In its August 12, 2025 article, the FAA described how overheating lithium-ion batteries can produce heavy smoke and, in some cases, fire.
Battery Incident Context
The FAA's August 2025 incident account reported 38 verified lithium-battery incidents involving smoke, fire or extreme heat through June 30, 2025, across passenger and cargo aircraft together. It also recorded 89 incidents in 2024. The agency described inspectors working with airlines on hazardous-materials procedures and on safe storage of passengers' items containing lithium-ion batteries. After an incident, inspectors contact people with key information as part of an investigation. A company that intentionally withholds information about shipment contents from a cargo carrier can face FAA enforcement and severe civil penalties.
Packed With or Contained In Equipment
Under 49 CFR 173.185, equipment is the device or apparatus that the lithium cells or batteries power. The section covers both lithium metal and lithium-ion chemistries. In its February 10, 2026 proposed rule, PHMSA proposed a 30 percent rated-capacity state-of-charge limit in Special Provision A100 for lithium-ion batteries packed with equipment when they exceed 2.7 Wh. For batteries at or below 2.7 Wh, the corresponding 30 percent level would be a recommendation. For lithium-ion batteries contained in equipment, the proposal described a recommendation for a 30 percent state-of-charge or an indicated battery capacity of no more than 25 percent.
Damaged Batteries and Return Shipments
FAA SafeCargo warns that an item originally shipped by air may lose authorization for a subsequent air shipment after it has been altered. Its examples include damaged, defective or recalled lithium batteries and packaging that has been opened, modified or used. The agency also identifies lithium batteries among products that can be unregulated by ground yet count as dangerous goods by air.
Air transport exposes products to vibration, static electricity, temperature changes and pressure changes. FAA SafeCargo says improperly handled products can leak, generate toxic fumes, catch fire or explode under those conditions. Such events can threaten aircraft, passengers, crews, transportation workers, emergency responders, the public and the environment.
Under 49 CFR 173.185(f), lithium cells or batteries damaged or identified by the manufacturer as defective for safety reasons, with the potential to cause dangerous heat, fire or short circuit, are limited to highway, rail or vessel transport. The section includes batteries being returned to the manufacturer for safety reasons as an example. It separately provides for transport of nonconforming cells or batteries under conditions approved by the Associate Administrator.
Crew-Carried Batteries
The FAA's September 9, 2025 battery alert addressed risks in aircraft passenger compartments, including batteries carried by passengers and crewmembers. It called for airline risk mitigation, clear messaging about potential battery fires, and reviews of firefighting procedures, equipment and training.
FAA PackSafe identifies power banks and cell phone battery charging cases as spare batteries. Spare lithium-ion and lithium metal batteries for personal electronics must travel in carry-on baggage. When a bag is checked at the gate or planeside, PackSafe says spares and power banks must be removed and kept with the passenger in the aircraft cabin. Its examples of personal electronics include cameras, cell phones, laptop computers, tablets, watches and calculators.
FAA PackSafe also states that lithium batteries must undergo safety testing. PackSafe says all lithium-ion batteries are capable of thermal runaway. It can arise without warning after damage, overheating, water exposure, overcharging or improper packing, or from manufacturing defects.