[Home](/)/[Resources](/resources)/TSA and FAA Battery Rules United StatesAviation # TSA and FAA Lithium Battery Rules (2026): Carry-On, Checked Bags, Power Banks and Air Cargo Under TSA and FAA rules, lithium-ion batteries up to 100 Wh can fly in carry-on baggage without approval, batteries from 101 to 160 Wh need the airline's approval, and anything over 160 Wh cannot travel in passenger baggage. Spare batteries and power banks must always go in carry-on, never in checked bags. Since 27 March 2026, international flights also limit passengers to two power banks and ban recharging them on board. This guide covers the passenger rules in 49 CFR 175.10, the 2026 ICAO and IATA changes, how to calculate watt-hours, and what hardware companies shipping batteries as air cargo need to get right. Copy Link[Share on WhatsApp](https://wa.me/?text=https%3A%2F%2Fkrono-labs.com%2Fguides%2Fus-tsa-faa-battery-regulations) At a glance Carry-on limit 100 Wh (101-160 Wh with airline approval) Spares and power banks Carry-on only, never checked Power banks (international) Max 2, no recharging on board Cargo state of charge 30% max (UN 3480, UN 3481 packed with) US rule 49 CFR 175.10(a)(18) ## Quick reference: what can fly where These are the limits in 49 CFR 175.10(a)(18) for batteries carried by passengers for personal use, plus the 2026 international power bank rule. Airlines are allowed to be stricter. Battery Carry-on Checked Notes Lithium-ion battery installed in a device (phone, laptop, camera), up to 100 Wh Yes Yes, if fully switched off and protected from activation (carry-on recommended) No quantity limit for personal use Spare lithium-ion battery or power bank, up to 100 Wh Yes No Terminals protected. International flights: max two power banks per person, no recharging them on board (ICAO, March 2026) Lithium-ion battery 101 to 160 Wh, installed in a device Yes, with airline approval Yes, with airline approval, device switched off Airline approval required Spare lithium-ion battery 101 to 160 Wh Yes, with airline approval No Maximum two spares per person Lithium-ion battery over 160 Wh No No Ship as dangerous goods cargo. Exception: batteries for wheelchairs and mobility aids under separate rules Lithium metal (non-rechargeable) battery, up to 2 g lithium Yes (installed or spare) Installed only; spares carry-on only 2 to 8 g only for medical devices, with airline approval ## Key rules behind aviation battery limits ### Who sets the rules: FAA, PHMSA, TSA and ICAO The passenger battery rules are written by PHMSA (the DOT Pipeline and Hazardous Materials Safety Administration) in 49 CFR 175.10 and enforced on board by the FAA. TSA officers screen bags at the checkpoint and follow the same limits, but TSA does not write the hazmat rules. International flights follow the ICAO Technical Instructions, which the airline industry publishes as the IATA Dangerous Goods Regulations (DGR). When you ship batteries as cargo rather than in baggage, the shipping rules in 49 CFR Parts 171 to 180 apply, and 49 CFR 171.22 and 171.24 allow US air shipments to be prepared under the ICAO Technical Instructions provided the extra US conditions are also met. ### The 100 Wh and 160 Wh thresholds Under 49 CFR 175.10(a)(18), each lithium-ion battery a passenger carries, installed or spare, must not exceed 100 Wh. With the airline's approval, devices may contain batteries from 101 to 160 Wh, and a passenger may carry up to two individually protected spare batteries in that range in carry-on baggage. Above 160 Wh, the battery cannot travel in passenger baggage at all (the only exception is batteries for wheelchairs and mobility aids, which have their own rules up to 300 Wh). For lithium metal batteries, the limit is 2 g of lithium content per battery. ### Spare batteries and power banks: carry-on only Spare lithium batteries must be carried in carry-on baggage only, regardless of size. 49 CFR 175.10(a)(18)(iv) states that articles whose primary purpose is to provide power to another device, which means power banks and portable chargers, must be carried as spare batteries. A 10 Wh power bank in a checked bag breaks the same rule as a 99 Wh one. The reason is access: a battery fire in the cabin can be reached by crew, a fire in the cargo hold cannot. If a gate agent checks your carry-on at the door, take spare batteries and power banks out first. ### Devices in checked baggage must be fully off Portable electronic devices with installed lithium batteries may go in checked baggage, but they must be completely switched off (not in sleep or hibernation mode) and protected against accidental activation or damage. Very small batteries are the exception: devices with lithium-ion batteries of 2.7 Wh or less, or lithium metal batteries of 0.3 g or less, do not need to be switched off. FAA guidance still recommends keeping devices with you in the cabin where possible. ### Terminal protection for every spare Each spare battery must be individually protected against short circuit. Acceptable methods named in the rule are the original retail packaging, taping over exposed terminals, or placing each battery in a separate plastic bag or protective pouch. A loose battery rattling against keys or coins is non-compliant, even if it is small. For companies that sell spare batteries, retail packaging that doubles as a travel case makes compliance easy for customers. ### UN 38.3 testing and Wh marking Every installed or spare battery a passenger carries must be of a