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Reguations about shipping Lithium Batteries Safely


IATA/ICAO Updates

New ICAO/IATA regulations will limit the State of Charge (SOC) to 30% for all lithium ion cells and batteries on both Passenger and Cargo aircraft. Please refer to Packing Instructions 965.

In this case, we will have to fully charge all the cells/packs and discharge to 30% of the capacity in our facility. It will delay the lead time significantly, so we strongly suggest you choose ship by Ground instead by air, because it will take equal or longer time than ship by Ground. If you have to choose ship by air, for example, oversea customers, please charge the cells/packs immediately when you receive them to maintain the cells/packs.

  • January 1st , 2017 – ICAO/IATA Air Regulations – Li Ion and Li Metal in Equipment
    This change refers to cells and batteries “contained in” equipment, Packing Instructions 967 (Lithium Ion) and 970 (LithiumMetal). Each package must be labeled with the Lithium Battery Handling Label. The only exceptions will be for:

    • Packages containing only button cell batteries installed in equipment (including circuit boards); and
    • Consignments of two packages or less where each package contains no more than four cells or two batteries installed in equipment.
      This label change for batteries/cells in equipment is not mandatory until January 1st, 2017.

  • IATA Packing Instruction 965-970
    • Standalone = package ONLY contains batteries, NO equipment
    • Packed with = package contains equipment + batteries that are NOT installed in the equipment
    • Contained in = package has equipment with batteries installed
    •   Lithium Ion Battery Lithium Metal Battery
      Standalone Lithium Ion Standalone (P.I. 965) UN 3480 Lithium Metal Standalone (P.I. 968) UN 3090
      Packed With Lithium Ion Packed With (P.I. 966) UN 3481 Lithium Metal Packed With (P.I. 969) UN 3091
      Contained in Lithium Ion Contained in (P.I. 967) UN 3481 Lithium Metal Contained in (P.I. 970) UN 3091


Transport within Passenger Baggage


Carrier's Shipping requirement for Lithium Batteries


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DOT (PHMSA) Updates

  • 49 CFR 173.185
  • Proper Shipping Names
    • UN 3480, Lithium Ion Batteries
    • UN 3481, Lithium Ion Batteries packed with equipment
    • UN 3481, Lithium Ion Batteries contained in equipment
    • UN 3090, Lithium Metal Batteries
    • UN 3091, Lithium Metal Batteries packed with equipment
    • UN 3091, Lithium Metal Batteries contained in equipment

Ship Prototypes of Lithium batteries

  • 173.185(e) - Must be shipped by ground as Class 9
  • A55 Cargo aircraft under approval. (The lead time for approval is around 3-6 months. Customer can contact PHMSA for shipping approval by air) (DOT)

Low Production Runs

  • 173.185(e) low production runs of not more than 100pcs, must be shipped by ground as Class 9, Packing Group I packaging. Applies to small batteries.
  • A88 Cargo aircraft under approval (The lead time for approval is around 3-6 months. Customer can contact PHMSA for shipping approval by air)

Damaged, defective or recalled Cells or Batteries

  • 173.185(f) - ship by class 9 , Packing Group I level


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Lithium Battery Calculations

  • Watt hours = Volts (V) x ampere hour (Ah)
  • Lithium Content is: Ah per cell x 0.3 gm x number of cells
  • Lithium Battery Calculation help document
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What to consider when designing Lithium Batteries?
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Bluetooth Technology for Lithium-ion/LiFePO4 Batteries
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UN 38.3 Safety Test

We own a national standard UN38.3 testing lab. We can provide UN38.3 test service to our customer.

If you want to set up your own lab, we also provide UN38.3 & IEC62133 equipments and onsite training. Email us for the quote and lead time.
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Lithium Battery Shipping Regulation
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Recommendations on How to get ≤30% Rated Capacity for Shipping
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Thermal Abuse Test for IEC62133
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Thermal Spread Material used in Battery Pack Assembly
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Show & Conference
The BatteryShow 2016, Sept 13-15, 2016, Novi Michigan, Booth#1716
33rd International Battery Exhibit, March 21-24, 2016, Florida, Booth#412
Lithium Battery Power and Safety, Baltimore MD, Nov 17-19, 2015
The Battery Show, Novi. MI, Sept 15-17, 2015 Booth#1716
Battery Power 2015, Denver, CO, August 5-6, 2015 Booth#29
Next Generation Batteries Conference, San Diego, CA, April 21-22, Booth#9
More ...
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