Traveling with Li Polymer Batteries Safely in 2025

You can bring li polymer batteries and lithium-ion batteries on airplanes in 2025. Almost every traveler carries devices with lithium batteries—about 96% of passengers in 2024 did so, often with multiple items like smartphones and laptops. To fly safely, you must follow airline and TSA rules. Carry spare lithium batteries only in your carry-on. Keep battery terminals protected from short circuits. Remember, lithium batteries in checked bags have strict limits. With the right steps, you can travel safely with your devices.

Airplane Rules for Li Polymer Batteries

Allowed Battery Sizes

You must follow strict regulations when you transport li polymer batteries and lithium-ion batteries by air. Airlines and the TSA set watt-hour (Wh) limits for batteries in carry-on luggage. The table below shows the current rules for 2025:

You can bring any number of li polymer batteries or lithium-ion batteries under 100 Wh in your carry-on luggage. For batteries between 100 Wh and 160 Wh, you need airline approval and can only carry up to two. Airlines do not allow batteries over 160 Wh on passenger flights. These rules help keep everyone safe and follow international air transport and dangerous goods regulations.

Carry-On vs. Checked Bags

You must always carry spare lithium-ion batteries and li polymer batteries in your carry-on luggage. Airlines and the TSA do not allow spare batteries in checked luggage because of fire risks. Devices with installed batteries can go in checked luggage if you turn them off and protect them from damage. You must protect loose batteries from short circuits by using original packaging, plastic bags, or taping the terminals.

Совет: Keep all power banks and spare batteries in your carry-on bag. If you pack them in checked luggage, security may remove them, and you could face penalties.

Lithium battery transport rules exist because lithium batteries can overheat or catch fire. Fires are easier to manage in the cabin than in the cargo hold. This is why regulations require you to keep spare batteries in the cabin. Airlines and the TSA enforce these standards to prevent accidents.

Airline Permission for Large Batteries

If you need to transport large li polymer batteries or lithium-ion batteries between 101 Wh and 160 Wh, you must get airline approval before your flight. Most airlines limit you to two large batteries per person. You must pack these batteries in your carry-on luggage and protect them from damage and short circuits. Airlines may ask for details about the battery, such as un 38.3 certification, to make sure it meets safety standards.

Here is a typical process for getting approval:

1. Contact your airline at least 72 hours before your flight.
2. Provide battery details, including watt-hour rating and un 38.3 certification.
3. Wait for airline instructions and approval.
4. Pack the batteries in protective cases and carry them in your carry-on luggage.

You must follow all requirements and specific regulations for lithium battery transport. Airlines may have extra rules, so always check before you travel. The transport of dangerous goods, like lithium batteries, follows strict standards to keep everyone safe.

Why Battery Safety Matters

Fire and Explosion Risks

You need to understand the risks that come with carrying lithium batteries on airplanes. Lithium polymer batteries can catch fire or even explode if they get damaged or charged the wrong way. Crushing or bending a battery can start a fire. Charging a battery during a flight can also cause problems. Over the past five years, airlines have reported hundreds of incidents involving lithium batteries. Some of these incidents led to fires or explosions.

These numbers show that lithium battery fires are not rare. About 15% of incidents result in fire or explosion. The main dangers come from thermal runaway, physical damage, and improper charging. Fires can spread quickly and cause serious harm to people and property. You must handle lithium batteries with care to protect yourself and others.

Airline Safety Measures

Airlines use many tools and rules to keep you safe from lithium battery fires. Flight crews receive special training to spot and handle battery fires fast. If smoke or fire appears, crew members put on oxygen masks and goggles right away. They use halon or water extinguishers to put out flames. After the fire goes out, they cool the device with water for at least 15 minutes. Only then do they move the device into a fire-resistant containment bag.

Airlines also follow strict rules for transport safety. They do not allow spare lithium batteries in checked bags. They limit the number and size of batteries you can bring. These steps help lower the risk of fire and keep everyone safe. The safety of lithium batteries depends on following these rules and using the right equipment.

