safety Alert Warns Airlines About Dangers of Lithium Batteries (September 2025) – https://www.cnn.com/2025/09/09/us/faa-battery-safety-alert
CNN – What Happens When a Device Nearly Every Passenger Carries Onboard a Plane Erupts in Smoke and Flames (August 2025) – https://www.cnn.com/2025/08/22/travel/battery-fire-risks-planes
Airbus – Flying with Lithium Ion Batteries in Passenger Luggage (August 2025) – https://www.airbus.com/en/newsroom/stories/2025-08-flying-with-lithium-ion-batteries-in-passenger-luggage
EcoFlow – Portable Batteries on Airplanes: What Are the New Rules in 2025? – https://www.ecoflow.com/us/blog/portable-batteries-on-airplanes-new-rules-in-2025
International Air Transport Association – Battery Shipping Regulations (2025) – https://www.iata.org/en/programs/cargo/dgr/lithium-batteries/
Federal Aviation Administration – PackSafe Lithium Batteries Guide (2025) – https://www.faa.gov/hazmat/packsafe/lithium-batteries