Aviation safety, passenger convenience, and the growing prevalence of portable electronics converge in the regulation of lithium batteries. This article examines IATA’s current and emerging guidelines, the underlying science of lithium battery hazards, and practical steps to ensure the safe carriage and shipment of lithium batteries by air.
1. Introduction: The Ubiquity and Risk of Lithium Batteries
From smartphones and laptops to drones, e-bikes, and smart luggage, lithium-based batteries power nearly every portable electronic device of modern life. The same properties that make them efficient—high energy density, rechargeability, and lightweight construction—also make them potentially hazardous in the aviation environment. When improperly packed, damaged, or short-circuited, lithium batteries can enter thermal runaway, a rapid self-heating reaction that can cause fires or explosions.
As of October 2025, global aviation authorities report a sharp rise in lithium battery incidents. The U.S. Federal Aviation Administration (FAA) has documented 50 verified cases of smoke, fire, or extreme heat from lithium batteries on U.S. flights through August alone—averaging over one per week. Internationally, incidents include an Air China flight's emergency landing in October due to a spontaneous battery combustion in carry-on luggage and a South Korean tarmac fire in January linked to a power bank. These events underscore the urgency of compliance with evolving regulations from bodies like the FAA, the Transportation Security Administration (TSA), the International Air Transport Association (IATA), and the European Union Aviation Safety Agency (EASA).
Such incidents are particularly dangerous in aircraft, where accessibility and suppression are limited. The International Air Transport Association (IATA), along with the International Civil Aviation Organization (ICAO), has thus established stringent global standards to ensure that these batteries can be carried and transported safely.
2. Understanding Lithium Batteries: Types and Ratings
Lithium batteries fall into two primary categories, each with distinct risks and regulatory treatment:
1) Lithium Metal Batteries (non-rechargeable)
a) Contain metallic lithium.
b) Common in small devices like watches, cameras, and remotes.
c) Classification: UN 3090 (batteries only), UN 3091 (batteries in/with equipment).
2) Lithium-Ion Batteries (rechargeable)
a) Contain lithium in ionic form.
b) Used in laptops, phones, tablets, and power banks.
c) Classification: UN 3480 (batteries only), UN 3481 (batteries in/with equipment).
Every battery shipped or carried on an aircraft must meet the UN Manual of Tests and Criteria, Part III, Subsection 38.3, ensuring its resilience against vibration, thermal shock, and overcharge.
3 . The Regulatory Framework: Key Authorities and 2025 Updates
Air travel regulations harmonize under the International Civil Aviation Organization (ICAO), but implementation varies by region. Here's a breakdown:
Authority | Scope | Key 2025 Focus |
FAA (U.S.) | Domestic and international U.S. carriers | Issued a September safety alert urging airlines to enhance passenger communications on battery risks; no major limit changes, but reinforced carry-on-only for spares. Updated PackSafe guidelines in February. |
TSA (U.S.) | Security screening | Aligns with FAA; emphasizes removal of spares from gate-checked bags. Final decisions at checkpoints rest with officers. |
IATA | Global airlines and cargo | 66th Edition Dangerous Goods Regulations (DGR) effective 2025 introduces a 3m stack test for non-UN packaging of batteries in equipment (Packing Instructions 966-II, etc.); new FAQs for sodium-ion batteries; multilingual traveller campaigns launched in October. |
EASA/ICAO (EU/International) | EU and global harmonization | May Safety Information Bulletin (SIB) reinforces passenger restrictions; October ICAO alert on cabin fire response; 300 Wh limit for mobility aid batteries; bans unmarked power banks on Chinese domestic flights. |
These updates reflect a post-pandemic surge in device usage and incidents, with IATA's global campaign emphasizing proper handling to prevent mishaps.
4. Passenger Carriage: IATA Guidance for Air Travelers
IATA’s Passenger Lithium Battery Guidance Document defines what passengers can safely carry on board or check in. The most critical distinction is between installed and spare batteries. Passengers often carry an average of four such devices per flight, amplifying potential hazards. Always check markings on the battery or device for Wh ratings; if absent, consult the manufacturer.
The golden rule: Spare lithium batteries must always travel in carry-on baggage. Checked baggage poses insurmountable risks, as fires in cargo holds are hard to detect and extinguish.
4.1. Installed Batteries (In Devices)
Devices with lithium batteries (phones, laptops, cameras, tablets) are generally allowed in both carry-on and checked baggage.
a) Carry-On: Unlimited for personal use, provided under 100 Wh. Devices like laptops must be powered off and protected.
b) Checked Baggage: Permitted if the device is fully protected from accidental activation and damage (e.g., padded in a case).
However, post-2025 FAA guidance strongly recommends carry-on to allow quick access in emergencies.
