LiFePO4 New ICAO Requirements for airline passengers were effective March 27, 2026
Bottom line:
Same as before: we can take two batteries over 100Wh but under 160Wh only as carry-on, and none larger. Airline approval still needed, and no exposed terminals - need to be taped or in protective pouches to prevent shorts.
While past reports show lax enforcement, new penalties and a crackdown on rules are due to increased battery fires and penalties for airlines if rules are not followed.
NEW: Airlines will not give last-minute approval at the gate. To get approval to carry batteries over 100Wh but under 160Wh, you must submit a written request to the airline along with your UN38.3 documentation 3 to 7 days before your flight. Carry a copy of the airline's written approval and your UN38.3 papers to the gate. Based on the process described, you may also need to present these documents to TSA or foreign security screeners.
More background and comments:
Even safer chemistries like LiFePO4 are subject to the same transport rules since all lithium batteries pose some fire risk in air travel.
UN38.3 Mandate: Reaffirmed that all lithium batteries carried by air must have passed UN38.3 testing, a global standard that verifies batteries can withstand the vibration, pressure changes, and temperature extremes of air travel without failure.
ICAO (International Civil Aviation Organization): Global Harmonization: Mandated that all member states adopt the UN38.3 testing requirement for lithium batteries, with no exceptions for consumer-grade devices.
Individual airlines may have stricter battery limits than the baseline. Always verify airline rules before travel.
If your battery is rejected or you have not met the pre-approval requirements, you will need to either surrender the battery, ship it to your destination via certified dangerous goods freight, or make alternate arrangements. Always verify airline-specific rules before travel, and carry UN38.3 documentation for 100–160Wh batteries.
Much of this is at https://jmbatteries.com; however, the citations at the end are not relevant.
I had to do a lot of research to find the source, which is already being used by some AI, which is how I first heard about it.
I believe the original source is ICAO Technical Instructions DOC 9284:
TECHNICAL INSTRUCTIONS FOR THE SAFE TRANSPORT OF DANGEROUS GOODS BY AIR REVISIONS INCORPORATED IN THE 2025-2026 EDITION
Notes:
I have confirmed on airlines I use, American, Air Canada and Porter (use for Toronto since now direct PHX-YYZ), have on-site permission for 100-160Wh, but only American includes permission required in the current rules. But airlines should update their websites to show new rules.
I have confirmed that Bioenno and Goldemate batteries are UN38.3 certified, but I need to find out how to obtain a copy of the certification.
I plan to use two Goldemate 12Ah 12v, which actually say 12.8v on the battery label, for a total of 153.6 Wh, which is under 160. I also have a 12Ah Bioenno and am comparing it, but others have praised the Goldemate at a much lower cost.
Dave WØJKT "Just Killing Time" since 1964. HF SSB Only. Extensive bio on QRZ