Why airlines are warning over lithium-ion batteries

Ben Wodecki, a seasoned globetrotter accustomed to the predictable rhythm of air travel and the diligent work of flight crews, found himself witnessing an unprecedented scene during a flight into Las Vegas in June. The technology journalist observed a palpable shift in the cabin’s atmosphere as visibly worried flight attendants hurried towards the rear of the aircraft. "There was a glint of fear. They were dour," Wodecki recounted, emphasizing that this was far beyond the concern for a passenger’s illness; it was an incident that deeply unsettled the crew.

The unfolding drama soon became apparent: smoke began to emanate from the back of the plane, followed by distressed passengers. The cause was a passenger’s battery pack, which had overheated and ignited during the flight, setting a seat ablaze. In a swift and decisive action, the flight crew managed to douse the device in a container of water, Wodecki explained. The aircraft then executed a "fast and aggressive" landing at Harry Reid International Airport in Las Vegas, where emergency services, including fire crews, were already on standby on the tarmac.

This dramatic event, a stark interruption to an otherwise routine flight, serves as a potent illustration of why airlines are increasingly issuing more frequent and emphatic warnings about the inherent dangers associated with carrying battery-powered devices, particularly those utilizing lithium-ion technology, on board. These warnings extend to cautioning passengers against attempting to retrieve personal electronic devices that may have slipped into the narrow crevices between seats, and a firm plea to refrain from placing lithium-ion devices in checked luggage.

According to Jonathan Nicholson of the UK’s Civil Aviation Authority (CAA), lithium-ion batteries have been a significant concern for the airline industry for "a good few years now," ranking either as the number one or within the top three risks. He cited a recent US study which revealed that the global aviation industry experiences approximately two lithium-ion battery-related incidents per week. These incidents can vary widely, from passengers inadvertently leaving devices in checked baggage, to devices emitting smoke or catching fire in airport baggage halls, or even inflight.

The consequences can be far more catastrophic. In January 2025, an Air Busan aircraft was completely destroyed on the tarmac at Gimhae Airport in South Korea. Investigators concluded that a power bank left in an overhead luggage compartment was the direct cause of the devastating fire. This incident prompted the International Air Transport Association (IATA) to launch a global awareness campaign, urging passengers to "Travel Smart with Lithium Batteries."

Nicholson clarified that there is nothing inherently more dangerous about lithium-ion technology itself that makes it problematic for air travel. Instead, he explained, "it’s a lot harder to deal with at 32,000 feet in an aircraft cabin." The escalating frequency of lithium-ion related incidents is attributed to a confluence of factors: "more people, more flights, more devices." The US Federal Aviation Administration (FAA) also confirms that battery safety remains a top priority, with its data consistently indicating an increase in confirmed incidents. For the year ending July 15th, the FAA reported 51 verified incidents.

Pierre Kubiak, a principal engineer specializing in battery technology at the UK’s National Physical Laboratory, highlighted the expanding range of personal electronic devices that are becoming increasingly common on flights. Beyond the ubiquitous cell phones, power banks, tablets, and laptops, he noted the growing presence of smartwatches, smart glasses, and vapes, all of which rely on lithium-ion batteries. Kubiak elaborated on the nature of the hazard, explaining that it is not the lithium itself that burns, but rather the surrounding organic materials and plastics. He emphasized the rapid and intense nature of the thermal runaway, stating, "The point is that it gets very, very hot, very fast. I mean, more than 700 to 1000 degrees super fast."

The dangers associated with lithium-ion batteries first captured widespread public attention about a decade ago, following a series of incidents involving fires originating from mobile phones. Kubiak attributed these early issues to design flaws, which he noted have since been largely addressed by manufacturers, with South Korea being a leader in these advancements. However, he expressed concern about the proliferation of cheaply produced battery packs from East Asia, as well as vapes and other powered devices, often manufactured with questionable quality control. "Price is everything," he commented, adding that passengers can exacerbate the problem through the use of unsuitable charging cables and general neglect of their devices.

Consequently, airlines are left with no alternative but to reinforce their existing warnings and rely on established protocols for training staff to respond effectively and swiftly to such incidents. Nicholson of the CAA stressed that "the most important thing is to bung it in water and cool it down," although some airlines have invested in specialized containment devices. This underscores the critical importance of keeping these devices in the cabin, rather than in overhead compartments or, most critically, in the aircraft’s cargo hold.

Nicholson also observed that passengers generally seem to be receptive to the warnings and restrictions. The primary challenge, he believes, lies in the simple fact that many travelers are unaware of the sheer number of everyday devices that are powered by lithium-ion battery technology.

Currently, there are no economically viable alternatives to lithium-ion technology that can meet the demands of the tech and personal device industries, which are heavily invested in its widespread adoption. Kubiak mentioned sodium-ion batteries as a potential alternative, but noted that the technology is currently twice as expensive for consumers. He emphasized that addressing this issue requires not only a technical solution but also a broader societal shift in approach.

Kubiak suggested a greater focus on enhancing safety measures and safeguards surrounding the existing lithium-ion technology, rather than outright banning battery banks from all flights. The goal, he posited, is to manage the risks effectively, ensuring that passengers can continue to travel with their essential electronic devices while mitigating the potential for hazardous incidents. The ongoing efforts by regulatory bodies and industry organizations aim to strike this balance, promoting awareness and responsible handling of lithium-ion batteries in air travel.