Flying with Lithium Batteries: TSA and FAA Rules & Safety Tips

flying with lithium batteries

When people discover my blog focuses on travel, they often ask me about flying with lithium batteries. The rules can be confusing at first, especially if you’re packing a power bank, laptop, or other electronic devices. Knowing the TSA and FAA regulations before you pack is essential.

Having spent years studying airline policies, I’ve seen many travelers face unexpected delays simply because they weren’t aware of the rules. The good news is that a little preparation can help you avoid these issues.

In this guide, I’ll cover everything you need to know about flying with lithium batteries, including size limits, spare battery rules, and the latest updates. And if you’re flying with a portable charger or power bank, check out our review of the best power banks to bring on your next international flight.

TSA and FAA Guidelines for Flying with Lithium Batteries

1.1 Lithium Battery Size Limits and TSA/FAA Rules

Lithium batteries are categorized based on their size, measured in watt-hours (Wh) for rechargeable batteries or grams of lithium content for non-rechargeable ones. The TSA and FAA set strict limits depending on these sizes:

  • Batteries Under 100 Wh: Most personal electronic devices, such as phones, tablets, laptops, and cameras, fall into this category. These batteries are permitted in both carry-on and checked luggage, but spares must be in carry-on only.
  • Batteries Between 100 Wh and 160 Wh: This category includes larger devices like CPAP machines, power banks, and portable medical equipment. Passengers can bring up to two spare batteries in their carry-on luggage with airline approval. Checked luggage is not allowed for these spares.
  • Batteries Over 160 Wh: These are typically found in electric wheelchairs and larger medical devices. They are prohibited in checked luggage but may be allowed in carry-on luggage with special airline approval. Passengers should contact their airline well in advance for clearance. (FAA Safe Travel)
  • Non-Rechargeable Lithium Metal Batteries: Limited to 2 grams of lithium content. These are common in watches and cameras. They are allowed in both carry-on and checked baggage, but spares must go in carry-on. (FAA PackSafe)

Prefer to read a chart? Check out the excellent breakdown of battery types and where to pack them by FAA on pages 2 and 3.

KEEN TIP: Protect spare batteries by keeping them in original packaging, insulating terminals, or placing them in individual plastic bags to prevent short circuits.

1.2 What Must Be in Carry-On

Spare lithium batteries, battery packs and power banks must always be packed in your carry-on luggage.

This rule applies to:

  • Loose or uninstalled lithium-ion and lithium-metal batteries
  • Power banks used for charging phones or laptops
  • Rechargeable battery packs for CPAP machines or portable oxygen concentrators

1.3 What Can Be in Checked or Carry-On

Devices with lithium batteries installed can be packed in either checked or carry-on luggage. This includes:

  • Laptops (with batteries installed)
  • Tablets and e-readers
  • Smartphones
  • Cameras
  • Electric toothbrushes and grooming devices
  • Smart luggage with built-in lithium battery trackers or USB charging ports (batteries must be removable and switched off)

If you decide to check devices with lithium batteries, they must be completely powered off, and any Wi-Fi or Bluetooth features must be disabled.

KEEN TIP: It’s always safer to keep these items in carry-on luggage to avoid damage from overheating or accidental activation during transit.

1.3 Special Considerations for Smart Luggage and Trackers

Smart luggage with removable lithium batteries must have the battery removed before being checked. The removed battery should then be carried in your carry-on luggage.

For luggage with non-removable lithium batteries, such as Bluetooth trackers (e.g., Apple AirTags) or built-in USB ports, these are generally permitted in checked bags as long as they meet FAA standards. Make sure all wireless functions are turned off to comply with airline rules.

1.4 Recent Changes in the Regulations

As of this writing, the TSA and FAA have both tightened their regulations slightly. There’s now more emphasis on ensuring that batteries are properly stored—either in their original packaging or with the terminals taped over.

There has also been an increase in scrutiny, especially for batteries between 100 and 300 watt-hours.

The FAA also continues to stress that any batteries over 100 watt-hours require airline approval.