Identifying Li Polymer and Lithium-Ion Batteries

Common Devices

You use lithium-ion batteries and lithium polymer batteries every day. These batteries power many of your favorite devices. Knowing which device uses which battery helps you pack and travel safely. The table below shows common devices and their battery types in 2025:

You will find lithium-ion batteries in most laptops and tablets. Cell phones and electric vehicles also use these batteries. Lithium polymer batteries appear in slim laptops, smartwatches, and power banks. Many wireless PC accessories and electronic cigarettes use lithium polymer batteries too. Always check your device manual if you are unsure about the battery type.

Battery Labels

When you travel with lithium batteries, you must check the labels. Airlines and international rules require clear labeling for safe transport. You will see special markings on packages that contain lithium-ion batteries or lithium polymer batteries. These labels help airport staff and you identify the contents quickly.

• Lithium battery handling labels must include:
  • Minimum size of 100mm x 100mm (4” x 4”) with a red border at least 5mm wide
  • Relevant UN identification number (such as UN3480 or UN3481)
  • Telephone number for more information
  • Battery symbol
• If the package is small, the label can be 100mm x 70mm (4” x 2.75”) but must follow the same rules
• Class 9 Dangerous Goods Label:
  • Diamond shape, 100mm per side
  • Top half has 7 black stripes, bottom half is white with a number 9
• Cargo Aircraft Only (CAO) Label means the package cannot go on passenger planes
• Labels must be easy to see on the outside of the package
• You must use strong, durable labels that stay on during travel

Примечание: If you do not follow these labeling rules, airlines may reject your shipment or you could face fines. Always check your battery labels before you fly.

Lithium Battery Transport Best Practices

Inspect Before Packing

Before you travel, always check your batteries to make sure they are suitable for transport. Follow these steps to inspect your lithium batteries:

1. Look closely at each battery for any damage. Watch for broken leads, cracks in the shrink wrap, puffiness, or anything that looks unusual.
2. Use a digital voltmeter to check the voltage of each cell. The voltage should be about 3.8 to 3.9 volts per cell.
3. If you find any damage or the voltage is much lower than expected, do not use or charge the battery. Contact the manufacturer or supplier for advice.

Damaged batteries are not safe for lithium battery transport. Only pack batteries that meet all safety requirements and have un 38.3 certification.

Storage Charge Level

Store your lithium batteries at about 50% charge or lower before you travel. Batteries at partial charge are less likely to cause problems during transport. Regulatory bodies like the FAA and IATA recommend a 30% state-of-charge for removable lithium-ion packs. This helps prevent thermal runaway and keeps your batteries healthy. Avoid storing batteries fully charged or fully discharged, as this can shorten their lifespan and increase safety risks.

Use of Safety Bags

You must protect your batteries from short circuits during lithium battery transport. Place each battery in a separate plastic bag or use a certified fireproof pouch. The LithiumSafe™ Battery Bag is an aviation-grade fire containment bag that meets strict standards and can handle high temperatures. Airlines prefer these bags because they help contain fires and meet EASA and FAA requirements. Always use packaging that can withstand drops and keeps batteries from moving around. Make sure your packaging follows all airline and TSA requirements, including un 38.3 certification labels and clear watt-hour markings.

Совет: Keep your spare batteries in your carry-on and make them easy to access for inspection. Check airline rules before every trip, as lithium battery transport standards can change.

Packing Li Polymer Batteries

Protective Cases

When you travel with lithium polymer batteries, you need a strong protective case. A good case keeps your batteries safe from bumps, drops, and heat. Look for cases with fire-retardant foam liners. These liners help protect against ignition if a battery fails. Choose cases that meet UN HazMat Certification. This means the case follows rules from groups like IATA and the FAA. You want a case that blocks dust, moisture, and extreme temperatures. Some cases use aerospace-strength materials, such as aluminum or tough plastic. Many cases have waterproof seals and strong locks for extra safety. You can see some important features in the table below:

Совет: No case can guarantee total fire protection. Always check with your airline for the latest rules before you fly.

