Spare lithium-ion batteries and power banks are allowed on commercial flights, but only in your carry-on. Never in checked baggage. The watt-hour (Wh) rating on the battery determines what’s permitted: Rechargeable lithium-ion batteries are allowed on passenger aircraft with varying restrictions depending on their watt-hour (Wh) rating: smaller batteries are generally allowed without restrictions, mid-sized batteries may require airline approval and are subject to quantity limits, and larger batteries are not permitted on passenger aircraft.
Quick rules at a glance:
- Carry-on only: All spare batteries, power banks, and charging cases — no exceptions
- Checked baggage: Devices with installed, non-removable batteries are generally fine; loose spares are never allowed
- Damaged or recalled batteries: Prohibited in all baggage, carry-on or checked
- Terminals must be protected against short circuit at all times (tape, original packaging, or a plastic pouch)
- Gate-checked bags: Remove every spare battery before handing the bag over
Screenshot that list.
Key Takeaways
Spare lithium-ion batteries and power banks must travel in carry-on baggage only; the watt-hour rating determines whether airline approval is required, and anything above 160 Wh is forbidden on passenger aircraft.
| Point | Details |
|---|---|
| Carry-on only for spares | All spare batteries and power banks must be in carry-on; checked baggage is never allowed for loose cells. |
| Wh tiers determine access | Under 100 Wh: unrestricted; 101–160 Wh: airline approval required, max 2 spares; above 160 Wh: forbidden. |
| Protect terminals always | Use original packaging, tape, or individual pouches to prevent short circuits before and during travel. |
| Gate-check trap | Remove every spare battery before handing a carry-on to be gate-checked at the boarding door. |
| Check airline policy | Federal rules are the floor; your carrier’s published policy may be stricter, especially on international routes. |
Table of Contents
- What do FAA, TSA, and DOT rules actually require?
- How watt-hours work and which tier your battery falls into
- How to pack batteries and prevent short circuits
- Power banks and spare batteries: quantity limits and airline variation
- Rules for e-cigarettes and vaping devices
- Wheelchairs, mobility aids, and larger battery systems
- How to get airline approval for 101–160 Wh batteries
- Damaged, defective, and recalled batteries
- Why the carry-on-only rule exists: thermal runaway explained
- What to do if you accidentally checked a spare battery
- Your preflight battery checklist (screenshot this)
- Authoritative resources to check before you fly
- A working photographer’s take on battery rules at checkpoints
- Sources
What do FAA, TSA, and DOT rules actually require?
The governing federal authority is 49 CFR § 175.10, the U.S. DOT hazardous-materials regulation that carriers apply when deciding what batteries may board a passenger aircraft. The FAA translates those rules into passenger-facing guidance through two key resources: FAA PackSafe and the FAA newsroom lithium battery page.
The core federal requirements are:
- Spare batteries travel in the cabin, period
- Battery terminals must be protected from short circuit
- Damaged, defective, or recalled batteries are prohibited from all baggage
- Devices with lithium batteries should stay in accessible carry-on, not buried in an overhead bin
TSA enforces carriage decisions at the security checkpoint. Agents can and do pull batteries that appear damaged or that exceed limits. Airlines then add their own layer of restrictions on top of federal minimums — which means the airline’s published policy is effectively the final word for your specific flight.
How watt-hours work and which tier your battery falls into
Watt-hours are the single number that determines whether your battery boards the plane. The formula is straightforward:
Wh = mAh × V ÷ 1000
A 10,000 mAh power bank rated at 3.7V works out to 37 Wh. A 26,800 mAh bank at 3.7V is about 99.2 Wh. Both clear the 100 Wh threshold with room to spare. A cinema camera battery rated at 14.4V and 10,000 mAh hits 144 Wh — that is the middle tier, and it needs airline approval before it flies.
