How should you pack batteries?
Nowadays, tech is everywhere when we travel, from power banks and portable fans to smart suitcases that follow their owners around the airport. But many of these devices come with a hidden risk.
In October, a British Airways flight was forced to make an emergency landing after a battery fire burned one of the passengers — and this is hardly an isolated incident. The Federal Aviation Administration reported 28 battery fire events on passenger and cargo planes in the first quarter of 2026 alone. That’s on track to beat last year’s tally of 97 events, up from 89 in 2024.
Fires can be particularly dangerous in the enclosed space of an airplane, so it’s critical for passengers to do their part by packing batteries correctly. Here’s an overview of the types of batteries you need to watch out for, what devices they’re in and how to pack them safely and legally.
The risks of batteries
Any battery can start a fire if stored improperly, but the biggest threats are lithium metal (non-rechargeable) and lithium-ion (rechargeable) batteries. These batteries have exploded in popularity in recent years. Unfortunately, they are also at risk of, quite literally, exploding.
According to the FAA, “All lithium-ion batteries are capable of overheating and experiencing a process called thermal runaway.”
Thermal runaway is a self-sustaining chemical reaction that produces extreme heat (up to 1,500 degrees F within seconds), toxic smoke, ultrafine particles and flames. It can occur without warning due to various factors, including damage to the battery, overheating, overcharging, exposure to water and manufacturing defects.
Lithium battery fires are often resistant to traditional extinguishing agents, making them tough for cabin crews to tackle. And since planes recirculate air rather than drawing fresh air from outside, toxic fumes from lithium fires can pose a health hazard to passengers long after the flames are extinguished.
As a result, the aviation industry has been tightening the rules on lithium batteries.
What devices contain lithium batteries?
The most common culprits behind aircraft fires are cell phones, laptops, vapes and power banks. For example, three passengers were injured when a laptop battery caught fire on an American Airlines plane in 2024, and a power bank caused a similar emergency on a Virgin Australia flight in 2025.
However, lots of other devices can contain lithium batteries, such as:
- Wireless earbuds and noise-canceling headphones
- Cameras and drones
- Handheld gaming consoles and controllers
- Wearables like smartwatches and fitness trackers
- Electric toothbrushes, razors, hair curling wands and flatirons
- Portable medical monitors, infusion pumps and hearing aids
To determine whether your device has a lithium battery, check the label or manual. The chemical symbol “Li” generally indicates the presence of lithium; you may see terms such as “Li-polymer,” “LiPo” or “Li+.” For coin-cell batteries, the label will typically start with “CR” if lithium is involved.
Where and how should you pack batteries?
As you can see, there’s a good reason for all the restrictions around batteries on planes — but they can be confusing. If you’ve ever wondered how you should store your camera battery or whether you can pack that portable fan in your checked luggage, you’ve come to the right place.
Here, I’ll answer all of your, ahem, burning questions about batteries.
Lithium batteries
The regulations around lithium batteries depend on the battery size and whether they are alone or installed in a device.
Non-rechargeable batteries are limited to 2 grams of lithium per battery, while rechargeable batteries are limited to a rating of 100 watt hours. According to TSA, this covers “nearly all types of lithium batteries used by the average person in their electronic devices.” Larger batteries require approval from the airline.
TSA prohibits spare or uninstalled lithium batteries — which include power banks and cell phone charging cases — in checked baggage. These batteries must go in your carryon, and if you end up gate-checking your bag, you must remove them and keep them with you during the flight.
For lithium batteries contained within a device, you can pack them in your checked bag as long as the device is fully powered off and “protected from accidental activation,” according to the FAA. For devices that generate extreme heat (such as lighters), you must protect the device from switching on inside your checked bag by removing the battery or heating element.
Your specific airline may have additional rules regarding lithium batteries. For instance, Southwest has one of the strictest battery policies in the sky: Passengers are limited to one power bank per person, batteries are prohibited in overhead bins and they must be visible while in use.
Dry batteries
The above guidelines apply only to lithium batteries. “Dry” batteries, such as AAs, button cells and 9-volts, are allowed in both checked and carry-on bags.
However, FAA guidelines state that “Battery terminals (usually the ends) must be protected from short circuit (i.e., the terminals must not come in contact with other metal).” You can keep your batteries safe by storing them in their original packaging, a battery case, the battery pocket of a camera bag or a plastic baggy. However, the FAA does not recommend packing rechargeable batteries in their charging unit.
What to do during a flight
Carrying lithium batteries onboard with you won’t prevent them from catching fire, but it will make it easier for flight crews to respond to any incidents. You can do your part by following these guidelines:
- If you drop a lithium battery or battery-containing device between the seats, notify a crew member immediately.
- Do not charge external lithium batteries or power banks onboard.
- Alert the crew if you notice a device overheating, expanding, smoking or burning.
- If your device’s battery is damaged or recalled, do not pack it — dispose of it properly and replace it.
Bottom line
Baggage regulations can be tricky, but it’s worth paying attention. Passengers who don’t follow the rules can be slapped with serious fines — and, more importantly, they pose a safety hazard to everyone on their flight.
Follow the packing tips above to travel safely and stress-free, and check out our other travel safety tips:
