Why airlines are warning over lithium-ion batteries

A recent flight to Las Vegas for technology journalist Ben Wodecki concluded with firefighters meeting the plane due to a battery fire, an incident that highlights why airlines are increasingly issuing warnings about lithium-ion batteries.

Wodecki, accustomed to global travel and observing airline crews, witnessed an unusual scene in June as worried flight attendants rushed to the rear of the aircraft. He described a "glint of fear" and a "dour" demeanor among the crew, indicating a serious situation beyond a passenger feeling unwell. Smoke and distressed passengers soon emerged from the back, revealing that a passenger's battery pack had overheated, ignited, and set a seat on fire.

According to Wodecki, the flight crew submerged the burning device in water. The plane then executed a "fast and aggressively" landing at Harry Reid International Airport in Las Vegas, where fire crews were waiting on the runway. This dramatic conclusion to an otherwise routine flight underscores the growing emphasis on the dangers of bringing battery-powered devices, particularly those with lithium-ion batteries, onto flights. These warnings include advice against retrieving devices that fall into seats and pleas to avoid placing lithium-ion devices in checked luggage.

Jonathan Nicholson of the UK's Civil Aviation Authority (CAA) states that lithium-ion batteries have been "within the top three risks" for the airline industry for several years, if not the number one concern. He cited a recent US study indicating two lithium-ion battery-related incidents per week globally. These incidents range from passengers realizing they left a device in checked baggage to devices smoking or catching fire in airport baggage halls or during flights.

The consequences can be severe. In January 2025, an Air Busan plane was destroyed on the tarmac at Gimhae Airport in South Korea, with investigators concluding that a power bank left in an overhead compartment was responsible. This incident prompted the International Air Transport Association (IATA) to launch a global campaign, "Travel Smart with Lithium Batteries," to educate passengers.

Nicholson clarified that flying itself does not make lithium-ion technology inherently more dangerous, but rather that "it's a lot harder to deal with at 32,000 feet in an aircraft cabin." He attributed the rise in lithium-ion related incidents to "more people, more flights, more devices."

The US Federal Aviation Administration prioritizes battery safety, with its data showing a "continued increase in confirmed incidents," totaling 51 verified incidents for the year up to July 15.

Pierre Kubiak, a principal engineer specializing in battery technology at the UK's National Physical Laboratory, noted that while cell phones, power banks, tablets, and laptops are common portable devices on planes, smartwatches, smart glasses, and vapes are becoming increasingly prevalent. He explained that "the lithium by itself doesn't burn; it's more all the organic material and plastic." He added that these devices can become "very, very hot, very fast," reaching temperatures of "more than 700 to 1000 degrees super fast."

Public awareness of lithium-ion battery dangers significantly increased about a decade ago following a series of phone-related fires. Kubiak attributed these to flawed designs that manufacturers have since addressed, with South Korea being a leader in this area. However, he highlighted the challenge of controlling the proliferation of cheaply produced battery packs, vapes, and other powered devices from East Asia, which often have questionable quality controls due to "price is everything." He also noted that passengers contribute to the problem by using unsuitable cables and neglecting device care.

Airlines are left with the primary option of reiterating warnings and relying on established protocols to ensure staff are trained to quickly manage incidents. Nicholson of the CAA emphasized that "the most important thing is to bung it in water and cool it down," although some airlines utilize specialized containment devices. This underscores the critical importance of keeping devices in the cabin, not in overhead compartments, and certainly not in the cargo hold.

Nicholson observed that customers generally respond well to warnings and restrictions, but the main issue is often their unawareness of how many devices rely on lithium-ion battery technology.

Kubiak stated that there are currently no economic alternatives to lithium-ion technology, as the tech and personal device industries are heavily invested in it. While sodium-ion batteries exist as an alternative, they are currently twice as expensive for consumers as lithium devices. Kubiak suggested a greater focus on safeguarding existing technology, stating, "We don't necessarily want to have battery banks banned from every plane," and that a solution must be both technical and societal.