Replacing a swollen (“bloated” or “puffed”) lithium‑polymer (LiPo) battery is not a routine repair—it’s a safety exercise. This guide walks you through exactly what to do, when to stop and seek professional help, and how to dispose of the damaged pack responsibly.
- Difficulty: Beginner to intermediate (varies by device)
- Time: 20–90 minutes (RC packs on the shorter end; embedded devices should usually be serviced professionally)
- Read first: If at any point you see smoke, hear hissing, or feel unusual heat, stop, move away, and call emergency services.
Important citations appear inline to back up safety and disposal steps.
1) Before You Start: Safety Warning
Stop using a swollen LiPo immediately. Do not charge it, puncture it, compress it, or try to “fix” it. The safest first steps are to power down, unplug from any chargers, and isolate the device/battery from flammables. Consumer safety pages from the U.S. EPA state not to put lithium‑ion batteries in the trash or curbside recycling and to tape terminals and bag batteries before drop‑off, guidance reiterated in the 2024–2025 era on the agency’s consumer page: see the EPA “Used Lithium‑Ion Batteries” guidance.
If you’re dealing with an embedded battery in a phone, tablet, or laptop, most people should not open the device themselves due to puncture and fire risk. The repair community’s guidance stresses powering down and taking the device to a professional in a fire‑safe container, as summarized by iFixit’s “What To Do with a Swollen iPhone Battery” (2018+, still referenced by their current repair docs).
2) Identify Swelling and Triage Your Situation
Look for these signs:
- Screen lifting from the frame or case seams separating
- Soft bulge when you press gently on the device back (don’t force it)
- Chemical or sweet solvent odor, unusual heat, or hissing
Choose your path:
- Embedded consumer device (phone/tablet/laptop): Follow Section 4 (service‑first)
- Removable RC LiPo pack (drones, cars, planes): Follow Section 5 (DIY with precautions)
Tip: Many hobby educators consider persistent swelling a retirement sign for the pack, not something to “recover.” See RC Helicopter Fun on puffed LiPos (updated over multiple years).
3) Gather PPE, Tools, and Set Up a Fire‑Safe Workspace
Prepare before you touch anything:
- PPE: safety glasses and gloves
- Non‑flammable surface: metal tray, ceramic tile, or concrete
- Ventilation: work in a well‑ventilated area
- Containment: LiPo‑safe bag or a metal container partially filled with sand
- Fire readiness: keep a household ABC extinguisher nearby and know your exit path; consumer guidance from fire safety organizations emphasizes prevention and calling 911 for battery incidents, as reiterated in the NFPA’s lithium‑ion safety resources hub
- Non‑conductive tools: plastic cards/spudgers; avoid sharp metal near pouches
Why this matters: Swollen LiPos can vent flammable gases; minimizing puncture/compression risk and having containment on hand reduces the chance of escalation.
4) If Your Battery Is Inside a Consumer Device: Safe Next Steps (Service‑First Path)
Most users should not DIY this. Here’s the safer route:
- Power down and unplug the device. If it’s still on, shut it down normally—don’t force the screen closed if it’s lifted.
- Do not charge it “one last time.”
- Place the device in a LiPo bag or a metal container with some sand. Transport it to an authorized repair provider or e‑waste/battery recycling site.
- The EPA advises to tape terminals and bag batteries and never place them in household trash or municipal recycling. See the EPA “Used Lithium‑Ion Batteries” page (accessed 2025).
- If you must open the device (advanced users only), reduce risk:
- Discharge the battery below roughly 25% when it’s safe to do so (before swelling becomes severe). Several current iFixit guides include this precaution to lessen heat if accidentally damaged, for example the iFixit Microsoft Surface Pro 6 Battery Replacement y iFixit MacBook Pro 14‑inch (Late 2023) Battery Replacement.
- Work on a non‑flammable surface with PPE and containment ready.
- Use non‑metallic, dull tools around the pouch. Do not pry against the cell.
- If you see smoke/odor/heat, stop, isolate, and seek help.
Expected outcome: Either a professional handles the replacement, or an advanced user proceeds with extreme caution. For everyone else, do not proceed with DIY on embedded batteries.
5) If You Have an RC LiPo Pack: Removal and Replacement Steps
These steps assume a removable pack (quadcopters, RC cars/planes, some power banks/tools). Move slowly and avoid bending the pouch.
Step A — Isolate and remove the swollen pack
- Power down the model and disconnect all power.
- Gently release any straps/Velcro. Support the pack—don’t yank by the leads.
- Avoid flexing or squeezing the swollen pouch. Lift using the edges.
- Immediately cover the main leads’ exposed metal with electrical tape or use terminal caps to prevent shorting.
- Place the pack into a LiPo bag or metal container with sand.
Step B — Verify your replacement pack’s specs before installing
- Voltage/cell count: Match exactly (e.g., 3S = 11.1 V nominal). Mismatching can damage electronics.
- Capacity (mAh) and C rating: Choose suitable values for your application.
