USPS allows shipping lithium batteries domestically under strict guidelines. Lithium-ion batteries under 100Wh can be mailed in devices or with equipment via ground transport. Standalone batteries require specific packaging and documentation. International shipments are prohibited for lithium batteries. Always declare contents, use protective packaging, and follow USPS Publication 52 for compliance to avoid penalties or shipment rejection.
What Are USPS Regulations for Lithium Battery Shipments?
USPS permits lithium batteries only in domestic mail when properly installed in devices or packed with equipment. Standalone batteries must be under 100Wh, require surface transportation, and protective packaging to prevent short circuits. International shipments of lithium batteries are strictly prohibited regardless of configuration.
How to Package Lithium Batteries for USPS Shipping?
Use non-conductive material to isolate battery terminals. Place cells in individual plastic bags and cushion with packing material. Outer packaging must display “Lithium Metal Batteries” markings. For installed batteries, secure devices to prevent movement and use rigid boxes with 2-inch cushioning on all sides. Ground transportation labels are mandatory for all lithium battery shipments.
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| Packaging Component | Requirement |
|---|---|
| Inner Packaging | Non-conductive dividers between cells |
| Outer Box | 200# burst strength minimum |
| Cushioning | 2 inches on all sides |
Advanced packaging considerations include using anti-static bags for lithium-ion cells and including silica gel packs in humid environments. For high-volume shippers, pre-certified UN-certified containers can streamline compliance. Always conduct a “drop test” with packaged batteries – if the device shifts position or terminals make contact during a 3-foot drop simulation, redesign the packaging configuration.
Which Lithium Battery Types Are USPS-Approved?
USPS accepts lithium-ion (rechargeable) under 100Wh and lithium metal (primary) under 2g lithium content per battery. Button cells powering medical devices have special exceptions. Prohibited batteries include damaged/swollen cells, non-certified imports, and any batteries exceeding watt-hour/gram limits. Always verify UN38.3 certification before shipping.
| Approved Batteries | Prohibited Batteries |
|---|---|
| Li-ion ≤100Wh | Damaged/swollen cells |
| Li-metal ≤2g | Non-UN38.3 certified |
| Medical button cells | Wet cell batteries |
Recent regulatory updates now require dual-language labeling (English/Spanish) for lithium battery shipments exceeding 5kg total weight. Special handling applies to prototype batteries – these require additional DOT exemption permits even when under watt-hour limits. Always check manufacturer specifications against the latest USPS Dangerous Goods Acceptance Manual revisions published quarterly.
Why Does USPS Restrict International Lithium Battery Shipments?
International air transport bans lithium batteries due to fire risks in pressurized cargo holds. USPS adheres to Universal Postal Union regulations prohibiting cross-border lithium battery mail. Exceptions exist only for diplomatic missions and military addresses using APO/FPO/DPO services with proper hazardous materials documentation.
Expert Views
“The evolving lithium battery regulations reflect aviation safety priorities. Shippers must understand the difference between ‘contained in equipment’ versus ‘with equipment’ classifications – this distinction impacts packaging requirements and allowable quantities. Recent FAA pressure means carriers like USPS will likely implement stricter screening processes in 2024.”
– Logistics Compliance Specialist, Battery Shipping Association
Conclusion
Navigating USPS lithium battery regulations requires attention to battery type, packaging specifications, and shipping method limitations. By understanding watt-hour limits, proper documentation, and transportation restrictions, businesses can maintain compliance while safely distributing battery-powered devices. Always consult current USPS Publication 52 before preparing shipments containing lithium cells.
FAQs
- Can I ship loose lithium batteries via USPS Priority Mail?
- No. USPS prohibits standalone lithium batteries in all air services including Priority Mail. Surface transportation is required for properly packaged batteries under 100Wh when shipped with equipment.
- Are lithium battery shipping labels required?
- Yes. All lithium battery shipments must display Class 9 hazard labels and proper lithium battery handling markings. Domestic ground shipments require specific “Lithium Batteries – Forbidden for Transport Aboard Aircraft” labels.
- How to calculate watt-hours for USPS compliance?
- Multiply battery voltage (V) by amp-hours (Ah). Example: 3.7V x 5Ah = 18.5Wh. For lithium metal batteries, check grams of lithium content (not total battery weight). Most consumer AA lithium batteries contain 0.3-1g lithium metal.