It finally happened. You’re standing in the security line at O’Hare, clutching a venti latte, and you realize your massive 30,000 mAh power bank is buried somewhere at the bottom of your checked suitcase. In the past, you might have shrugged it off. Not anymore.
The TSA issues new carry-on rules for lithium-ion battery-powered devices that are changing how we pack for 2026. This isn't just about making sure your phone doesn't die during a long layover. It’s about a spike in "thermal runaway" events—basically, batteries turning into mini-blowtorches in the cargo hold. FAA data shows that battery-related fires on planes have jumped roughly 15% over the last few years. That’s a scary number when you're 35,000 feet in the air.
Why the Rules Changed Right Now
Honestly, the sheer volume of batteries we carry is the problem. Think about it. You’ve got a phone, a laptop, maybe a tablet, noise-canceling headphones, and a vape. That’s five lithium-ion sources in one backpack. Multiply that by 200 passengers.
The TSA and the FAA are tightening the screws because cabin crews are actually trained to fight fires in the cockpit or the seating area. They have fire containment bags. They have extinguishers. But if a spare battery in a checked bag starts smoking in the belly of the plane? Nobody knows until the smoke detectors go off, and by then, it might be too late.
Starting in January 2026, the enforcement has moved from "suggestions" to hard limits. Most of the pressure is coming from international bodies like IATA, but the TSA is the one at the front lines making sure your power bank doesn't become a hazard.
The 100 Watt-Hour Rule: The Line in the Sand
Everything basically boils down to a number: 100.
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Most people have no clue what a "Watt-hour" (Wh) is. We usually shop for batteries based on milliamp-hours (mAh). But the TSA doesn't care about mAh. They care about total energy capacity.
- Under 100 Wh: You’re usually fine. This covers your iPhone, your MacBook Pro (mostly), and standard power banks. You can bring as many as you want for "personal use," though "as many as you want" is still subject to an officer's "does this look like you're starting a store?" vibe.
- 101 to 160 Wh: This is the "Special Permission" zone. You need airline approval. You are limited to exactly two spare batteries in this range. Think professional camera rigs or those massive "pro" laptop battery extenders.
- Over 160 Wh: Forget about it. Unless it's for a mobility device like an electric wheelchair, these are banned from passenger planes entirely. They have to go via specialized cargo freight.
If your battery only lists mAh, you can do the math yourself. It’s (mAh x Voltage) / 1000. For a standard 20,000 mAh power bank at 3.7 volts, that’s 74 Wh. You’re safe. But those "extra-large" 40,000 mAh bricks? You’re pushing the 150 Wh limit and might get stopped.
The "Gate Check" Trap
This is where people get caught most often. You’re at the gate, the flight is full, and the agent says, "We’re out of overhead space, we need to check your carry-on."
You hand over the bag. You forget that your spare camera batteries or your vape is in the side pocket.
Under the new 2026 guidelines, TSA is putting more pressure on airlines to verify that lithium-ion spares are removed before a bag is moved to the hold. If a fire starts in the cargo hold because you forgot a power bank in a gate-checked bag, the legal ramifications are getting much heavier. Honestly, it’s just not worth the risk. Always keep your "spares" in your personal item—the bag that stays under the seat in front of you.
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Power Banks: The New Restricted List
There is a weird nuance here that most people miss. A power bank is considered a "spare battery." Even if it’s inside a case, it’s not "installed" in a device.
New rules for 2026, specifically highlighted by groups like the Lufthansa Group and being adopted by others, are even more restrictive about using them. Some carriers are now banning the charging of devices via power banks while the plane is in flight. They want the batteries stored in the seatback pocket or under the seat—never in the overhead bin. Why? Because if a battery starts to swell or smoke in a bin, it takes longer to notice. If it's in your seatback pocket, you’ll smell it (or feel the heat) instantly.
How to Pack Without Getting Flagged
- Tape the terminals. If you have loose batteries (like for a DSLR), put a piece of electrical tape over the metal contacts. This prevents a "short circuit" if they touch a coin or a paperclip in your bag.
- Use original packaging. If you can’t, put each battery in its own Ziploc bag. It sounds like overkill, but it works.
- Check the label. If the Wh rating is rubbed off or missing, the TSA has the right to confiscate it. They won't take your word for it that "it’s just a small one."
- Don't "stack" them. Don't tape three power banks together to save space. To an X-ray tech, a dense block of batteries looks like something much more dangerous.
E-Cigarettes and Vapes
These are still a massive headache for security. They must be in your carry-on. Period. But the 2026 update adds a specific "no-charging" rule. You cannot plug your vape into the plane’s USB port or a power bank while on board. Several recent diversions were caused by vapes "autofiring" in a bag or overheating while being charged in the cabin. If you’re caught charging one, expect a very stern talking-to from a federal air marshal or the flight lead.
What Happens if You Break the Rules?
Usually, they just take the battery. You lose your $80 power bank, and you're annoyed for the rest of the trip.
However, if you are found to be "recklessly" packing large quantities of batteries or high-capacity cells (over 160 Wh) without declaring them, the fines are getting steeper. We’re talking thousands of dollars. The TSA is leaning into the "safety first" narrative more than ever because battery fires are no longer a "maybe"—they are happening weekly on US flights.
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Moving Forward: Your 2026 Travel Checklist
Check your gear before you even start packing. Look for the "Wh" mark on the back of your devices. If it's not there, do the math and maybe even write it on a piece of tape on the device to show you're a prepared traveler.
Keep your electronics in your carry-on, but keep your spare batteries in an even more accessible spot. If you have to gate-check your suitcase, you should be able to grab your "battery pouch" in three seconds flat.
Stay aware of the 100 Wh limit, keep your terminals covered, and never—ever—let a lithium-ion battery go into the belly of the plane.
Next Steps for Your Trip:
- Check the bottom of your power bank for the Wh rating; if it's over 100, call your airline now.
- Pick up a small fire-retardant "Lipo Bag" for your spare drone or camera batteries for an extra layer of safety.
- Audit your "tech pouch" and remove any old, swollen, or generic-brand batteries that don't have clear safety markings.