4.2. Spare Batteries (Including Power Banks)
a) Spare lithium batteries, including power banks and vape devices, must be carried in carry-on baggage only.
b) Checked baggage carriage is prohibited, as fires in cargo holds are difficult to detect or extinguish.
c) Terminals must be insulated (e.g., by taping over contacts or using protective pouches) to prevent short-circuit.
d) Gate-Checked Bags: Remove all spares before handing over; keep them in the cabin.
4.3. Capacity and Quantity Limits
IATA uses Watt-hour (Wh) rating for lithium-ion batteries and lithium content (grams) for lithium metal batteries:
Battery Type | Carry-On Limit | Checked Limit | Approval Needed? |
Installed ≤100 Wh | Unlimited | Allowed (protected) | No |
Spare ≤100 Wh | Unlimited | Prohibited | No |
Installed/Spare 101–160 Wh | Up to 2 spares | Prohibited for spares | Yes (airline) |
>160 Wh | Prohibited | Prohibited | N/A |
Lithium metal ≤ 2 g | Permitted. | Prohibited | No |
Lithium metal > 2 g | Prohibited | Prohibited | N/A |
These limits apply to most personal electronics. High-capacity batteries (e.g., for professional film cameras, drones, or medical equipment) require explicit airline approval before travel.
5. Specific Items and Scenarios
a) Power Banks and Portable Chargers: Top incident culprits (39% of FAA cases since 2006). Carry-on only; no charging devices onboard with them (e.g., Southwest Airlines ban since May 2025). South Korea mandates clear safety markings.
b) E-Cigarettes and Vapes: Carry-on only; batteries must be removed and protected. No use or charging onboard. Prohibited in checked bags.
c) Laptops and Tablets: Carry-on preferred; if checked, ensure shutdown and padding. Extended-life batteries may need approval.
d) Medical Devices (e.g., CPAP Machines): Exempt from Wh limits if for personal medical use; notify airline in advance.
e) Commercial Quantities: Prohibited; only personal-use batteries allowed.
5.1. Packing and Handling Best Practices
To prevent short-circuiting—the primary trigger for thermal runaway—follow these steps:
a) Protect Terminals: Use original packaging, tape over contacts, or non-conductive pouches.
b) Avoid Extremes: Do not expose to heat (>140°F), cold, or moisture; turn off devices.
c) Stowage: Keep visible and accessible (e.g., seat pocket, not buried in overhead bins) for quick monitoring.
d) Charging: Use only aircraft seat power; no power banks onboard.
e) Pre-Flight Check: Verify no damage (e.g., swollen batteries) and review airline policy via apps or websites.
IATA's 2025 multilingual resources offer visual guides for packing.
5.2. Damaged, Defective, or Recalled Batteries
Do not fly with these—ever. Cracked screens, swelling, or recalls indicate internal damage priming thermal runaway. Check the U.S. Consumer Product Safety Commission (CPSC) or manufacturer sites. Remove and dispose safely per local hazardous waste rules; airlines may offer disposal guidance. In 2025, millions of chargers and vapes were recalled globally for fire risks.
5.3. Smart Baggage and Emerging Technologies
“Smart luggage” — bags containing built-in tracking, charging, or weighing systems — has prompted additional restrictions.
IATA’s Guidance on Smart Baggage with Integrated Lithium Batteries and Electronics mandates:
a) Lithium batteries must be removable if the bag is checked in.
b) Smart bags with non-removable batteries are only allowed as carry-on items.
c) If the battery exceeds 100 Wh or 2 g lithium, airline approval is required even for carry-on.
Airlines such as Lufthansa, Emirates, and Air India have adopted these standards, aligning their policies with IATA’s baseline.
6. Air Transport as Cargo: The IATA Dangerous Goods Regulations (DGR)
The IATA Dangerous Goods Regulations (DGR) provide the definitive framework for the safe shipment of lithium batteries by air. The relevant Packing Instructions (PI) are:
1) PI 965 — Lithium-ion batteries (UN 3480)
2) PI 966/967 — Lithium-ion batteries packed with/in equipment (UN 3481)
3) PI 968 — Lithium metal batteries (UN 3090)
4) PI 969/970 — Lithium metal batteries packed with/in equipment (UN 3091)
6.1. State of Charge (SoC) Limit
For stand-alone lithium-ion batteries (UN 3480), IATA mandates that they be shipped at no more than 30% State of Charge (SoC). This significantly reduces the likelihood of thermal events during transport.
From 1 January 2026, this 30% SoC restriction will extend to batteries packed with equipment (UN 3481) and vehicle batteries (UN 3556), reflecting growing concern over energy storage devices in larger systems.
6.2. Packaging, Marking, and Labelling
All lithium battery shipments must:
a) Use UN-specification packaging tested to withstand pressure and impact.
b) Display the lithium battery mark — a black battery symbol with red hatching and a telephone number for additional information.
c) Include proper documentation and dangerous goods declarations (where applicable).
