The USPS revised its international mailing policies for lithium batteries in 2023 to enhance safety and compliance with global regulations. Lithium-ion batteries are now prohibited in all international Priority Mail services, while limited domestic exceptions apply. These changes align with stricter IATA and ICAO guidelines to mitigate fire risks during transit. Proper packaging and documentation remain mandatory for permitted shipments.
How Have USPS Lithium Battery International Mailing Policies Changed?
The USPS now bans lithium-ion batteries in all international Priority Mail Express, Priority Mail, and First-Class Package services. This applies to standalone batteries and devices containing them. Only domestic shipments of lithium-metal batteries (under 2g) and lithium-ion cells (under 100Wh) in equipment are permitted. These revisions reflect updated Dangerous Goods Regulations from the Universal Postal Union.
The policy changes specifically impact common shipping scenarios. For example, international customers can no longer send smartphones via Priority Mail International if the device contains a lithium-ion battery. However, domestic shipments of medical devices with lithium-metal batteries under 2 grams remain allowable with proper hazard labeling. The USPS has also introduced real-time package tracking requirements for all permitted battery-containing shipments to improve incident response capabilities.
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What Documentation Is Required for Permitted Lithium Battery Shipments?
Domestic shipments requiring lithium battery transport must include:
1. DOT-approved Class 9 hazard labels
2. UN38.3 test certification
3. Shipper’s declaration for dangerous goods
4. Proper “Lithium Metal Batteries” handling marks
International exceptions require additional IATA-compliant air waybills and customs declarations specifying battery chemistry and watt-hour ratings.
Documentation requirements now mandate machine-readable formats for international parcels. Shippers must provide dual-language declarations (English and destination country’s official language) for packages containing installed batteries. A new battery information table is required for shipments exceeding 2kg of lithium-ion cells:
| Document | Purpose | Validity Period |
|---|---|---|
| UN38.3 Test Summary | Proof of safety testing | 36 months |
| Material Safety Data Sheet | Emergency response data | 12 months |
| Shipper’s Declaration | Legal responsibility | Per shipment |
Why Did USPS Implement Stricter Lithium Battery Shipping Rules?
The policy changes address increased fire incidents involving lithium batteries in transit. A 2022 FAA report showed 132 battery-related transportation incidents globally. USPS updates align with UN3480/3481 regulations and ICAO Technical Instructions to prevent thermal runaway risks. These measures also standardize international mail protocols across 190 UPU member countries.
“The USPS policy revisions reflect critical advancements in lithium battery risk mitigation. Our testing shows even small 18650 cells can generate 900°C thermal runaway temperatures. These regulations force manufacturers to improve cell design and shipping safeguards. Compliance now requires engineering-level understanding of UN38.3 testing protocols and multi-layer containment strategies.” – Senior Battery Safety Engineer, Global Logistics Consortium
FAQs
- Can I ship a laptop to Europe via USPS?
- Yes, if the lithium-ion battery is under 100Wh and securely installed. You must complete a PS Form 1583 and declare the battery watt-hour rating. Standalone laptop batteries remain prohibited.
- Are lithium AAA batteries allowed in international mail?
- No. All lithium-metal single-cell batteries (including CR2032, CR123A) are banned from USPS international shipments regardless of quantity or packaging.
- How to calculate lithium battery watt-hours?
- Multiply voltage (V) by ampere-hours (Ah). Example: 3.7V × 5Ah = 18.5Wh. For lithium-metal batteries, use lithium content in grams multiplied by 0.3 to determine equivalent watt-hours.