Terminal Protection

You must protect the terminals of your lithium batteries to prevent short circuits. Always cover the terminals with insulating tape or use the original packaging. Never let the terminals touch metal objects. Store each battery in its own bag or case. This keeps the batteries safe from damage and stops them from touching each other. These steps help you avoid fires and follow airline safety rules.

• Use the manufacturer’s original packaging if possible.
• Cover exposed terminals with tape.
• Keep batteries away from coins, keys, or other metal items.

Security Screening

At airport security, you will need to show your lithium batteries. Security officers check that your batteries are not damaged or recalled. They also make sure your batteries have proper packaging and terminal protection. You must keep all spare batteries in your carry-on bag. Security will not allow spare lithium batteries in checked luggage. If you follow these steps, you will pass through screening quickly and safely.

Remember: Security staff want to keep everyone safe. Proper packaging and safe handling make your trip easier.

Damaged Battery Response

Signs of Damage

You need to check your lithium polymer batteries before you travel. Damaged batteries can cause fires or other safety problems on airplanes. Look for these common signs of damage:

• Swelling or puffiness in the battery pack
• Discoloration or burn marks on the terminals
• Leaking battery fluid or any wet spots
• Overheating or feeling hot to the touch
• Cracks, dents, or other physical damage to the battery case
• Strange smells, smoke, or hissing sounds coming from the battery

If you see any of these signs, do not use the battery. Never try to recharge or test a damaged battery. You should dispose of it safely at a battery recycling center. Devices or batteries that show swelling, overheating, or any physical damage must stay off the plane.

Совет: If you drop your device on the plane, do not try to retrieve it yourself. Ask a flight attendant for help. Moving seats or reaching into tight spaces can crush or puncture the battery, which increases the risk of fire.

Emergency Steps

If you find a damaged battery or see signs of a battery fire during your flight, you must act quickly. Follow these steps to keep yourself and others safe:

1. Turn off the device or disconnect it from power right away.
2. Move the device or battery away from flammable materials if it is safe to do so.
3. Tell a flight attendant immediately. Do not try to handle the situation alone.
4. If you see flames, crew members will use a halon fire extinguisher to put out the fire.
5. Crew will then cool the battery with water to stop it from reigniting.
6. The crew will place the device in a fire-resistant bag or container for the rest of the flight.

Cabin crew receive special training to handle battery fires. You should always follow their instructions. Quick action can prevent a small problem from becoming a serious emergency.

Быстрый контрольный список

Before You Fly

1. Pack all spare lithium polymer batteries in your carry-on bag. Do not place them in checked luggage.
2. Protect each battery from short circuits. Use the original packaging, or place each battery in a plastic bag, or cover the terminals with tape.
3. Check that each battery is under 160 watt-hours. You may carry up to 20 spare batteries under 100Wh, or up to 2 between 100Wh and 160Wh (with airline approval).
4. Inspect batteries for damage. Do not bring any battery that looks swollen, cracked, or has been recalled.
5. Avoid bringing smart bags with non-removable lithium batteries. Airlines do not allow these on flights.
6. Prevent physical damage. Do not crush, puncture, or bend your batteries.
7. Review your airline’s rules for lithium batteries. Some airlines have extra restrictions.

Совет: Make a checklist before you pack. This helps you remember every safety step.

At the Airport

• Keep all spare batteries in your carry-on bag at all times.
• If you must gate-check your bag, remove all lithium batteries first.
• Show your batteries at security if asked. Security officers may check for damage or proper packaging.
• Protect batteries from short circuits by taping terminals or using original packaging.
• Check for airline-specific rules, especially if you carry large batteries.
• Get airline approval if you have batteries between 100Wh and 160Wh.
• Follow all TSA and FAA guidelines for packaging and labeling.

Security staff may take away batteries that do not meet safety rules.

