What Were the TSA Lithium Battery Rules in 2017?

Short In 2017, the TSA restricted lithium batteries in checked baggage, allowing only smaller ones (under 100 watt-hours) in carry-ons. Passengers could bring two larger spares (100–160 Wh) with airline approval. These rules aimed to reduce fire risks, aligning with FAA safety protocols. Always declare batteries and check airline-specific policies before flying.

Rack-mounted LiFePO4 Battery

How Did TSA Regulate Lithium Batteries in 2017?

The TSA enforced FAA guidelines in 2017, limiting lithium-ion batteries to 100 watt-hours (Wh) in carry-ons. Spares above 100 Wh but under 160 Wh required airline approval, with a maximum of two. All loose batteries had to be protected from short-circuiting. Checked baggage prohibited lithium batteries except those installed in devices. These measures addressed fire hazards linked to thermal runaway in lithium cells.

The 100 Wh threshold was based on extensive testing showing smaller batteries posed lower combustion risks. For context, most smartphone batteries range from 5–20 Wh, while high-end laptops typically use 50–100 Wh cells. The TSA required passengers to declare batteries exceeding 100 Wh during security screening, with non-compliant items confiscated. Airlines like American and JetBlue provided pre-flight checklists to help travelers calculate watt-hours using voltage and milliamp-hour (mAh) ratings. A common exception allowed photographers to carry up to 20 spare camera batteries if individually wrapped—a concession for professional equipment.

Why Were Lithium Batteries Restricted in Checked Luggage?

Checked baggage compartments lack fire-suppression systems, making lithium battery fires catastrophic. The TSA banned loose lithium batteries in checked bags to mitigate uncontrolled in-flight blazes. Devices with installed batteries (e.g., laptops) were permitted if powered off. This rule prioritized containment, as cabin crews could manage fires in carry-ons using extinguishers.

Cargo holds use Halon gas systems ineffective against lithium fires, which require specialized copper aerosol suppressants. At 35,000 feet, a single thermal runaway event can reach 1,100°F—hot enough to melt aluminum aircraft frames. The FAA recorded 31 air/airport incidents involving lithium batteries in 2016 alone, prompting the 2017 crackdown. Notable cases included a Samsung Galaxy Note 7 recall affecting air travelers and a cargo plane fire traced to mislabeled battery shipments. By restricting loose batteries to cabins, crews gained critical response time—on average, 3 minutes faster detection compared to cargo fires.

“The 2017 TSA rules were a critical step in aviation safety. Lithium batteries’ energy density makes them indispensable but hazardous. By standardizing carry-on limits and improving crew training, the industry prevented dozens of potential in-flight incidents. However, passengers must stay vigilant—non-compliant batteries still cause 30% of aviation fire reports annually.” — Redway Power Solutions Safety Team

FAQ

Could I Bring a 200Wh Power Bank in 2017?

No. The maximum allowed was 160Wh with airline approval. Power banks above 160Wh were universally prohibited.

Were Laptop Batteries Restricted?

Most laptops (under 100Wh) were permitted in carry-ons. Those over 100Wh required airline authorization but couldn’t exceed 160Wh.

Did These Rules Apply to Checked Cameras?

Cameras with installed batteries were allowed in checked bags if powered off. Spare camera batteries had to stay in carry-ons.