On 9 September 2025, the Federal Aviation Administration (FAA) issued a Safety Alert for Operations (SAFO) warning about the dangers of lithium batteries carried on board aircraft by passengers and crew.
The three-page document emphasises the risk of smoke or fire from lithium batteries, particularly in carry-on bags, due to their potential to enter thermal runaway—a self-sustaining overheating process.
“Today, the FAA issued a safety alert on risks lithium batteries placed in aircraft passenger compartments can pose – smoke or even fire. The safety alert provides airline operators risk mitigation strategies to keep passengers and crewmembers safe,” the FAA wrote in a post on X.
Today, the FAA issued a safety alert on risks lithium batteries placed in aircraft passenger compartments can pose – smoke or even fire. The safety alert provides airline operators risk mitigation strategies to keep passengers and crewmembers safe. Read more:… pic.twitter.com/wrvn285TKu
— The FAA ✈️ (@FAANews) September 9, 2025
The alert underscores the limitations of current firefighting methods, stating, “Use of Halon extinguishers can briefly suppress open flames; however, they do not halt the thermal runaway process.” Instead, the FAA recommends using large amounts of water to cool the battery and suppress flames, a critical step for crew members in an emergency.
This warning follows a recent FAA demonstration showing how a battery pack overheating in a seat-back pocket can erupt in sparks and ignite a fire. The increasing prevalence of electronic devices heightens these risks, making proactive measures critical. Southwest Airlines, for instance, is the only U.S. carrier requiring passengers to keep portable chargers and power banks visible during use, a policy aimed at preventing hidden overheating incidents during flights.
To protect the safety of the flight crew and passengers, please check for damaged or recalled battery-powered electronics and power banks before you fly. These devices can spark or overheat and are strictly prohibited on aircraft. To learn more visit https://t.co/yJCBWqQIhS.… pic.twitter.com/zUNZDT6bJv
— The FAA ✈️ (@FAANews) June 29, 2025
The FAA advised airlines and operators to stay up to date on firefighting protocols and review their emergency messaging systems. With the sheer number of electronic devices in use, the risk lithium batteries present to flights is greater than ever. They can be found in electric toothbrushes, portable chargers, tablets, laptops, and other everyday electronic devices.
Globally, other regions are tightening regulations. Earlier in 2025, China banned uncertified power banks on domestic flights, resulting in the confiscation of thousands of travellers’ devices. Similarly, Emirates updated its safety guidelines for power banks. According to the new rules, starting 1 October 2025, passengers will be allowed to carry only one power bank per person (maximum of 100 watt-hours), which must remain unused during the flight.
“Every regulation we have in aviation comes from an incident happening. Clearly, this is something that’s getting increasingly dangerous as time goes on, and more devices come onboard,” said Rich Henderson, a flight attendant at a major U.S. airline and one of the authors of the Two Guys on a Plane blog.