- Connector type and polarity: Ensure the same plug and correct wiring.
- Physical size/weight: Confirm it fits and doesn’t upset balance/CG.
Note: Charger manuals emphasize balance charging and selecting appropriate current for LiPo packs. For example, SkyRC’s product manuals and pages outline balance charge modes and current selection, such as the SkyRC B6ACneo balance charger page.
Step C — Install the new pack
- Place the new pack securely with padding/straps so it cannot move or chafe.
- Route wires away from props/gears and hot components.
- Double‑check polarity before connecting.
Step D — First charge procedure (conservative)
- Use a quality balance charger in LiPo balance mode.
- Set a conservative current (commonly up to 1C max; lower is fine for initial cycles). Monitor cell voltages.
- Charge on a non‑flammable surface, in a LiPo bag or fire‑resistant area, and stay nearby during the entire first charge.
- Stop immediately if you notice swelling, odor, or unusual heat. RC education sites stress that persistent swelling means the pack is unsafe—see RC Helicopter Fun on puffed LiPos.
Expected outcome: A properly spec’d replacement installed, first charged safely in balance mode, with no abnormal heat or swelling.
6) Post‑Replacement Checks
After installation and the first charge:
- Feel for abnormal warmth after a short, gentle test run. Any heat or odor? Stop.
- Verify the device/model operates normally (no resets, brownouts, or cutoffs).
- For RC: update your charger profile and low‑voltage cutoff settings as needed.
- If storing, charge/discharge to storage voltage and keep packs in a cool, dry place. Hobby educators discuss storage best practices; see an overview at RC Helicopter Fun’s storage guide.
7) How to Dispose of the Swollen Battery (U.S., 2025)
Never throw it in the trash or curbside recycling. Follow this prep:
- Tape the terminals with non‑conductive tape and bag the battery individually. The EPA consumer page on used lithium‑ion batteries explicitly recommends taping and bagging.
- Use a certified drop‑off or household hazardous waste (HHW) program. Call2Recycle’s consumer page says to “bag or tape your batteries” before drop‑off and provides a locator—see Call2Recycle “Recycle Your Batteries” and the Call2Recycle locator.
- Do not mail damaged, defective, or recalled (DDR) lithium batteries. USPS policy states these are nonmailable hazardous materials. See USPS Postal Bulletin 22600 update on DDR lithium batteries y USPS Publication 52 overview.
If a manufacturer runs a recall/return, follow their exact instructions and packaging—they’ll provide compliant shipping materials if mailing is required.
8) Troubleshooting: If You See Smoke, Smell Odors, or Feel Heat
- Unplug power if you can do so safely.
- Move the device/battery away from combustibles, ideally outdoors or to a non‑flammable area.
- Isolate it in a metal container with sand or a LiPo bag and monitor from a safe distance.
- If flame appears, evacuate and call 911 immediately. Consumer fire‑safety messaging, including the NFPA’s lithium‑ion safety resources, emphasizes calling emergency services and prioritizing life safety over property.
9) Myths and Mistakes to Avoid
- “Saltwater disposal” for LiPos: Outdated and discouraged. Use proper taping/bagging and certified recycling—per the EPA guidance on used Li‑ion batteries y Call2Recycle consumer prep.
- Freezing, puncturing, or “flattening” a puffed pouch: Dangerous—don’t do it. Repair pros advise against it; see iFixit’s swollen battery guidance and hobby education at RC Helicopter Fun.
- Reconditioning a swollen LiPo: Don’t attempt it. Replace and recycle instead.
10) Quick Checklists and Resources
Do/Do‑Not
- Do: Power down, isolate, wear PPE, set up a fire‑safe workspace.
- Do: Tape terminals, bag individually, and use certified recycling/HHW.
- Don’t: Charge, puncture, compress, mail DDR packs, or trash them.
PPE & Setup
- Safety glasses, gloves, non‑conductive tools
- Non‑flammable surface and good ventilation
- LiPo‑safe bag or metal container with sand; ABC extinguisher nearby
RC First‑Charge Protocol
- Balance mode, conservative current (≤1C), monitor cell voltages and temperature; stop if swelling/odor/heat appears. Charger documentation (e.g., SkyRC B6ACneo page) covers balance modes and current selection principles.
Resource Links
- EPA: Used Lithium‑Ion Batteries (consumer guidance)
- Call2Recycle: Recycle Your Batteries (prep + locator) y Drop‑off Locator
- USPS: DDR lithium batteries are nonmailable (Postal Bulletin 22600); Publication 52 overview
- NFPA: Lithium‑Ion Battery Safety hub
- iFixit: What To Do with a Swollen iPhone Battery
- RC education: Puffed LiPo overview; Charging LiPo batteries; Storage best practices
- Charger reference: SkyRC B6ACneo
You’ve done the careful thing by approaching this as a safety task first. Replace swollen packs, don’t try to fix them, and lean on professional service for embedded batteries. If in doubt at any step, stop and seek help.
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