Aviation authorities and safety experts are emphasizing the critical importance of correctly handling lithium-ion batteries, a move spurred by a notable increase in fire incidents involving these power sources on commercial aircraft.
Lithium-ion batteries, commonly found in rechargeable electronics like power banks, cameras, vapes, and laptops, are considered fire hazards due to their potential to overheat, explode, or ignite fires. These batteries are now mandated for carry-on luggage rather than checked baggage on flights. "These incidents on airlines have increased a lot. There’s been about a 15% increase" from 2024 to 2025, said Kelly Ransdell, director of public education for the National Fire Protection Association (NFPA).
Ransdell highlighted that many consumers are unaware that rechargeable batteries require different handling than other battery types, a misconception that extends to travel. "Rechargeable lithium-ion batteries are the source of 'so many fires,'" she stated, noting that these incidents occur not only on planes but also in homes and workplaces.
While many common electronics like cellphones and laptops are manufactured to meet minimum safety standards, some products, particularly portable chargers and e-cigarettes, present greater risks. "Part of the problem with many of the power banks and e-cigarettes and vapes is they’re not listed, which means the quality of the materials in them doesn’t meet the U.S. quality standards," Ransdell explained. This issue can arise with both internationally manufactured goods and some domestic products that are cheaply made. To mitigate this, Ransdell advises purchasing rechargeable electronics from reputable stores or directly from trusted online retailers, warning that counterfeit products can be disguised as safety-compliant items.
Items not meeting safety standards are more susceptible to overheating, a process known as "thermal runaway." This occurs when a component within the battery, such as the separator, is damaged by factors including extreme temperatures, rapid charging, or physical impact. Manufacturing defects can also contribute to battery damage, according to the Federal Aviation Administration (FAA).
During thermal runaway, the battery overheats to the point of perforation and potential explosion. "You can imagine on an airline, if you were to have a battery and it were to go into thermal runaway in your suitcase or somewhere out of sight … these are big fires from little bitty devices," Ransdell said. "That’s why the airlines have said we want to make sure that people can access it if something were to go wrong." The NFPA advises travelers to "keep it in sight when you’re in flight" and to refrain from bringing any damaged or defective lithium batteries aboard an aircraft.
To maintain safety with rechargeable electronics, experts recommend several precautions. Always use the original charging cable or a correctly specified replacement. Avoid charging devices on soft surfaces like beds or furniture, which can impede heat dissipation. Once a device is fully charged, disconnect it from the charger, as prolonged charging can degrade the battery. Exposure to extreme hot or cold temperatures can also damage lithium-ion batteries.
Signs of a potential battery issue include swelling, discoloration, unusual noises, odd smells, or excessive heat. Such indicators should be treated as red flags, signaling a possible problem with the battery. Flight crews can respond more effectively to incidents if rechargeable items are kept within reach during a flight.