type that has passed the UN Manual of Tests and Criteria, Part III, sub-section 38.3. For shipping, 49 CFR 173.185(a)(5) requires each lithium-ion battery to be marked with its Wh rating on the outside case (beginning May 10, 2024). For travellers, a clearly printed Wh rating is also the fastest way through a checkpoint question. Without it, staff have to work it out from mAh and voltage, and may refuse the item if they cannot. ## What changed in 2026 ### ICAO power bank addendum (effective 27 March 2026) ICAO issued an addendum to the Technical Instructions that treats power banks separately from other spare batteries. For international flights, passengers and crew may carry no more than two power banks for personal use, must not recharge a power bank while on board, and are recommended not to use a power bank to charge devices in flight. Power banks stay carry-on only and must be protected against short circuit. IATA has said the option to carry 100 to 160 Wh power banks with airline approval will not be carried into the 68th edition of the DGR, which takes effect on 1 January 2027. ### US domestic flights As of October 2026, the US regulation itself, 49 CFR 175.10(a)(18), still has no two-power-bank limit for batteries up to 100 Wh. That does not mean there is no limit in practice: airlines can set stricter rules, and several US carriers have adopted their own power bank limits. Check the airline's dangerous goods page before you fly, especially if you are carrying more than two power banks. ### IATA DGR 67th edition: 30% state of charge (cargo) The 67th edition of the IATA DGR took effect on 1 January 2026. Lithium-ion batteries shipped on their own (UN 3480, Packing Instruction 965) already had to be shipped at no more than 30% state of charge. From 1 January 2026, the 30% limit also applies to lithium-ion batteries packed with equipment (UN 3481, PI 966), including Section II batteries over 2.7 Wh. Shipping above 30% needs written approval from the State of Origin and State of the Operator. For batteries contained in equipment (PI 967), 30% (or an indicated battery level of 25% or less) is strongly recommended but not yet mandatory. ## How to calculate watt-hours (with examples) 01 Wh = nominal voltage (V) x rated capacity (Ah). To convert from mAh, divide by 1,000 first. 02 A 20,000 mAh power bank with 3.7 V cells: 3.7 x 20 = 74 Wh. Carry-on only, no approval needed. 03 A 26,800 mAh power bank at 3.7 V: 3.7 x 26.8 = about 99 Wh. Just under the 100 Wh line, which is why so many power banks are sized here. 04 A 14.4 V, 9.0 Ah camera or drone battery: 129.6 Wh. Needs airline approval, and you may carry at most two as spares. 05 A 500 Wh e-bike battery or a large portable power station: over 160 Wh, so it cannot go in passenger baggage. It has to be shipped as dangerous goods cargo. 06 Use the nominal voltage of the cell (usually 3.6 V or 3.7 V for lithium-ion), not the 5 V USB output voltage. Using 5 V overstates the rating. ## Shipping lithium batteries as air cargo Passenger limits do not apply to commercial shipments. Inventory, returns and replacement batteries sent by air are dangerous goods shipments, classified by UN number and IATA packing instruction. The table summarises the 67th edition (2026) of the IATA DGR. Configuration UN / PI Sections Passenger aircraft Batteries on their own (lithium-ion) UN 3480, PI 965 Section IA (over 20 Wh cell / 100 Wh battery) or IB (smaller) Forbidden. Cargo Aircraft Only. Max 30% state of charge Batteries packed with equipment (lithium-ion) UN 3481, PI 966 Section I, or Section II for small cells and batteries Allowed, 5 kg per package. 30% state of charge from 1 Jan 2026 Batteries contained in equipment (lithium-ion) UN 3481, PI 967 Section I, or Section II for small cells and batteries Allowed, 5 kg per package. 30% state of charge recommended Lithium metal batteries on their own UN 3090, PI 968 Section IA or IB Forbidden. Cargo Aircraft Only Standalone batteries shipped under Section IA or IB, and equipment shipments under Section I, need a Shipper's Declaration for Dangerous Goods and Class 9 lithium battery hazard labels. Section II shipments of small batteries packed with or contained in equipment use the lithium battery mark instead and do not need a declaration, but the people preparing them still need adequate instruction. Standalone lithium-ion and lithium metal batteries cannot go on passenger aircraft at all, which is why they must carry the Cargo Aircraft Only label. ## Compliance process for hardware companies with battery products 01 Work out the Wh rating of every battery in your product line (nominal voltage x rated capacity in Ah) and print it on the battery case. For lithium-ion batteries this marking is required for transport under 49 CFR 173.185(a)(5). 02 Confirm each cell and battery design has a UN 38.3 test summary. Passengers are only allowed to carry batteries of a tested type, and you cannot ship them without it. 03 Classify each product by how the battery travels: installed in the device, packed with the device in the same box (UN 3481), or sold on its own as a spare or power bank (UN 3480, the strictest category). The same physical battery falls under different rules depending on how it is packed. 04 For consumer products, put travel information where customers will see it: the Wh rating, whether the battery can be removed, that spares and power banks must go in carry-on only, and whether the battery is over 100 Wh (airline approval needed). A one-line travel note in the manual and on the product page prevents most checkpoint confiscations. 