Flying With Tech Gear: How to Safely Pack Lithium Batteries for Your Next Trip

Greg Doig is a seasoned traveler and tech enthusiast who understands the challenges that come with bringing gadgets on the go. Having experienced firsthand the pitfalls of flying with lithium batteries, Greg has made it his mission to educate fellow travelers about the regulations and risks involved. Through his engaging show, Greg combines real-life stories with practical advice, offering science-backed explanations to make sure listeners don’t get burned—literally or figuratively—when it comes to flying with tech gear. His approachable style and commitment to clear guidance help travelers stay safe, avoid confiscated equipment, and prevent disasters, all while navigating the ever-evolving rules of modern travel.

Transcript

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Don't get burned! What every traveler needs to know about flying with batteries. Welcome back everyone. I'm Greg Doig and today we're talking about something that affects basically every single person who travels with tech gear. Which, if you're listening to this show, is almost certainly you. Lithium batteries, specifically the rules around flying with them because a lot of people get this wrong. And the consequences can range from having your gear confiscated at the gate to, well,— an actual fire on a plane. So let's get into this. First, a quick science lesson. Don't worry, I'll keep it brief. Lithium-ion batteries, the kind in your phone, your laptop, your camera, your power bank— they're incredibly energy-dense. That's why we love them. But the same property makes them capable of something called thermal runaway. It's a fancy way of saying the battery starts generating more heat than it can handle, —which generates more heat, which— you get the idea. It can happen with zero warning, and it can happen because of physical damage, overcharging, exposure to heat, water, or even just a manufacturing defect. The FAA tracks these incidents. Flight crews are trained specifically for lithium battery fires. This is not theoretical. It happens on planes, which is exactly why the rules exist. Here's the single most important thing to take away from today's episode. Spare lithium batteries, including power banks, must go in your carry-on, not checked baggage. If you're checking a bag, that power bank has to come out and stay with you in the cabin. Period. The reason is simple. If a battery ignites in the cargo hold, no one can get to it. In the cabin, flight crew can intervene. And here's where people get caught off guard. If your carry-on gets gate-checked, you know, when the overhead bins are full and they take your bag at the door, you need to pull your power banks and spare batteries out before they take the bag. That's on you to do proactively. All right, let's talk specs because this is where it gets a little technical. For lithium-ion rechargeable batteries, the kind in most of your gadgets, the limit is 100 watt-hours per battery. Most consumer electronics fall well under that. Your typical phone battery, well, that's about 15 to 20 watt-hours. A standard laptop battery, usually 50 to 75. You're almost certainly fine. If you don't see a watt-hour rating on your battery, here's how to calculate it. Multiply the voltage by amp-hours. So if your battery says 3.7 volts and 10,000 milliamps, that's 10 amp-hours. You've got 37 watt-hours. —so you're safe. Now if you got larger batteries in the 101 to 160 watt-hour range, some professional camera rigs, certain extended laptop batteries, you can bring those but you need airline approval and you're limited to 2 of those larger batteries per person. For lithium metal batteries, the non-rechargeable kind like certain camera batteries and some specialty cells, the limit is 2 grams of lithium per battery with the range up to 8 grams for oversized ones. Again, with airline approval and a 2-battery cap. So here's the thing that catches a lot of people off guard. You have to protect the battery terminals from short-circuiting. The terminals are the metal contacts on the battery. If they touch other metal like loose change, keys, or other batteries rattling around in your bag, you can get a spark or heat buildup. The FAA is very clear on this. The fix is easy. Leave batteries in their original retail packaging, put tape over the terminals, use a battery case or sleeve, or just drop them in separate Ziploc bags. If you're a photographer hauling a bunch of camera batteries, get a dedicated battery case. They're cheap and this is exactly what they're for. Now this one seems obvious but needs to be said. If your battery is damaged, swollen, cracked, leaking,— but don't fly with it. Don't even take it to the airport. A damaged battery is a fire risk and the FAA explicitly prohibits bringing them aboard— in carry-on or checked bags— unless the battery has been removed or made safe. Same goes for recalled batteries and devices. If there's been a recall on your device's battery, check the Consumer Product Safety Commission website at cpsc.gov— don't fly with it until you've addressed the recall. So, okay, let's bring this home with some practical takeaways. Number 1, know what's in your bag. Count your power banks, spare camera batteries, and external battery packs before you get to the airport. Number 2, keep them accessible in your carry-on. Don't bury them at the bottom if you might need to pull them out at the gate. And 3, protect the terminals. Tape, cases, bags, Just don't let bare metal rattle around loose. 4. Inspect your batteries before travel. If anything looks swollen or damaged, leave it home. And 5. When in doubt, carry it on. The rule

of thumb is simple: 5:05

if it has a lithium battery, it belongs in the cabin with you. So that's your lithium battery briefing for today. This is the kind of thing that seems like fine print until it isn't, either because TSA pulls your gear or worse, something goes wrong mid-flight. Know the rules, travel smarter, and keep your gear and everyone else on that plane safe. If you found this useful, share it with someone who's heading out on a trip. And as always, you can find more tech tips, news, and deep dives listening right here with your host, Greg Doig. That's me. Once again, thanks for listening and come back soon.