Per IATA guidance, the three regulatory tiers break down like this:
| Wh Rating | Carry-on | Checked Baggage | Airline Approval Needed | Quantity Limit |
|---|---|---|---|---|
| Under 100 Wh | Allowed | Never (spares) | No | Reasonable personal use |
| 101–160 Wh | Allowed | Never (spares) | Yes | Max 2 spare batteries |
| Above 160 Wh | Forbidden | Forbidden | N/A — not permitted | None |
Worked examples:
- iPhone 15 Pro battery: roughly 3.7V × 3,274 mAh ÷ 1,000 = ~12.1 Wh. No restrictions apply.
- Standard 20,000 mAh power bank at 3.7V: 74 Wh. Carry-on, no approval needed.
- Canon BP-A60 cinema battery (14.4V, 6,200 mAh): 89.3 Wh. Carry-on, no approval needed.
- Anton Bauer Cine 150 (14.4V, ~150 Wh): Sits in the 101–160 Wh tier. Airline approval required; maximum two spares.
If the Wh label is missing or unreadable, the airline may refuse carriage outright. Label cine batteries permanently with a marker before you travel.
How to pack batteries and prevent short circuits
The FAA is specific about this, and so is ICAO’s Technical Instructions addendum: each spare battery must be individually protected against short circuit. A loose battery rattling against keys or coins in a bag pocket is a fire risk.
Packing steps that meet FAA and ICAO standards:
- Keep all spare batteries in carry-on baggage, accessible under the seat in front of you
- Use original retail packaging, individual plastic pouches, or tape over the terminals
- Never stack loose batteries together without protection between them
- Avoid overstuffing bags — crushed or bent cells can fail
- For devices with non-removable batteries (phones, laptops), pack them normally in carry-on; they may also travel in checked baggage as installed devices
- For devices with removable cells, remove the battery and pack it separately in carry-on if the device goes into checked luggage
Pro Tip: If your carry-on gets gate-checked at the boarding door, pull every spare battery and power bank out before handing the bag over. Gate agents will not always remind you, and a spare battery in the hold is a federal violation — not just an inconvenience.
Power banks and spare batteries: quantity limits and airline variation
Power banks are treated identically to spare lithium-ion batteries under federal rules. They must travel in carry-on, terminals protected, and they count toward your spare battery total.
The federal baseline allows a “reasonable” number of spares under 100 Wh for personal use. In practice, airlines are tightening that language. Multiple carriers have moved in 2025–2026 to cap passengers at two power banks under 100 Wh, ban in-flight recharging via power banks, and restrict power bank storage to under-seat positions rather than overhead bins.
“Passengers are advised to carry power banks in their hand luggage only and not to use them to charge devices during the flight.” This language, or something close to it, now appears in the restricted-items policies of a growing number of international carriers following updated ICAO and IATA guidance.
Key points to know before you fly:
- Check your specific airline’s restricted-items page — not just the FAA baseline
- Carry the manufacturer’s spec sheet for any power bank over 50 Wh; agents sometimes ask
- Two large spares (101–160 Wh) require written airline approval; bring that documentation to the gate
- Do not recharge power banks from a seat power outlet mid-flight on airlines that prohibit it — enforcement is increasing
For filmmakers traveling with drone batteries or cinema rigs, the two-spare cap for the 101–160 Wh tier is the most common point of friction at international checkpoints.
Rules for e-cigarettes and vaping devices
Electronic cigarettes and personal vaporizers contain lithium cells and follow the same carry-on-only logic — with one additional restriction: they must be protected against accidental activation.
- E-cigarettes and vapes must travel in carry-on or on your person; checked baggage is not allowed
- The device must be protected so the heating element cannot fire accidentally (use a case, lock the button, or remove the cartridge)
- Recharging vaping devices on board is prohibited on most U.S. carriers
- Keep the device accessible, not buried in a bag that goes into the overhead bin on airlines with under-seat rules
Pro Tip: Use a dedicated silicone sleeve or hard case for vaping devices. A loose vape in a jacket pocket that activates in the overhead bin is the kind of incident that gets a flight diverted.
Wheelchairs, mobility aids, and larger battery systems
Mobility devices get a separate set of rules because the batteries involved are often larger and the devices are not optional for the passenger. Airlines are required to accommodate them, but the process requires advance notice.
