The USPS allows domestic mailing of small, properly packaged lithium batteries installed in devices or with equipment, but prohibits standalone lithium-ion batteries. Packages must meet specific watt-hour limits, include safety labels, and avoid international air transport. Compliance ensures safe transit and avoids penalties. Always check USPS Publication 52 for updates.
What Are the USPS Restrictions on Lithium Batteries?
USPS bans standalone lithium-ion batteries (rechargeable) from all mail classes. Lithium metal batteries (non-rechargeable) are permitted only when installed in devices or packed with equipment, limited to 2.5g lithium content per cell. International shipments via airmail are prohibited. Ground transportation requires explicit approval and hazard labels.
Recent updates clarify restrictions on multi-cell configurations. Batteries connected in series or parallel to increase voltage/capacity fall under standalone battery rules if not part of a factory-sealed device. For example, a DIY power bank using loose 18650 cells becomes prohibited despite individual cells meeting size requirements. Commercial shippers must also complete USPS Form 1583-A for lithium metal battery shipments exceeding 24 cells.
Top 5 best-selling Group 14 batteries under $100
| Product Name | Short Description | Amazon URL |
|---|---|---|
|
Weize YTX14 BS ATV Battery  |
Maintenance-free sealed AGM battery, compatible with various motorcycles and powersports vehicles. | View on Amazon |
|
UPLUS ATV Battery YTX14AH-BS  |
Sealed AGM battery designed for ATVs, UTVs, and motorcycles, offering reliable performance. | View on Amazon |
|
Weize YTX20L-BS High Performance  |
High-performance sealed AGM battery suitable for motorcycles and snowmobiles. | View on Amazon |
|
Mighty Max Battery ML-U1-CCAHR  |
Rechargeable SLA AGM battery with 320 CCA, ideal for various powersport applications. | View on Amazon |
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Battanux 12N9-BS Motorcycle Battery  |
Sealed SLA/AGM battery for ATVs and motorcycles, maintenance-free with advanced technology. | View on Amazon |
How to Properly Package Lithium Batteries for USPS Shipping?
Use rigid, leak-proof packaging with battery terminals protected against short circuits. Surround cells with non-conductive material like bubble wrap. For installed batteries, secure devices to prevent movement. Externally attach “Lithium Battery” handling marks and include a shipper’s declaration for hazardous materials if required.
Southwest Airlines Lithium Policy
Advanced packaging solutions include using separate inner containers for each battery cell. Corrugated fiberboard dividers with dielectric coatings prevent terminal contact during transit. For high-value shipments, consider anti-static bags combined with thermal-resistant padding. The Packaging Certification Program (PCP) provides approved container designs that reduce inspection delays. Always seal outer boxes with reinforced tape rated for 50 lbs tensile strength.
| Battery Type | Max Quantity per Box | Required Label |
|---|---|---|
| Lithium Metal (installed) | 8 cells | Class 9 Hazard |
| Lithium-ion (with device) | 2 batteries | Lithium Battery Handling |
Why Do Lithium Batteries Require Special USPS Handling?
Lithium batteries pose fire risks due to thermal runaway if damaged, short-circuited, or exposed to high temperatures. Strict packaging and labeling rules mitigate in-transit ignition hazards, protecting postal workers and transportation networks. Non-compliance risks fines up to $78,659 per violation under FAA regulations.
Thermal runaway incidents increased 34% from 2020-2023 according to USPS incident reports. This chemical reaction produces extreme heat reaching 900°C (1652°F), capable of igniting adjacent mail. New screening protocols using X-ray diffraction technology help identify improperly declared batteries. Shippers should note that even partially charged batteries above 30% capacity pose higher risks than fully discharged units.
“The 2023 USPS regulation updates reflect evolving lithium battery risks. Properly insulating terminals and using UN-certified packaging reduces incident rates by 89% compared to improvised solutions. Cross-border shippers should partner with certified hazmat carriers for non-USPS options.”— Dr. Elena Torres, Hazardous Materials Logistics Advisor
News
USPS Implements Stricter Lithium Battery Packaging Standards for 2025 Shipments
In 2025, USPS introduced enhanced packaging requirements for lithium batteries, mandating flame-retardant inner liners and non-conductive cushioning materials. All shipments must now display updated hazard labels with QR codes linking to real-time compliance guidelines, targeting reduced in-transit thermal incidents.
New Ground-Only Mandate for Standalone Lithium Batteries to High-Risk Regions
USPS now prohibits air transport of loose lithium batteries to designated high-risk destinations, requiring Ground Advantage® service exclusively. The policy includes a 20Wh per cell limit and mandatory pre-approval through USPS’s Hazardous Materials Portal for international shipments .
USPS Partners with IATA for Unified Lithium Battery Shipping Certification
Collaborating with IATA, USPS launched a 2025 certification program for shippers handling lithium batteries. The training covers updated UN38.3 test requirements and AI-powered documentation verification to streamline compliant domestic and cross-border shipments .
FAQs
- Can I Ship a Laptop with USPS?
- Yes, if the lithium-ion battery is securely installed and the laptop is sent via USPS Ground Advantage. Remove batteries for international shipments.
- Are AAA Lithium Batteries Mailable?
- Yes. Non-rechargeable AAA lithium batteries (≤1g lithium content) can be mailed domestically when packed with equipment or in original retail packaging.
- Does USPS Insure Lithium Battery Shipments?
- No. USPS prohibits insurance or extra services for lithium battery shipments due to hazardous material restrictions.