How to Ship Lithium Batteries?

Shipping lithium batteries depends on what battery it is, how it is packed, and whether it goes by air, sea, or ground.

The basic rule is this: lithium batteries are treated as dangerous goods, so you usually cannot ship them like ordinary cargo. All lithium cells and batteries offered for transport must have passed the UN 38.3 tests, and transport rules vary depending on whether they are shipped by themselves, packed with equipment, or installed in equipment.

1) Identify exactly what you are shipping

First classify the shipment:

Lithium-ion / rechargeable batteries, such as batteries for electronics, power tools, e-bikes, ESS modules, etc.

Lithium metal / non-rechargeable batteries.

Shipped as:

battery only

battery packed with equipment

battery contained in equipment

This matters because the packing instructions, labeling, documentation, and whether the shipment can move on passenger aircraft all change based on that classification. IATA’s current guidance is based on the 2025–2026 ICAO Technical Instructions and the 67th edition of the IATA DGR.

2) Make sure the battery is legally transportable

Before shipping, the battery normally needs:

UN 38.3 test compliance

protection against short circuit

packaging that prevents movement, damage, and accidental activation

confirmation that it is not damaged, defective, recalled for safety reasons, or being shipped for disposal/recycling under normal channels

Damaged or defective lithium batteries are heavily restricted or prohibited in normal transport channels, and major carriers like FedEx and UPS call this out explicitly.

3) Pack it correctly

In general, you should:

insulate or cover terminals

use inner packaging or separators so batteries cannot touch each other

use strong outer packaging

prevent the device from turning on accidentally if batteries are installed in equipment

UPS specifically notes that packages containing lithium batteries must be packed to prevent short circuits and overheating, and FAA guidance for batteries carried by passengers also stresses terminal protection and strong packaging for spare batteries.

4) Choose the transport mode
Air

Air is the strictest mode. Battery-only lithium-ion shipments are especially sensitive, and carriers may only accept them as fully regulated dangerous goods. UPS states that all air shipments of lithium ion or lithium metal batteries shipped without equipment must be fully regulated dangerous goods.

Also, some recent industry updates tightened rules further, including stricter charge limits for certain lithium-ion shipments packed with equipment.

Sea

Sea freight follows the IMDG Code. The IMO has adopted IMDG Code Amendment 42-24, which includes lithium battery provisions, and consignors/carriers must keep dangerous goods transport documentation for at least three months.

Ground

Ground transport depends on the country. In the U.S., PHMSA points shippers to 49 CFR 173.185 for lithium battery requirements.

5) Label and document it

Depending on the battery type and packing method, you may need:

the lithium battery mark

Class 9 hazard labels

shipper’s declaration / dangerous goods documentation

proper UN number and shipping description

carrier-specific approval in some cases

FedEx notes that some special provisions require prior approval, and both carrier and regulator guidance emphasize that the correct marking, labeling, and documentation depend on the exact battery and packing instruction used.

6) Check the carrier’s own rules before booking

Even if regulations allow a shipment, the carrier may still refuse it or apply extra conditions. UPS and FedEx both publish their own lithium battery guides, and carrier acceptance rules can be narrower than the base regulations.

Practical safest process

For a real shipment, this is the safest workflow:

Confirm battery chemistry and whether it is battery only / with equipment / in equipment.

Confirm UN 38.3 test status and keep the test summary available.

Check the exact rule set for your mode:

IATA/ICAO for air

IMDG Code for sea

local ground rules such as 49 CFR 173.185 in the U.S.

Pack to prevent short circuit, movement, crushing, and accidental activation.

Apply the correct marks/labels and prepare any required dangerous goods paperwork.

Confirm acceptance with the courier, airline, freight forwarder, or ocean carrier before dispatch.

Common mistakes that cause rejection

The most common problems are:

no UN 38.3 documentation

wrong classification

battery terminals left exposed

damaged or recalled batteries

missing lithium battery mark or Class 9 label

trying to send battery-only lithium cargo by air without full DG handling

assuming UPS/FedEx/DHL all follow the same acceptance rules

Those risks are repeatedly highlighted in IATA, PHMSA, UPS, and FedEx guidance.