Key rules for mobility aid batteries:
- Installed lithium-ion batteries in power wheelchairs may be allowed up to 300 Wh per battery with airline notification, and up to two batteries in some configurations
- Lithium metal batteries in mobility aids have gram-based limits (typically up to 8g lithium content) and require airline approval
- The battery must be securely attached to the device or, if removed, packed per airline instructions
- Notify the airline at least 48–72 hours before departure; many carriers require written confirmation
For production crews traveling with large battery systems for lighting or camera rigs, the mobility device exemption does not apply. Those batteries follow the standard passenger tiers, and anything above 160 Wh stays on the ground or ships as cargo under separate hazmat rules.
How to get airline approval for 101–160 Wh batteries
Airline approval for larger spare batteries is not automatic. Here’s the process that works:
- Find the Wh rating on every battery you plan to bring. If it’s not printed, calculate it (mAh × V ÷ 1,000) and write it on the battery permanently.
- Check the airline’s restricted-items page for your specific carrier and route. International flights often carry stricter rules than domestic legs.
- Contact the airline’s special-assistance or dangerous-goods desk at least 48 hours before departure. Request approval in writing (email is fine).
- Prepare documentation: manufacturer spec sheet, calculated Wh, number of spares, and confirmation that batteries are removable.
- Bring everything to the gate: approval email, spec sheet, and the batteries in their protective pouches.
Airlines typically ask for the Wh rating, the number of spare batteries, and whether the cells are removable from the device. Approval is usually granted for professional media crews, but it is not guaranteed — and verbal approval at check-in does not substitute for written confirmation.
Pro Tip: Save the approval email as a PDF on your phone and print a hard copy. At international checkpoints, a printed spec sheet and a visible Wh label on the battery resolve most disputes in under two minutes. Without them, you’re negotiating from a weak position.
Damaged, defective, and recalled batteries
A swollen, leaking, or scorched battery is not a borderline case. It is prohibited from all baggage, full stop. The FAA newsroom guidance is explicit: damaged or recalled batteries must not be carried on any aircraft.
Signs a battery is damaged and must not fly:
- Visible swelling or bulging
- Leaking electrolyte (oily residue, chemical smell)
- Scorch marks, melted casing, or exposed wiring
- Any battery that has been recalled by the manufacturer
If a battery overheats or shows damage at the airport or in flight:
- Do not put it in a bag or cover it
- Notify TSA staff immediately if you’re at the checkpoint
- Notify the flight crew immediately if you’re on board; they are trained to respond
- Follow crew instructions — do not attempt to extinguish a lithium fire with water
- If safe to do so, place the device in a fireproof containment bag if the crew provides one
Check CPSC Recalls before travel if you have any doubt about a battery’s status. A recalled battery that causes an incident in the cabin is both a safety emergency and a federal violation.
Why the carry-on-only rule exists: thermal runaway explained
Lithium-ion cells can enter thermal runaway — a self-sustaining chain reaction where heat causes the cell to release more heat, potentially resulting in fire or explosion. The chemistry is the reason the rule exists, not bureaucratic caution.
The critical factor is crew access. A battery fire in the cabin can be detected within seconds, isolated, and suppressed using onboard equipment. The same fire in the cargo hold may go undetected long enough to become uncontrollable. FAA PackSafe confirms that flight crews receive specific training for lithium battery thermal events, including detection, isolation, and suppression procedures.
Why carry-on placement matters:
- Crew can see and smell early warning signs (heat, smoke, chemical odor)
- Halon fire suppression systems in cargo holds are not designed for lithium battery fires
- Passengers can assist by immediately alerting crew rather than trying to handle the device themselves
The ICAO Technical Instructions require UN 38.3 testing for all lithium cells — a series of abuse tests (shock, vibration, temperature extremes) that batteries must pass before they can be transported by air. That testing standard is the baseline; the carry-on rule is the safety net for everything that passes testing but still fails in the field.