Failure to comply can lead to shipment rejections, regulatory penalties, or, in worst cases, in-flight fires.
7. Operational Considerations for Airlines and Crew
7.1. Cabin Safety and Fire Mitigation
a) Flight and cabin crew should be trained to identify signs of battery failure — swelling, overheating, smoke, or odor.
b) IATA recommends the use of non-alcoholic water or halon extinguishers for initial flame suppression, followed by cooling with water to prevent re-ignition.
c) Passengers should immediately report dropped or damaged devices in seat mechanisms.
7.2. Dispatch and Ground Handling
a) Ground personnel must verify the correct packing instructions and SoC compliance for any battery shipments.
b) Safety management systems (SMS) should integrate lithium battery carriage procedures, risk assessments, and incident reporting mechanisms.
c) Airlines are encouraged to pre-emptively align with the 2026 SoC amendment to avoid last-minute operational disruptions.
7.3. Passenger Communication
a) Airline websites, check-in counters, and pre-flight announcements must clearly communicate lithium battery restrictions.
b) Harmonized signage (following IATA templates) improves compliance and reduces confrontations at security checkpoints.
7.4. Responding to an Emergency
If you notice overheating, smoke, or fire:
a) Alert Crew Immediately: Do not attempt to extinguish yourself—crews are trained with specialized tools like fire sleeves and cooling agents.
b) Evacuation Protocol: Follow crew instructions; isolate the device if possible.
c) Post-Incident: Report via FAA's hotline (1-866-TELL-FAA) to aid research.
8. Regulatory Evolution and Future Outlook
Lithium battery transport remains one of the most rapidly evolving areas in dangerous goods regulation. IATA’s 66th Edition (2025) DGR introduces several critical updates:
a) Expanded rules for sodium-ion batteries, an emerging lithium alternative.
b) Mandatory SoC limitation for more categories of batteries.
c) Revised training frameworks under ICAO’s competency-based training and assessment (CBTA) model.
As eVTOL aircraft, drones, and electric ground vehicles proliferate, the interface between passenger transport and energy storage will grow even more complex. A coordinated approach—linking design standards, certification, and transport regulation—will be key to ensuring both operational efficiency and public safety.
DGCA currently follows ICAO/IATA baselines; multiple Indian news outlets (Oct 2025) report DGCA is actively considering stricter rules for power banks after several incidents.
9. Recent Incidents and Emerging Trends
2025 has seen a 42% rise in U.S. lithium fires over five years, driven by increased device carriage. Notable events:
a) August: American Airlines emergency landing after device fire post-takeoff.
b) September: FAA alert following 50 incidents, including injuries and diversions.
c) October: Air China diversion; Airbus guidance on in-flight risks.
Trends point to power banks as primary offenders, prompting bans like Southwest's on onboard charging. Research into detection tech (e.g., EASA projects) promises future enhancements.
10. Summary and Best Practices
3.1. For Passengers:
1) Carry spare lithium batteries and power banks only in cabin baggage.
2) Protect terminals to prevent short-circuits.
3) Do not pack spares in checked baggage.
4) Obtain airline approval for batteries exceeding 100 Wh.
5) Remove or switch off batteries in smart baggage if checking in.
6) If a bag is selected for gate Check-in, remove all electronic items and batteries.
3.2. For Airlines and Operators:
1) Train crew and ground staff in lithium battery hazard recognition and response.
2) Verify SoC and packaging compliance for all shipments.
3) Integrate IATA’s latest DGR changes into manuals and SMS.
4) Communicate restrictions clearly to passengers at every touchpoint.
11. Conclusion
Lithium batteries are indispensable to modern life—but their energy potential demands respect and regulation. Flying with lithium batteries is safe when passengers prioritize knowledge and caution. Adhere to carry-on mandates, secure approvals for larger capacities, and pack proactively to sidestep the rare but severe risks of thermal runaway. As aviation evolves with battery-dependent tech, staying informed via official sources like FAA PackSafe or IATA's DGR ensures not just compliance, but collective safety. Bon voyage—powered responsibly.
References
1) IATA. Lithium Battery Guidance Document (2025 Edition).
2) IATA. Passenger Lithium Battery Guidance.
3) IATA. Dangerous Goods Regulations (66th Edition, 2025).
4) ICAO. Technical Instructions for the Safe Transport of Dangerous Goods by Air (Doc 9284).
5) RRC Power Solutions. New IATA Regulations for Lithium Battery Transport (2025–2026).
6) Lion Technology. State of Charge Recommendations for 2025.
7) Reuters. Airlines Updating Lithium Battery Policies (2025).
Author: GR Mohan
