FAA Clarifies Power Bank Rules for Flights Amid Rising Incidents

Recent in-flight fire incidents involving consumer electronics have intensified scrutiny on the regulations governing power banks and other spare lithium-ion batteries on commercial aircraft. While the rules are not new, a significant rise in battery-related events underscores the critical importance of passenger compliance. The Federal Aviation Administration (FAA) and global bodies maintain strict airline power bank policy to mitigate the risk of thermal runaway events, making it essential for travelers to understand the current carry on battery restrictions.

At the core of these aviation safety regulations is a simple mandate: all spare lithium-ion batteries, which includes portable power banks, must be transported in carry-on baggage only. This rule is designed to ensure that if a device ignites, it occurs in the passenger cabin where flight crews are trained to manage and extinguish the fire. A battery fire in the inaccessible cargo hold could have catastrophic consequences. According to FAA data, there were 579 aviation-related incidents involving lithium batteries between March 2006 and November 2024, highlighting the persistent nature of this threat.

Understanding the Regulations

The rules for power banks on flights are standardized globally, based on guidelines from the International Civil Aviation Organization (ICAO) and the International Air Transport Association (IATA). In the United States, the FAA provides clear, specific limits based on the battery’s energy capacity, measured in Watt-hours (Wh).

• Up to 100 Wh: Most consumer power banks fall into this category. Passengers can carry these devices without needing special airline approval. A 100 Wh battery is roughly equivalent to 27,000 mAh, covering the majority of commercially available chargers.
• 101-160 Wh: For larger, professional-grade batteries, passengers must receive approval from the airline prior to travel. A maximum of two spare batteries in this range is permitted per person.
• Over 160 Wh: Lithium-ion batteries exceeding this capacity are strictly forbidden on passenger aircraft.

Beyond capacity limits, passengers are required to protect spare batteries from short-circuiting. The FAA's Pack Safe guidance stipulates that battery terminals must be covered with tape, or each battery must be placed in its original retail packaging or a separate plastic bag. These measures prevent metal objects like keys or coins from making contact with the terminals and causing a fire.

The Rising Threat of In-Flight Fires

The urgency behind these regulations is driven by a sharp increase in incidents. Data from the FAA shows 69 lithium battery events occurred in the first 11 months of 2024, representing a 388% increase since 2015. A 2024 data review by UL Standards & Engagement found that, on average, two flights per week experienced a thermal runaway incident involving a lithium-ion battery. The same report identified vapes and power banks as the leading sources of these events.

Critically, the UL report noted that 89% of these incidents occurred on the aircraft itself, reinforcing the logic behind the carry-on-only rule. When a Portable Electronic Device (PED) begins to overheat or emit smoke in the cabin, the crew can deploy specialized fire containment bags and extinguishers. This rapid response capability is a key pillar of in-flight fire prevention.

Airline and Passenger Responsibilities

While the Transportation Security Administration (TSA) screens for prohibited items, compliance largely falls on passengers. Industry trends show a heavy focus on passenger awareness campaigns to educate the public before they arrive at the airport. However, incidents of power banks being incorrectly packed in checked luggage persist.

Regulations also govern electronic devices that are placed in checked baggage. Any PED in a checked bag must be completely powered off—not in sleep or hibernate mode—and packed in a way that protects it from accidental activation or damage. Airlines are also enhancing cabin crew training, using IATA and ICAO guidance to ensure staff can respond effectively to a lithium battery fire on an aircraft.

Why This Matters

The proliferation of high-capacity PEDs has made lithium battery management a critical and ongoing safety challenge for the global aviation industry. As the frequency of thermal runaway incidents continues to rise, strict passenger adherence to established regulations is the primary defense against potential in-flight emergencies. The data clearly shows that while the rules are in place, continuous education and vigilant enforcement are necessary to ensure the safety of all travelers.

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