Why airlines are warning over lithium-ion batteries

Lithium-Ion Battery Risks on Flights

The use of lithium-ion batteries on flights has become a significant concern for the airline industry. According to the UK's Civil Aviation Authority (CAA), lithium-ion batteries are one of the top three risks for the industry. The CAA has been warning passengers about the dangers of lithium-ion batteries on flights, and the International Air Transport Association (IATA) has launched a global campaign to encourage passengers to 'Travel Smart with Lithium Batteries'.

The risks associated with lithium-ion batteries on flights are not unique to the UK. A recent study showed that there are two lithium-ion battery-related incidents a week worldwide. These incidents can range from passengers forgetting to retrieve devices from checked luggage to devices smoking or catching fire in airport baggage halls or on flights.

In January 2025, an Air Busan plane was destroyed on the tarmac in Gimhae Airport in South Korea due to a power bank battery pack left in an overhead luggage compartment. This incident prompted the IATA to launch its global campaign.

The CAA's Jonathan Nicholson explains that lithium-ion batteries are not inherently more dangerous than other types of batteries. However, they are harder to deal with at high altitudes in an aircraft cabin. Nicholson attributes the prevalence of lithium-ion related incidents to 'more people, more flights, more devices'.

Pierre Kubiak, a principal engineer specialising in battery technology at the UK's National Physical Laboratory, adds that while cell phones, power banks, tablets, and laptops are the most obvious portable devices people bring on planes, smart watches, smart glasses, and vapes are increasingly common.

Kubiak explains that the lithium by itself does not burn, but the organic material and plastic surrounding it can catch fire. He notes that the point of concern is that the lithium can get very hot, very fast, reaching temperatures of over 700 to 1000 degrees in a short amount of time.

The dangers of lithium-ion batteries have been in the public consciousness for over a decade, following a series of phone-related fires. Kubiak notes that this was due to flawed designs, which manufacturers have since addressed. However, the proliferation of cheaply produced battery packs from East Asia, as well as vapes and other powered devices with questionable quality controls, remains a concern.

Passengers often contribute to the problem by using unsuitable cables and not caring for devices. The CAA's Nicholson stresses that the most important thing is to 'bungle it in water and cool it down' when dealing with a lithium-ion battery incident. Some airlines use specialised containment devices, but the key is to keep devices in the cabin, not in overhead compartments, and definitely not in the hold.

The biggest problem is that passengers are often unaware of just how many devices rely on lithium-ion battery technology. There are no economic alternatives to lithium-ion technology at present, and the tech and personal device industries are heavily invested in the technology. One alternative is sodium-ion batteries, but the technology is currently double the cost of lithium devices for consumers.

Kubiak suggests that there should be more of a focus on safeguarding around the existing technology. 'We don't necessarily want to have battery banks banned from every plane,' he says.