Global Regulators Tighten Airline Power Bank Rules Amid Fire Risk

A significant increase in in-flight fire events has prompted global aviation regulators to enforce stricter rules for carrying portable power banks and other spare lithium-ion batteries. These harmonized lithium battery flight regulations are not an outright airline power bank ban but a targeted effort to mitigate the risk of thermal runaway in the cabin. According to data from the FAA (Federal Aviation Administration), there were 89 reported incidents in the U.S. involving lithium batteries smoking or igniting on aircraft in 2024 alone.

The updated rules directly impact how passengers pack for air travel, requiring a clear understanding of device capacity and baggage restrictions. The core issue is the fire risk associated with Lithium-ion (Li-ion) batteries, which can enter a state of thermal runaway if damaged, short-circuited, or defective, leading to intense fires that are difficult to extinguish. With power banks becoming ubiquitous for traveling with electronics, aviation authorities have standardized rules to manage this growing safety concern, focusing on capacity limits and prohibiting their transport in checked luggage where a fire could go undetected.

The Regulatory Framework: FAA, IATA, and EASA Rules

Global aviation safety bodies have aligned on a clear set of rules for carrying power banks, which are classified as spare lithium-ion batteries. The FAA sets the standard in the United States, which is closely mirrored by the IATA (International Air Transport Association) and the EASA (European Union Aviation Safety Agency). The primary restriction is based on the battery's energy capacity, measured in Watt-hours (Wh).

According to the FAA's PackSafe guidance, the rules are as follows:

• Under 100 Wh: Most power banks fall into this category and are permitted in carry-on baggage without prior airline approval. Passengers can typically carry multiple devices.
• 101-160 Wh: Passengers may carry up to two larger spare batteries in this range, but only with explicit airline approval.
• Over 160 Wh: Lithium-ion batteries exceeding this capacity are strictly forbidden from passenger aircraft.

Crucially, all spare lithium batteries, including power banks, are completely forbidden in checked baggage. The TSA (Transportation Security Administration) enforces this rule at security checkpoints. This is because the crew can more effectively respond to a fire in the cabin than one in the cargo hold. IATA's Dangerous Goods Regulations (DGR) provide the global standard that most airlines adhere to, ensuring these carry-on battery restrictions are consistent worldwide.

A Growing Safety Concern: The Data on In-Flight Incidents

The tightening of regulations is a direct response to a documented rise in in-flight fire safety events. FAA data reveals a sharp increase in lithium battery incidents on U.S. flights, surging 388% between 2015 (16 incidents) and 2024. Of the 89 incidents recorded in 2024, 77 occurred on passenger aircraft.

Further analysis shows that power banks and battery packs are the leading cause of these events, accounting for 27 incidents in 2024. Data from the UL Standards & Engagement Thermal Runaway Incident Program indicates that these are not minor events; in 2024, 18% of on-board thermal runaway incidents resulted in a diverted landing, return to the gate, or an emergency evacuation. This translates to an average of two flights per week experiencing a lithium battery incident, underscoring the urgency behind the regulations.

Airline Policies and In-Flight Use

Beyond carriage rules, a growing number of airlines are now restricting the use of power banks during flight. EASA's Safety Information Bulletin (SIB) 2025-03 recommends that power banks should not be used to charge devices, nor be charged themselves, while airborne. This is to minimize the risk of an overheating event going unnoticed. Airlines that have implemented this policy include Virgin Australia, Qantas, Jetstar, and Emirates.

Regulations also extend to "smart luggage" equipped with built-in chargers. IATA rules mandate that the installed power bank must be removable by the passenger. If the battery cannot be removed, the bag is prohibited from being carried on the aircraft as either checked or carry-on baggage.

What Comes Next for Passengers

Regulatory bodies are continuing to evolve their approach to aviation safety concerns. IATA has announced that effective January 1, 2026, it will mandate a State of Charge (SoC) limit not exceeding 30% for certain lithium-ion batteries shipped with equipment, a rule that could eventually influence passenger-carried items. In the meantime, public awareness remains a key focus. The FAA's 'PackSafe' campaign and similar initiatives from EASA aim to educate passengers on how to check their device's Wh rating and pack safely before arriving at the airport.

Why This Matters

For passengers, the harmonized regulations on power banks remove ambiguity but place the responsibility on the individual to verify their devices comply with the 100Wh battery limit. This development signals a permanent shift in how personal electronic devices are managed in air travel, treating high-capacity batteries as dangerous goods that require careful handling. For the industry, it represents a proactive, data-driven approach to managing a modern fire risk and protecting passengers and crew in the confined environment of an aircraft cabin.

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