Planning to fly with your power bank, cordless curler, or tablet? Think again—new 2025 airline rules around batteries on planes are stricter than ever, and travelers who don’t pay attention could face delays, confiscated gear, or even safety risks.
With lithium battery incidents on the rise—62 reported so far this year alone, according to the Federal Aviation Administration (FAA)—authorities are cracking down on where and how you pack anything that plugs in or recharges .
Why Batteries on Planes Are a Big Deal in 2025
The core concern? Thermal runaway—a chain reaction in lithium-ion or lithium-metal batteries that can cause them to overheat, smoke, or even explode. In January 2025, a fire that destroyed an Air Busan plane on the tarmac in South Korea was possibly sparked by a power bank .
“While incidents remain rare, they’re increasing,” says Jeff Marootian, CEO of UL Standards & Engagement. “And the more rechargeable devices we carry, the higher the risk.”
What Counts as a ‘Battery Device’?
If it’s rechargeable, it likely contains a lithium battery. That includes:
- Smartphones and tablets
- Laptops and e-readers
- Smartwatches and wireless earbuds
- Electric toothbrushes and shavers
- Vapes and e-cigarettes
- Portable power banks
- Certain cordless hair tools (especially butane-powered ones)
“Don’t overcomplicate it,” Marootian advises. “Just ask: Can I plug this in to recharge it? If yes—it belongs in your carry-on.”
2025 Airline Rules at a Glance
| Device Type | Allowed in Carry-On? | Allowed in Checked Bag? | Special Notes |
|---|---|---|---|
| Phones, laptops, tablets | ✅ Yes | ⚠️ Only if completely powered off | Must be protected from damage/accidental activation |
| Power banks / spare batteries | ✅ Yes | ❌ No | Never allowed in checked luggage |
| Vapes / e-cigarettes | ✅ Yes | ❌ No | Must stay with passenger in cabin |
| Butane-powered curlers/dryers | ✅ One per person | ❌ No | TSA will hand to airline if found in checked bags |
| Damaged or recalled devices | ❌ Avoid entirely | ❌ Never allowed | Cracked screens may indicate battery damage |
What If My Bag Gets Gate-Checked?
This is a common blind spot. If you’re asked to check your carry-on at the gate, you must remove all lithium-powered devices first—including your phone charger, smartwatch, and vape.
Yet according to UL Standards, 30% of travelers who gate-check bags aren’t reminded to do this—and 38% admit to packing lithium batteries in checked luggage anyway .
Pro Tips for Safe, Stress-Free Travel
- Inspect devices before packing: Look for swelling, overheating, or physical damage.
- Keep batteries in your personal item: Not just carry-on—ideally in a bag under the seat for quick access.
- Never charge devices in overhead bins: This is a fire hazard and often against airline policy.
- When in doubt, leave it out: Damaged or recalled devices shouldn’t fly at all.
The Bottom Line
Batteries on planes aren’t banned—but how and where you pack them matters more than ever in 2025. With safety agencies and airlines tightening enforcement, a little awareness can save you time, gear, and peace of mind.
