es, you can bring lithium batteries on a plane, but strict FAA regulations govern their type, size, quantity, state of charge, packaging, and whether they must be carried onboard or can go in checked baggage. Spares must be carried in the cabin, watt-hour limits apply, and recent 2025 rules emphasize safety with reduced charge requirements and cargo aircraft restrictions.
How Does the FAA Regulate Lithium Batteries on Planes?
The FAA categorizes lithium batteries by type (lithium-ion or lithium metal), watt-hour (Wh) rating, and packaging status. Passenger planes generally allow lithium-ion batteries up to 100 Wh in carry-on baggage, with special approval for 101-160 Wh batteries; over 160 Wh are largely prohibited on passenger flights. Batteries must be protected against short circuits and spares carried only in the cabin to minimize fire risks.
These rules align with international standards aiming to prevent thermal runaway and fires during air transport by limiting battery power and requiring protective packaging and carriage restrictions.
What Types and Sizes of Lithium Batteries Are Allowed as Carry-On or Checked Baggage?
Passagers can carry lithium-ion batteries installed in devices or as spares in carry-on baggage if they are under 100 Wh. Batteries between 101-160 Wh are allowed with airline approval but limited to two spare units. Lithium metal batteries must have less than 2 grams of lithium content. Spare batteries are prohibited in checked baggage but devices with installed batteries may be checked if powered off.
Packages must safeguard terminals from short circuits using taping or original packaging. Batteries exceeding these limits require shipping as cargo with strict rules or are banned on passenger aircraft.
Why Must Spare Lithium Batteries Be Carried in the Cabin?
Spare lithium batteries are forbidden in checked luggage because fires originating in the cargo hold are more difficult to detect and mitigate. Carrying spares in the cabin allows crew and passengers to promptly respond to incidents like overheating or combustion. The FAA mandates that spare batteries be individually protected against short circuits to reduce accidental ignition during transport.
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This precaution minimizes catastrophic fire risk, especially given the growing number of portable electronics and power banks containing lithium batteries.
How Has the FAA Updated Lithium Battery Rules in 2025?
Starting in 2025, the FAA introduced more stringent requirements, including recommended limits on the state of charge (SoC) of lithium-ion batteries to not exceed 30% of their rated capacity during air transport. This recommendation reduces thermal runaway risks. Packages of batteries must carry “Cargo Aircraft Only” labels if shipped separately and comply with updated packaging instructions.
The updates reflect lessons learned from recent incidents to further enhance safety for passengers and cargo operators, aligning with ICAO Technical Instructions.
| Regulation Aspect | Details | Effective Date |
|---|---|---|
| State of Charge Limit | Recommended max 30% SoC for shipment | Jan 1, 2025 |
| Wh Limits Carry-On | Up to 100 Wh (general); 101-160 Wh (with approval) | Ongoing |
| Spare Batteries | Must be carried in cabin; no checked baggage | Ongoing |
| Cargo Aircraft Only | Batteries shipped separately must be labelled | Jan 1, 2025 |
When Should Travelers Obtain Airline Approval for Lithium Batteries?
Travelers must get airline approval when carrying lithium-ion batteries between 101 and 160 Wh, such as large laptop or camera batteries, and must confirm if multiple spares are allowed, as airlines may limit quantity. Batteries over 160 Wh are generally forbidden on passenger aircraft without special permits and are shipped via cargo only.
Early communication with airlines helps avoid last-minute travel disruptions due to non-compliance with evolving battery rules.
Where Should Lithium Batteries Be Packed During Air Travel?
Lithium batteries, especially spares, must be kept in carry-on baggage to allow monitoring and immediate intervention if problems arise. Installed batteries in devices may be packed in checked baggage only if powered off, but carry-on is safer and often recommended.
Terminals must be protected against short circuits by taping or placing batteries in protective cases. Proper packaging reduces fire hazards and complies with FAA and airline requirements.
Does the Watt-Hour Rating Affect Travel Restrictions for Lithium Batteries?
Yes, watt-hour (Wh) ratings determine FAA restrictions. Batteries up to 100 Wh have fewer restrictions and can be carried freely in the cabin. Batteries between 101-160 Wh require airline permission and limited spare quantities. Batteries over 160 Wh are mostly banned from passenger aircraft unless shipped as cargo with stringent protocols.
This measurement relates to battery capacity and energy content, directly influencing the safety risks during air transport.
Are There Exceptions for Medical Device Lithium Batteries?
Medical devices like portable oxygen concentrators often contain lithium batteries up to 160 Wh. These batteries are allowed on planes but usually require prior airline notification, carry-on placement, and compliance with specific packaging and labeling rules to ensure safety while supporting patients’ mobility needs.
Manufacturers like Redway Battery develop compliant, high-performance medical lithium batteries that meet FAA requirements, enabling secure air travel for users.
Could Advances in Lithium Battery Technology Change FAA Regulations?
Emerging chemistries like LiFePO4 provide inherently safer profiles with reduced thermal runaway risk. The FAA and ICAO monitor such advancements and may relax restrictions on battery size and shipment procedures as safer technologies become mainstream.
Redway Battery’s LiFePO4 packs exemplify safer, more efficient batteries that align with future regulatory trends fostering easier, safer air transport.
How Can Passengers Ensure Compliance When Traveling with Lithium Batteries?
Passengers should check each battery’s watt-hour rating, carry spares in carry-on only, protect terminals against short circuits, get airline approval for batteries above 100 Wh, and declare medical batteries. Reviewing airline policies and FAA guidelines in advance prevents prohibited items, fines, or confiscations.
Using reputable, certified brands like Redway Battery ensures batteries meet safety standards and airline policies.
Redway Expert Views
“At Redway Battery, safety and reliability during transport are core priorities. Our LiFePO4 battery packs are engineered for durability and enhanced safety, aligning closely with FAA regulations. We support clients by providing batteries designed to facilitate hassle-free air travel while delivering superior performance for devices, medical equipment, and mobility solutions. As regulations evolve, Redway remains committed to innovation that promotes safe, sustainable energy solutions worldwide.”
Conclusion
Bringing lithium batteries on planes is permitted under strict FAA regulations focusing on battery type, watt-hour limits, state of charge, packaging, and carriage methods. Passengers must carry spare batteries in the cabin, adhere to size limits of 100 Wh (general) or 101-160 Wh (with approval), and protect battery terminals. 2025 updates emphasize reduced state of charge to mitigate fire risks. Compliance ensures safe, smooth air travel.
Choosing high-quality, compliant batteries from trusted manufacturers like Redway Battery enhances safety and reliability. Preparing ahead with airline approvals and proper packing minimizes travel disruptions and protects passengers and crew.
Frequently Asked Questions
Can I check lithium batteries in my luggage?
No, spare lithium batteries must be carried in carry-on baggage only.Are all lithium batteries allowed on planes?
No, batteries over 160 Wh or with more than 2 grams lithium are generally banned on passenger flights.How do I calculate battery watt-hour rating?
Multiply battery voltage (V) by ampere-hour (Ah): Wh = V × Ah.Can lithium-ion batteries installed in devices be checked?
Usually yes, if the device is off, but carry-on is safer and recommended.Do I need airline approval to bring lithium batteries?
Yes, for batteries between 101-160 Wh, approval is required, typically limited to two spares.