On the Plane

• Store your carry-on bag with batteries under the seat in front of you.
• Do not use or charge damaged batteries during the flight.
• Keep batteries away from heat sources and direct sunlight.
• Never use or bring battery-powered vehicles like hoverboards or scooters.
• If a device gets hot, smells strange, or starts to smoke, alert a flight attendant right away.
• Devices with non-removable batteries may get extra checks. Follow crew instructions if asked.

Stay alert and follow these steps to keep your flight safe and smooth.

Safety Tips for Travelers

Do’s and Don’ts

When you travel with li polymer batteries, you must follow important safety steps. These do’s and don’ts help you avoid problems during transport and keep your trip smooth:

Do’s:

• Carry all spare lithium polymer batteries in your carry-on bag for safer transport.
• Check battery capacity limits before you fly. Most airlines allow batteries up to 100 Wh. Batteries over 160 Wh are not allowed for air transport.
• Keep batteries in their original packaging or use plastic cases. Tape the terminals to prevent short circuits during transport.
• Inspect every battery for swelling, leaks, or damage. Only transport batteries that look safe and work properly.
• Store batteries in a cushioned, separate compartment. This protects them from bumps and sharp objects.
• Notify your airline if you plan to transport multiple or high-capacity batteries. Some regulations require airline approval.
• Charge your devices before your flight. Security may ask you to power them on.
• Inform the flight crew right away if a device overheats, smokes, or shows signs of damage.

Don’ts:

• Do not place spare batteries, power banks, or vaping devices in checked luggage. Always transport these in your carry-on.
• Never carry damaged, defective, or recalled batteries. Airlines follow strict regulations and may confiscate unsafe items.
• Avoid storing batteries near metal objects like keys or coins. This can cause accidental activation or short circuits.
• Do not use water to put out a lithium battery fire. Flight crews use special extinguishers for these incidents.
• Never ignore airline or international regulations. Breaking transport rules can delay your trip or lead to confiscation.

Совет: Always separate batteries from other electronics in your bag. This makes security checks faster and safer.

Regulation Resources

You need to stay updated on the latest transport regulations for lithium polymer batteries. Many organizations provide helpful resources to guide you:

• IATA Dangerous Goods Regulations: This site explains the main rules for air transport of lithium batteries, including dangerous goods regulations.
• IMDG Code: This code covers international maritime transport regulations for batteries.
• DOT Hazardous Materials Regulations: This resource details U.S. transport regulations for hazardous materials, including lithium batteries.
• Epec Engineered Technologies: Their website offers updated guides on packaging, labeling, and transport documentation for lithium battery shipments.
• Educational blogs and airline websites: These sources help you understand new regulations and best practices for safe battery transport.

Примечание: Always review transport documentation and check for updates before every trip. Regulations can change, so staying informed keeps your travel safe and legal.

When you travel with lithium-ion batteries or li polymer batteries, you must follow key rules for safe transport:

• Carry all spare lithium-ion batteries in your carry-on, never in checked bags.
• Protect battery terminals and use approved packaging for transport.
• Check battery size limits and airline policies before every trip.
• Never transport damaged or recalled lithium-ion batteries.

Careful transport and preparation lower the risk of incidents. Always review airline and TSA guidelines. With the right steps, you can enjoy safe and easy air travel with your lithium-ion batteries.

ЧАСТО ЗАДАВАЕМЫЕ ВОПРОСЫ

Can you bring Li Polymer batteries in your checked luggage?

No, you cannot bring spare Li Polymer batteries in checked luggage. You must pack all spare batteries in your carry-on bag. Airlines do not allow them in checked bags because of fire risks.

How many spare batteries can you carry on a plane?

You can carry as many spare batteries as you want if each is under 100 Wh. For batteries between 100 Wh and 160 Wh, you need airline approval and can only bring two.

What should you do if your battery looks swollen or damaged before a flight?

Never pack a swollen or damaged battery. Take it to a battery recycling center. Damaged batteries can catch fire. Airlines will not let you fly with them.

Do you need to declare Li Polymer batteries at airport security?

You do not need to declare small Li Polymer batteries under 100 Wh. If you carry batteries over 100 Wh or have many batteries, tell the security officer. Always follow airline instructions.