Can Lithium Batteries Be Shipped by Air? Requirements and Guidelines

As far as I know, lithium batteries are classified as dangerous goods. To avoid having your shipment rejected or facing penalties, they must meet specific safety requirements for air transport. This includes proper hazardous material labeling and strict adherence to air transport regulations for dangerous goods—every detail matters, as even one oversight can result in an entire shipment being denied.

There are two primary methods for shipping lithium batteries by air: cargo transport and personal carry-on. Each has its own set of requirements, detailed below:

Cargo Shipment Requirements

When Packed with Equipment:
 - Equipment must be secured to prevent accidental activation
 - Maximum package weight: 35 kg (77 lbs)
 - Must display appropriate labels with proper UN identification numbers
 - For built-in non-removable batteries, recommended state of charge (SoC) is no higher than 25%

Individual/Cell Batteries:
 - Must use short-circuit prevention packaging
 - Maximum package weight: 35 kg (77 lbs)
 - Must display Class 9 hazardous material labels and "Cargo Aircraft Only" labels
 - State of charge must not exceed 30%

Installed in Equipment:
 - Equipment must be powered off with measures taken to prevent accidental activation
 - Packaging must pass 3-meter stack test requirements

Required Documentation:
 - UN38.3 Test Report
 - Transport Classification Document
 - Dangerous Goods Declaration
 - Safety Data Sheet (SDS)
 - State of Charge Test Records

Personal Carry-On Requirements

Spare Batteries:
 - Carry-on only—strictly prohibited in checked baggage
 - ≤100 Wh: No quantity restrictions
 - 101-160 Wh: Airline approval required, maximum 2 batteries permitted
 - >160 Wh: Transport is strictly prohibited

Power Banks:
 - Carry-on only
 - Recommended state of charge ≤30%
 - Rated ≤100 Wh for safest transport

Devices with Built-in Batteries:
 - Mobile phones, laptops, and similar devices may be carried in either carry-on or checked baggage
 - Devices must be powered off
 - Must take measures to prevent accidental activation during transport