Portable Batteries on Airplanes: What Are the New Rules in 2025?
Lithium-ion (Li-ion) batteries are ubiquitous in modern life.
You’re probably reading this article on a Li-ion-powered device — such as a phone, tablet, or laptop — right now.
Lithium-ion batteries have many benefits, including fast charging and extended battery life compared to older battery chemistries like lead-acid.
However, the convenience of Li-ion battery technology doesn’t come without some risk…
In rare circumstances, lithium-ion batteries cause fires and explosions that could lead to disaster, especially in enclosed spaces like airplanes.
Thanks to several high-profile incidents, many airlines worldwide are enforcing stricter policies regarding the use and storage of lithium-ion rechargeable devices on passenger planes.
Understand the Changing Landscape of Airline Regulations
If you’re a frequent flyer, you probably already know that lithium-ion battery-powered devices are banned from being stored in checked baggage.
Unlike the rules regarding taking rechargeable devices like smartphones, laptops, power banks, and e-cigarettes as carry-on, the ban on checking Li-ion batteries as baggage on passenger planes is global. It applies to all domestic and international flights.
However, the rules regarding what lithium-ion-powered devices passengers can carry and use on a plane vary significantly by carrier, leading to confusion among many passengers.
If you plan on bringing rechargeable devices with you on a flight, it’s essential to confirm with the individual airline what you’re allowed to carry on the plane.
Regulations also vary regarding what devices you can use in-flight or store in the overhead bins.
If you don’t check in advance, you may be forced to leave your devices behind if you want to board the plane.
Recent Incidents Prompting Stricter Rules
On January 28th, 2025, Air Busan Flight 391, bound for Hong Kong from South Korea’s Gimhae International Airport, was engulfed in flames just as it was about to taxi down the runway.
According to CNN, “all 169 passengers and seven crew members were evacuated, with three having minor injuries.”
The BBC reports that “investigation results indicate the fire may have started because insulation inside a power bank battery had broken down.
The power bank was found in an overhead luggage compartment where the fire was first detected, and its debris had scorch marks.”
As of March 1, 2025, the South Korean government imposed strict new guidelines for passengers boarding planes in the country with power banks (portable lithium-ion battery packs) and e-cigarettes.
Many Asian airlines, including Thai Airways, Singapore Airlines, Cathay Pacific, and China Airlines, have imposed similar restrictions. Some have banned the use of or charging of power banks on flights.
In the United States, Southwest Airlines now restricts power bank use in-flight, requiring passengers to keep portable chargers visible at all times while operating, meaning no more charging your phone in your bag or overhead compartment.
As concerns over fire risks that Li-ion batteries pose to passenger airlines mount, it’s more essential than ever to confirm what you can and can’t take or use on a flight before you leave for the airport.
Fire Risks Associated with Lithium-Ion Batteries
Traditional lithium-ion batteries are prone to a relatively rare but dangerous phenomenon: thermal runaway.
Thermal runaway is a rapid, unstoppable chain reaction in Li-ion cells and can quickly result in a battery fire.
An initial short circuit in a battery cell causes a burst of heat that can quickly trigger a similar reaction in neighboring components and cells in the device.
In seconds, the chain reaction cascades exponentially, resulting in temperatures over 900°F (500°C), causing sparks and jets of flame that can easily ignite nearby materials like clothes and luggage in an overhead bin.
The thermal runaway “domino effect” happens so quickly that fire suppression systems in airplane cargo holds will likely be overwhelmed by the blaze.
The global ban on power banks and spare Li-ion batteries in checked luggage has effectively been in place since 2016.
Restricting power banks to “carry-on only” doesn’t diminish the numerical risk of a battery fire occurring…
Rather, it reduces the risk of a disastrous outcome by giving passengers and flight crew the opportunity to suppress any fire before it gets out of control.
Similarly, having a portable battery on board an airplane doesn’t make thermal runaway inherently more likely than on the ground…
It’s the risk of a potentially catastrophic outcome from a battery fire that increases in a confined space like an airplane flying at 35,000 feet.
Causes of Thermal Runaway
Thermal runaway is an exceedingly rare phenomenon, especially considering the countless lithium-ion batteries in the world today.
Newer subtypes of Li-ion chemistry, like lithium iron phosphate (LFP/LiFePO4), are increasingly used in high-capacity rechargeable battery storage solutions like portable power stations and are far more stable and not prone to thermal runaway.
For most traditional consumer devices, the most frequent causes of thermal runaway are:
Physical damage
Manufacturing defects
Overcharging from a faulty charger
Using damaged or low-quality charging cables
Exposure to external heat sources like direct sunlight
If your power bank or portable battery becomes swollen, dented, or damaged, stop using it immediately.
It’s far better to safely recycle it and purchase a replacement than to risk a dangerous outcome.
(Source: Federal Aviation Administration)
Essential Guidelines for Traveling with Portable Batteries
Carry-On Only: You might be able to “get away” with putting extra Li-ion batteries or devices in your checked luggage, but you’d be putting yourself and other passengers at serious risk. Power banks, e-cigarettes, and other rechargeable devices are banned in all commercial airplane cargo cabins.
Check the storage capacity: There is some variation between different carriers' regulations regarding the storage capacity of portable batteries permitted to be used onboard a flight. However, the FAA’s Packsafe regulations for lithium-ion rechargeable batteries are as follows:
Allowed: Up to 100 watt-hours (Wh) per battery
Allowed with airline approval: 101Wh - 160Wh per battery
Forbidden: All lithium batteries over 160Wh
Many power banks and portable rechargeable devices list storage capacity in milliamp-hours (mAH). Convert mAh to Wh here.
Get airline approval for high-capacity batteries: Li-ion rechargeable batteries with storage capacity between 100Wh and 160Wh require permission from the airline you’re flying with.
Protect battery terminals: Prevent short circuits by taping over exposed battery contacts or keeping power banks in separate cases.
Always confirm the regulations with your airline before leaving on a trip: Going to the airport is stressful enough. Don’t potentially ruin your trip by being forced to leave your unauthorized devices behind.
Inspect batteries for damage: Check for swelling, dents or other visible defects
Buy reputable brands: Manufacturing quality significantly impacts li-ion battery safety. With power banks, as with most things in life, you get what you pay for.
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Works Cited
Reuters. 2025. “Passenger Plane Catches Fire in South Korea Prompting Mass Evacuation, Three Injured.” CNN. January 29, 2025. https://edition.cnn.com/2025/01/28/asia/air-busan-airbus-fire-south-korea-intl-latam/index.html.
Butler, Gavin. 2025. “Air Busan: Power Bank Likely Caused Plane Fire, Investigators Say.” Bbc.com. BBC News. March 14, 2025. https://www.bbc.com/news/articles/cj3n25rdr3lo.
Korea Tourism Organization, KTO. 2025. “Strengthened Safety Measures for Power Banks and E-Cigarettes on Flight.” https://english.visitkorea.or.kr/svc/contents/contentsView.do?vcontsId=221426.
“Southwest Airlines.” 2025. Help Center | Southwest Airlines. 2025 https://support.southwest.com/helpcenter/s/article/Traveling-with-lithium-batteries-e-cigarettes-and-lighters
“PackSafe - Lithium Batteries | Federal Aviation Administration.” 2025. Faa.gov. “Frequently Asked Questions Q1. Are Passengers Allowed to Travel with Batteries in Their Checked or Carry-on Bags? Batteries Carried by Airline Passengers.” n.d. Accessed July 10, 2025. https://www.faa.gov/hazmat/packsafe/resources/airline-passengers-batteries.