Lithium battery regulations: what you need to know right now
Can a phone battery stop a plane? Not usually — but lithium batteries are the one item regulators watch closest. Rules exist because these batteries can overheat, catch fire, or short-circuit. This page gives clear, practical rules for travel, shipping, testing, and everyday safety.
Start with the basics: there are two main types to watch for. Lithium-ion (rechargeable) is used in phones, laptops, e-bikes. Lithium metal (primary, non-rechargeable) powers some cameras and medical devices. International transport treats them differently and assigns UN numbers: UN3480 for lithium-ion cells, UN3481 when packed with or contained in equipment, and UN3090/UN3091 for lithium metal.
Air travel rules: carry-on is your safest bet
Most airlines follow IATA rules. For passengers: spare lithium batteries must be in carry-on only — never in checked baggage. Small devices and batteries under 100 Wh (watt-hours) are generally allowed in carry-on without airline approval. For larger batteries (100–160 Wh), many airlines allow them but require airline approval and limits on quantity. Batteries over 160 Wh are normally forbidden in passenger aircraft.
Practical tips: tape or cover exposed terminals, keep batteries in original packaging or individual plastic bags to stop shorts, and carry chargers in your bag. Many carriers and the FAA recommend keeping lithium-ion batteries at about 30% state-of-charge for air transport to reduce risk.
Shipping and commercial transport: documentation, testing, and labels
If you ship batteries, you’ll hit rules fast. UN38.3 testing is mandatory for lithium cells and batteries before they can be transported as cargo. That testing covers altitude simulation, thermal, vibration, shock, short-circuit, and impact. Packagers must use the correct packing instruction from IATA (air), IMDG Code (sea), or ADR (road in Europe). Expect to add hazardous goods paperwork, the lithium battery handling label, and the proper UN number on the shipment.
Some common shipping mistakes: using weak packaging, failing to declare dangerous goods, and not following the state-of-charge limits carriers require. Reputable carriers will refuse non-compliant shipments — and you can face fines or cargo delays if you ignore the rules.
For businesses, follow technical standards too: IEC 62133 for cell safety, and keep production records and test reports handy. Retailers should check supplier certificates proving UN38.3 testing and compliance with local transport rules.
At home or work, store batteries in a cool, dry place away from metal objects. Recycle or dispose of batteries through official collection points. Don’t toss them in household trash — many jurisdictions have rules and fines for improper disposal.
Want a quick checklist? 1) Know the battery type and Wh or lithium content, 2) Carry spare batteries in carry-on with terminals insulated, 3) Check airline limits and get approvals for >100 Wh, 4) For shipping, confirm UN38.3 test reports and correct labels, 5) Recycle old batteries properly. Follow these steps and you’ll avoid most headaches and keep people safe.
