FAA - Lithium Battery Incidents

FAA – Lithium Battery Incidents

Lithium batteries power our modern lives—they’re inside smartphones, laptops, e-scooters, medical devices, and countless other gadgets we use every day. But while these compact powerhouses enable technological convenience, they also pose serious risks, especially when they’re onboard airplanes. The Federal Aviation Administration (FAA) has been increasingly focused on the dangers lithium batteries can present in aviation, particularly concerning fire and explosion hazards.

Lithium batteries, including lithium-ion/sodium ion (rechargeable) and lithium metal (non-rechargeable)—can overheat and catch fire under certain conditions. These fires are often triggered by a phenomenon called thermal runaway, a chemical chain reaction that causes temperature and pressure to spike rapidly, potentially leading to combustion or even explosion.

Common causes of lithium battery failures include:

Manufacturing defects
Physical damage or punctures
Overcharging or short-circuiting
Exposure to high heat
Improper packaging during shipping

Inside an aircraft cabin or cargo hold, such failures pose a critical safety risk—especially mid-air, where rapid response and containment are vital.

The FAA’s latest report paints a troubling picture. In 2024, there were 89 verified lithium battery incidents aboard aircraft involving batteries that smoked, ignited, or produced extreme heat—a 16% increase from the previous year.

77 incidents occurred on passenger aircraft
12 incidents were on cargo aircraft

The FAA tracked the source of these incidents to the following types of devices:

Device Type	Number of Incidents
Battery packs / batteries	27
Cell phones	16
e-Cigarette / vape devices	15
Laptops	13
Other electronics	18

These numbers only reflect verified cases. The FAA notes that many incidents likely go unreported or undocumented, as the agency relies heavily on hazmat incident reports submitted by air carriers to compile this data.

To combat the rising threat of in-flight lithium battery incidents, the FAA has established comprehensive safety protocols:

Passenger Regulations

Spare lithium batteries are only allowed in carry-on luggage, not checked bags.
Batteries must have protected terminals to prevent short circuits (e.g., by taping or packaging).
Larger batteries (over 100 Wh) require airline approval before boarding.

Cargo Rules

Lithium-ion batteries shipped as cargo (i.e., not installed in or packed with equipment) are prohibited on passenger aircraft in any quantity or size, as mandated by both the FAA and international regulations (ICAO/IATA).
Such batteries may only be transported on cargo-only aircraft under strict conditions.
All lithium battery shipments must comply with Hazardous Materials Regulations (HMR), which include rigorous packaging, labeling, documentation, and state-of-charge limits.
Airlines and freight operators use fire-containment packaging, temperature monitoring, and hazmat detection systems to manage potential in-flight failures.

Everyone has a part to play in aviation safety. This includes both shippers and passengers. Here’s how you, yourself, can help reduce the risk:

Don’t pack loose batteries in checked luggage.
Avoid damaged or knockoff electronics—use only certified and reputable brands.
Keep an eye on devices—especially power banks and vapes—for signs of swelling or heat.
Report any overheating devices to flight attendants immediately.

The spike in lithium battery incidents is a reminder: even the smallest device can pose a significant risk at 35,000 feet.

As always, should you have any questions regarding lithium-ion batteries, check out our Lithium Battery FAQ or contact ICC Compliance Center at 1.888.442.9628 (USA) or 1.888.977.4834 (Canada).