Another update includes stronger guidelines for power banks. Travelers are encouraged to label their power banks clearly with capacity in watt hours and avoid carrying damaged or swollen batteries, as these will not be allowed on board.

KEEN TIP: If you don’t have the original packaging, search for your device online and print out the specifications, including battery capacity.

2. How to Safely Pack Lithium Batteries

2.1 Packing Instructions for Various Types of Batteries

When packing lithium batteries, it’s important to protect them against damage. For smaller batteries, like those in phones or laptops, keeping them in the device is usually sufficient.

But if you’re carrying spares, make sure they’re in a protective case or wrap each battery separately in a non-conductive material like bubble wrap. For larger batteries, particularly those used in medical devices, consider using a hard case with padding to prevent any movement during transit.

Here are the official FAA regulations: FAA: PackSafe Lithium Batteries

Always keep spare batteries in their original packaging if possible, or at least in a case that prevents them from short-circuiting. Trust me, you don’t want to be fumbling around at security trying to explain why your spare battery isn’t properly stored.

2.2 Using Protective Cases and Insulating Materials

It’s smart to invest in good quality protective cases specifically designed for lithium batteries that not only protect them from physical damage but also help in insulating them against temperature changes. These cases are especially useful if you’re carrying multiple batteries, like spares for your medical devices or power banks for long flights.

KEEN TIP: If you don’t have a protective case, place tape over the terminals. Both the TSA and FAA emphasize the importance of keeping the terminals covered to avoid accidental contact with metal objects, which could cause a short circuit.

The FAA also recommends using fireproof bags for added safety, especially for larger or multiple batteries. These bags can contain a fire should a battery malfunction, giving you and the flight crew valuable time to react.

Here are the current FAA regulations for how to carry lithium batteries.

2.3 What to Do with Damaged or Recalled Batteries

If you’ve got a battery that’s damaged or has been recalled, do not try to bring it on a plane. Damaged batteries are a serious safety hazard and can cause all sorts of problems, from overheating to catching fire.

3. Understanding Different Types of Lithium Batteries

3.1 Common Devices That Use Lithium Batteries

Lithium batteries are in just about everything these days—from smartphones and laptops to medical devices like insulin pumps and portable oxygen concentrators. Each type of device has different battery requirements, so it’s important to know what you’re dealing with.

3.2 Differences Between Lithium-Ion and Lithium-Metal Batteries

Lithium-ion batteries are rechargeable and are commonly found in devices like laptops and smartphones.

Lithium-metal batteries, on the other hand, are usually single-use and have a higher energy density, which can make them more dangerous if not handled correctly. They are found in medical devices. The FAA has specific guidelines for these batteries, particularly in terms of how they should be packed and transported.

3.3 Specific Packing Rules for Each Type of Battery

When it comes to packing, lithium-ion batteries are generally safer and easier to travel with as long as they’re in your carry-on and properly insulated. You will typically be asked to place them in ‘Airplane’ mode while in the air.

Lithium-metal batteries, due to their higher risk, must be packed with extra care. If you’re traveling with medical devices that use lithium-metal batteries, make sure they’re securely packed in a case that’s both shockproof and insulated.

PRO TIP: The FAA advises that you always carry a few spare batteries, especially if you’re traveling internationally where replacements might not be as readily available. Place each battery in its own non-conductive container or case.

3.4 Special Considerations for Medical Devices and Power Banks

Medical devices need special attention, not just because they’re vital, but also because they often have larger batteries. For example, a portable oxygen concentrator might have a battery that’s close to the 300-watt-hour limit. It’s important to get airline approval ahead of time for such large batteries.

Power banks, while common, also require careful packing—especially since some can exceed the 100-watt-hour threshold. Always double-check the specifications and pack accordingly.

4. International Travel Considerations

4.1 Key Differences in International vs. Domestic Regulations

Traveling internationally with lithium batteries can be a whole different ball game; what’s allowed in the U.S. might not fly in Europe or Asia. For example, some countries have stricter limits on the watt-hour rating of batteries you can bring on board.

