New rule mandates all lithium battery devices be hand-carried; Southwest adds visibility policy as fire concerns grow
By Zachary Fields | Washington, D.C. | May 28, 2025
The Transportation Security Administration (TSA) has reinforced its longstanding policy barring power banks and lithium-ion batteries from checked luggage. The updated reminder, issued May 28, comes amid heightened concerns over battery-related fires aboard aircraft.
Passengers are now urged to carry all such devices in their hand luggage, with major airlines adopting new, stricter enforcement policies. Southwest Airlines has simultaneously announced a companion rule: portable chargers must remain visible and not be stored in personal items while in use.
This renewed focus on safety follows several incidents involving battery malfunctions mid-flight, most notably a recent fire aboard an aircraft in South Korea, believed to be caused by an overheated power bank.
Lithium-Ion Batteries and Flight Risk
Lithium-ion batteries, commonly found in smartphones, laptops, and portable charging devices, are capable of catching fire or exploding when damaged or exposed to heat. Fires that occur in an aircraft’s cargo hold—where checked baggage is stored—can be especially dangerous, as they may go undetected until they spread.
The TSA’s statement reiterated that the potential for thermal runaway—a chain reaction leading to intense fire—is the main reason lithium batteries must be accessible during flight.
“Passengers must store power banks and spare batteries in their carry-on luggage. Doing so ensures a faster response in the rare event of a malfunction,” a TSA representative emphasized.
Reports of electronic device fires have increased over the past five years. Most incidents involved personal devices that either overheated while charging or experienced internal short-circuits. If stored inside checked luggage, these devices become inaccessible during flight, elevating the threat.
Southwest Airlines Enacts Visibility Rule
In a move to further bolster in-flight safety, Southwest Airlines introduced a new policy requiring passengers to leave power banks visible while in use. Effective immediately, travelers must avoid placing charging devices inside bags, seat pockets, or other covered areas during operation.
“Our goal is to allow the crew to detect overheating quickly and act immediately,” a Southwest spokesperson said.
This measure aligns with international safety discussions currently underway, following high-profile incidents that prompted a global reexamination of airline battery protocols.
What Travelers Should Know Before Flying
To avoid delays or confiscation of devices at security, travelers are encouraged to familiarize themselves with these updated guidelines:
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Carry-on only: Place all power banks, spare lithium batteries, and similar devices in hand luggage.
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Visible use: If using a portable charger during flight, keep it outside of bags so crew can monitor for overheating.
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Capacity limits: Batteries exceeding 100Wh may require airline approval; over 160Wh are generally not allowed.
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Inspect devices: Do not fly with visibly damaged, swollen, or leaking batteries.
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Use certified products: Avoid low-cost, uncertified chargers that may lack proper safety mechanisms.
Travelers are also advised to pack devices in fire-resistant pouches when possible and refrain from using faulty accessories that could cause short circuits.
Summer Travel Surge Increases Risk
With the summer travel season kicking off, U.S. airports are expected to see record numbers of passengers. As more people fly with personal electronics and backup batteries, the importance of adherence to TSA regulations becomes even more critical.
Airlines are working closely with airport security and flight crews to ensure safe handling of electronic items. Enhanced signage and passenger awareness campaigns are being rolled out nationwide.
Expert Tips for Battery Safety in the Air
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Use OEM (original equipment manufacturer) chargers to avoid compatibility issues.
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Avoid charging while sleeping during flights to reduce unattended risks.
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Do not daisy-chain power banks or connect multiple batteries together.
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Replace old batteries: Devices older than three years may pose a higher risk of failure.
Passengers who notice smoke or excessive heat from a device should immediately alert the flight crew. Quick action can prevent incidents from escalating and ensure everyone’s safety on board.
