Can I fly with a Dewalt battery?

Lithium ion batteries installed in a personal electronic device can be transported as checked or carry-on baggage. Lithium ion batteries not installed in a device (spares) must be in carry-on baggage and no more than two (2) spares between 100 and 160-watt hours are allowed.



Yes, you can fly with a DeWalt (lithium-ion) battery, but you must follow strict FAA and TSA safety regulations regarding "spare" batteries. First and foremost, spare lithium batteries of any kind—including those for power tools—are strictly prohibited in checked luggage due to the risk of "thermal runaway" or fire. They must be packed in your carry-on bag. Most standard DeWalt 20V Max batteries are under the 100-Watt-hour (Wh) limit, meaning you can carry as many as you want for personal use. However, if you are using the high-capacity DeWalt FLEXVOLT batteries (which can be 180Wh or 240Wh), you are limited to a maximum of two per passenger, and they may require airline approval. To be safe in 2026, you should cover the battery terminals with electrical tape or place each battery in a separate plastic bag to prevent short-circuiting. DeWalt also provides a specific "shipping cap" for FlexVolt batteries that "disconnects" the cells to keep them under the 100Wh threshold for air travel; always ensure this cap is clicked into place before heading to the security checkpoint.

People Also Ask

Lithium batteries can catch fire
While not all batteries are prohibited in checked luggage, lithium batteries are considered hazardous and should not be packed in checked bags. If a lithium battery overheats and catches fire inside the cargo hold, the fire can quickly spread and become difficult to control.

MORE DETAILS

Spare (uninstalled) lithium ion and lithium metal batteries, including power banks and cell phone battery charging cases, must be carried in carry-on baggage only. With airline approval, passengers may also carry up to two spare larger lithium ion batteries (101–160 Wh) or lithium metal batteries (2-8 grams).

MORE DETAILS

Spare (uninstalled) lithium ion and lithium metal batteries, including power banks and cell phone battery charging cases, must be carried in carry-on baggage only.

MORE DETAILS

Spare (uninstalled) lithium ion and lithium metal batteries, including power banks and cell phone battery charging cases, must be carried in carry-on baggage only. With airline approval, passengers may also carry up to two spare larger lithium ion batteries (101–160 Wh) or lithium metal batteries (2-8 grams).

MORE DETAILS

Consumer-sized batteries (up to 2 grams of lithium per battery) may be carried. This includes all the typical non-rechargeable lithium batteries used in cameras (AA, AAA, 123, CR123A, CR1, CR2, CRV3, CR22, 2CR5, etc.)

MORE DETAILS

Spare (uninstalled) lithium ion and lithium metal batteries, including power banks and cell phone battery charging cases, must be carried in carry-on baggage only. With airline approval, passengers may also carry up to two spare larger lithium ion batteries (101–160 Wh) or lithium metal batteries (2-8 grams).

MORE DETAILS

For example, flyers often wonder if a 20000mah power bank is allowed on flight. As 20000mah makes for less than 100 watt-hours, it can be carried in cabin luggage.

MORE DETAILS

In summary: Power banks are allowed on planes in carry on bags only. Power banks are not allowed in checked luggage / cargo luggage. You can bring power banks up to 27,000 mAh on most passenger aircraft.

MORE DETAILS

If carry-on baggage is checked at the gate or planeside, spare lithium batteries, electronic cigarettes, and vaping devices must be removed from the baggage and kept with the passenger in the aircraft cabin. Even in carry-on baggage, these items should be protected from damage, accidental activation and short circuits.

MORE DETAILS

Such a hazard, in fact, that the FAA has issued a new warning on the dangers such batteries could pose to aircraft, and the could on board, essentially calling for their ban. Lithium batteries present a risk of both igniting and fueling fires in aircraft cargo/baggage compartments.

MORE DETAILS

5 A maximum of 15 Personal Electronic Devices per passenger and 20 lithium metal batteries per passenger are permitted on each flight.

MORE DETAILS

Lithium batteries can produce dangerous heat levels, cause ignition, short circuit very easily, and cause inextinguishable fires. That's why renowned aviation authorities, including those in the USA, have banned lithium batteries when traveling.

MORE DETAILS

Spare (uninstalled) lithium ion and lithium metal batteries, including power banks and cell phone battery charging cases, must be carried in carry-on baggage only. With airline approval, passengers may also carry up to two spare larger lithium ion batteries (101–160 Wh) or lithium metal batteries (2-8 grams).

MORE DETAILS