What to do if you accidentally checked a spare battery
It happens more than you’d think, especially with gate-checked bags. Here’s what to do:
- At the gate, before the bag goes down: Tell the gate agent immediately. Ask to retrieve the battery. Most agents will allow it.
- After the bag has been tagged but not loaded: Ask the gate agent to contact the ramp crew. It’s worth asking — bags are sometimes retrievable.
- If you realize it mid-flight: Notify the flight crew. They will log it and may take precautionary steps depending on the battery type and quantity.
- Possible outcomes: Confiscation of the battery, denial of carriage for the bag, or a requirement to carry the battery in the cabin for the remainder of the flight.
Penalties for accidental violations are rare when travelers self-report and cooperate. Ignoring the issue and hoping nothing happens is the approach that leads to enforcement action.
Your preflight battery checklist (screenshot this)
Run through this before you leave home:
- [ ] Confirm the Wh rating on every spare battery and power bank
- [ ] Pack all spares in carry-on, terminals protected (tape, pouch, or original packaging)
- [ ] Count total power banks and spares against your airline’s published limit
- [ ] For any battery 101–160 Wh: request written airline approval and bring the confirmation
- [ ] Carry manufacturer spec sheets for any battery over 50 Wh
- [ ] Check CPSC Recalls for any battery that has been in storage
- [ ] Remove all spares from any bag that may be gate-checked
- [ ] Verify your airline’s specific policy for your route, not just the FAA baseline
One-line reminder: Spares in carry-on, terminals covered, Wh documented, airline approval in hand.
Authoritative resources to check before you fly
Verify current rules directly from primary sources before every trip:
- FAA PackSafe — Lithium Batteries: the FAA’s passenger-facing tool for checking what’s allowed
- FAA Newsroom — Lithium Batteries in Baggage: plain-language guidance on carry-on vs. checked rules
- IATA Passenger Lithium Battery Guidance: the international standard that most airline policies derive from
- ICAO Technical Instructions Addendum 2025–2026: the international packing and testing framework
- 49 CFR § 175.10: the U.S. DOT hazmat regulation that governs U.S. carrier enforcement
- CPSC Recalls: check any battery that’s been in storage or came from a recalled product line
- Your airline’s restricted-items page: search “[airline name] + prohibited items + batteries” for route-specific rules
A working photographer’s take on battery rules at checkpoints
The rules above are clear on paper. At a checkpoint in Islamabad or Chengdu at 4 AM with a pelican case full of cinema batteries, they feel considerably less clear — especially when the agent has never seen a V-mount battery before and the Wh label has worn off.
The single most effective thing I’ve done for international shoots is label every battery with a permanent marker: voltage, mAh, and the calculated Wh, right on the cell. That one habit has resolved more checkpoint conversations than any amount of documentation. A visible number gives the agent something to check against their list. An unlabeled brick gives them a reason to pull you out of line.
For shoots that require planning travel logistics and coordinating equipment transport, I keep a dedicated battery pouch — separate from the main camera bag — that goes directly under the seat. Every spare lives there. The approval emails for larger cells are saved as PDFs and printed. The spec sheets are clipped to the outside of the pouch. It takes ten minutes to set up at home and saves an hour at the gate.
The other thing worth knowing: airline staff at international hubs are increasingly strict about power banks in overhead bins. Keep them under the seat. It’s not worth the argument, and on some routes it’s now a hard rule.
If you’re building out a kit for a professional outdoor or adventure shoot that involves multiple international legs, treat battery compliance as part of pre-production, not an afterthought. The rules are manageable when you plan for them. They’re a nightmare when you don’t.
This article is general information, not a substitute for advice from a qualified lawyer. Consult a qualified legal professional about your own circumstances before acting on anything here.
Sources
- PackSafe – Lithium Batteries | Federal Aviation Administration
- Lithium Batteries in Baggage
- Passengers travelling with lithium batteries (IATA guidance)
- ICAO Technical Instructions addendum (2025–2026)
- 49 CFR § 175.10 — Use of passenger-carrying aircraft, published text