05 For air cargo shipments of inventory, classify under the current IATA DGR edition, identify the packing instruction and section, set lithium-ion batteries to 30% state of charge where required, and prepare the Shipper's Declaration for Dangerous Goods for Section IA, IB and Section I shipments. Staff who prepare dangerous goods shipments must be trained. 06 Check carrier and forwarder acceptance rules. Many airlines and integrators are stricter than the IATA minimum, and some will not accept standalone lithium batteries at all. 07 Track the annual IATA DGR cycle. Each new edition is published in the autumn and takes effect on 1 January. The 68th edition applies from 1 January 2027 and will incorporate the 2026 ICAO power bank changes. ## Frequently asked questions ### Can you put a power bank in checked luggage? No. A power bank counts as a spare lithium battery under 49 CFR 175.10(a)(18), and spare lithium batteries are allowed only in carry-on baggage. This applies to every size, from a small 5,000 mAh unit to a 26,800 mAh pack. If your carry-on is gate-checked, remove power banks and spare batteries first and keep them with you in the cabin. ### What is the TSA and FAA watt-hour limit for lithium batteries? Up to 100 Wh per lithium-ion battery is allowed without airline approval, installed or spare. From 101 to 160 Wh you need the airline's approval, and you may carry at most two spare batteries in that range. Over 160 Wh is not allowed in passenger baggage. For non-rechargeable lithium metal batteries the limit is 2 g of lithium per battery (up to 8 g for medical devices with airline approval). Airlines can set stricter limits. ### How many power banks can I bring on a plane in 2026? On international flights, the ICAO addendum that took effect on 27 March 2026 limits each passenger to two power banks in the cabin, and you must not recharge a power bank during the flight. On US domestic flights, the federal rule has no fixed count for power banks up to 100 Wh, but many airlines now apply their own limits, so check your carrier. For power banks of 101 to 160 Wh, the limit is two with airline approval. ### Can I bring a 20,000 mAh power bank on a plane? Yes, in carry-on baggage. At a typical 3.7 V cell voltage, 20,000 mAh works out to about 74 Wh, which is under the 100 Wh limit and needs no airline approval. It cannot go in checked luggage. A 27,000 mAh power bank at 3.7 V is about 100 Wh, which is right at the limit, so check the Wh figure printed on the case. ### Have the TSA battery rules changed since 2023? The core rules are the same: 100 Wh without approval, 101 to 160 Wh with approval, spares and power banks in carry-on only. What changed in 2026 is the treatment of power banks on international flights (a two-per-person limit and no recharging on board, from 27 March 2026) and the 30% state of charge requirement for lithium-ion batteries packed with equipment when shipped as air cargo (from 1 January 2026). ### Can a device with a lithium battery go in checked luggage? Yes, if the battery is within the limits and the device is completely switched off (not in sleep mode) and protected from being turned on or damaged. Devices with very small batteries (2.7 Wh or less lithium-ion, or 0.3 g or less lithium metal) do not need to be switched off. The FAA still recommends carrying devices in the cabin. E-cigarettes and vapes are the exception: they must always be carried on your person or in carry-on baggage. ### How does a hardware company communicate battery rules to customers? State four things clearly in the manual, on the product page and ideally on the product: the battery's Wh rating, whether it is removable, that spare batteries and power banks must travel in carry-on baggage only, and whether the battery is over 100 Wh (airline approval required). Products near or above 100 Wh generate the most checkpoint questions, so a short travel note in the box is worth the space. ### What happens if a cargo shipment of batteries is not declared correctly? Undeclared or misdeclared lithium battery shipments violate federal hazardous materials law. Under 49 CFR 107.329, the maximum civil penalty is $102,348 per violation, rising to $238,809 if the violation causes death, serious illness, severe injury or substantial property destruction, and each day of a continuing violation counts separately. Willful violations can also be prosecuted criminally under 49 U.S.C. 5124. In practice, carriers also reject the freight, and repeat offenders can lose access to carriers. **Disclaimer:** Educational resource only, current as of October 2026. Airline policies can be stricter than the regulations, and dangerous goods rules change with each IATA DGR edition. Check the FAA PackSafe pages, your airline, and a trained dangerous goods specialist before flying with or shipping batteries. πŸ‡ΊπŸ‡Έ US roadmap for your product Every standard, document, and test that applies β€” free, no account required. See your free roadmap[ Want an expert to take your product through πŸ‡ΊπŸ‡Έ US compliance for you? One consultant from Krono's compliance team takes your product from requirements to legal sale, with a fixed quote before any work starts. See compliance services](/services) Learn this properly In-depth course that teaches the full process, not just this one answer. 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