4.2 Tips for Travelers Flying to or From Countries with Stricter Rules

My tip is to travel light if possible. If you’re flying to a country with stricter regulations, try to minimize the number of spare batteries you bring and ensure that each one is properly packed and labeled.

Having a doctor’s letter explaining the necessity of your medical devices can also smooth the process at security checkpoints.

The FAA advises that international travelers should always check the battery regulations for each country on their itinerary to avoid any issues at customs. A good way to do this is to check your airline’s guidelines—they often align with the destination country’s rules and might be more restrictive than TSA and FAA guidelines.

4.3 How to Handle Customs and Security Checks

Customs can be tricky when traveling with lithium batteries, especially if you’re carrying multiple devices or spares.

One tip is to keep all your batteries together in one easily accessible part of your carry-on. This makes it easier to show them to customs officers without having to dig through your entire bag.

4.4 The Importance of Carrying a Doctor’s Letter for Medical Devices

I can’t stress this enough: if you’re traveling with medical devices, always carry a doctor’s letter. This letter should explain why the device is necessary and provide details on the battery type and capacity.

A doctor’s letter can make all the difference when dealing with security personnel who might not be familiar with the specifics of your device.

5. What to Do in Case of Battery Malfunctions During Flight

Battery malfunctions can happen, and when they do, it’s important to know the signs. Overheating, swelling, and strange smells are all red flags. If you notice any of these, inform the flight crew immediately. 

Flight attendants are trained to deal with overheating batteries; they have fire containment bags that can safely store a malfunctioning battery until the plane lands. I can assure you they will appreciate that you took steps to prevent a larger issue.

6. Frequently Asked Questions (FAQ’s)

6.1 Are there any restrictions on the number of lithium batteries I can bring on a flight?

Yes, there are restrictions on the number of spare (uninstalled) lithium batteries you can carry. For most devices with batteries under 100 watt-hours, there is no limit to the number of devices or batteries you can carry in your carry-on. However, for larger batteries (100-300 watt-hours), you are typically limited to two spare batteries. Any batteries over 300 watt-hours require airline approval.

6.2 Can I pack lithium batteries in my checked luggage?

You shouldn’t pack loose lithium batteries in checked luggage due to the risk of fire. Most airlines and the FAA require that spare lithium batteries be carried in your carry-on baggage.

6.3 What should I do if I need to fly with a large lithium battery, such as one for a wheelchair or mobility device?

If you’re flying with a large lithium battery (over 300 watt-hours) for a wheelchair or mobility device, you’ll need to contact the airline in advance. The FAA requires airlines to allow such batteries, but advance notice is necessary to ensure proper handling and storage. Airlines may provide specific instructions for packaging and transporting these batteries safely.

6.4 Are there special considerations for flying with lithium batteries on international flights?

Yes, international flights may have different regulations regarding lithium batteries, depending on the destination country’s aviation authority. It’s important to check the specific regulations for each country you will be traveling to or through, as they may be stricter than U.S. regulations. Additionally, bring documentation if you are carrying a medical device such as a doctor’s note, in both English and the language of the destination.

6.5 Can I bring lithium batteries in a battery-powered electronic cigarette or vaping device on a plane?

Yes, you can bring lithium batteries in battery-powered electronic cigarettes or vaping devices on a plane, but there are specific rules. The device must be carried in your carry-on luggage or on your person, and it should not be placed in checked baggage. Additionally, the FAA requires that the device be turned off and not charged during the flight to prevent accidental activation.

7. Wrap Up

Flying with lithium batteries, particularly in medical devices, requires some preparation, but it’s entirely manageable if you know the rules and take the right precautions.

The key is to stay informed about the latest TSA and FAA guidelines, pack your batteries safely, and be prepared for any potential issues that could arise during your flight.

So, next time you’re packing for a trip, give a little extra thought to your lithium batteries. Whether it’s for a power bank, CPAP machine or just your everyday gadgets, following these guidelines will help you avoid any unwanted surprises both at the airport and on your flight.

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