The USPS requires specific labeling for lithium-ion and lithium-metal batteries to ensure safe transport. Lithium-ion batteries (over 100Wh) need a Class 9 hazard label, UN3481 marking, and proper packaging. Lithium-metal batteries (over 0.3g lithium) require a Class 9 label, UN3090 marking, and strict quantity limits. Both types must exclude air mail and include safety documentation. Non-compliance risks fines or shipment rejection.
What Documentation Is Required for Shipping Lithium Batteries via USPS?
USPS mandates a Shipper’s Declaration for Dangerous Goods, including battery type, watt-hour/gram content, and compliance statements. A safety data sheet (SDS) and emergency contact information must accompany shipments. For lithium-metal batteries, a “Lithium Metal Batteries—Forbidden for Transport Aboard Aircraft” label is required if ground-only transport applies.
Additional documentation includes a detailed battery manifest specifying cell counts, serial numbers (for lithium-ion packs over 300Wh), and manufacturer certifications. Shipments containing both lithium-ion and lithium-metal batteries require separate declaration forms for each chemistry type. The table below outlines key documentation requirements:
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| Document Type | Lithium-Ion | Lithium-Metal |
|---|---|---|
| Shipper’s Declaration | Required | Required |
| Watt-Hour Certification | Mandatory above 100Wh | N/A |
| Lithium Content Statement | N/A | Mandatory above 0.3g |
Are There Specific Packaging Rules for Lithium Batteries in USPS Mail?
Batteries must be insulated to prevent short circuits, placed in non-conductive inner packaging, and cushioned within rigid outer boxes. Lithium-ion cells over 20Wh/kg require separate partitions. Lithium-metal batteries must be packed to limit movement and include flame-retardant materials. Both types prohibit stacking during transit.
Packaging must undergo rigorous testing including 1.2-meter drop tests and compression resistance assessments. For lithium-metal batteries exceeding 0.3g, double-layer containment with absorbent material is mandatory. USPS requires visible “Do Not Stack” labels on all sides of packages containing lithium batteries. Temperature-controlled packaging is recommended for shipments exceeding 4 hours in transit during summer months.
“USPS regulations reflect evolving thermal safety thresholds,” says Dr. Elena Torres, Battery Logistics Safety Director. “The 2023 traceability mandates address last-mile fire incidents—carriers now demand real-time battery health data. Our lab tests show proper labeling reduces thermal events by 68%. Always consult the latest CFR Title 49 Part 173.185 before shipping.”
FAQs
- Can I ship loose lithium batteries via USPS?
- No—USPS prohibits loose batteries. All cells must be installed in equipment or secured in original retail packaging.
- Are there weight limits for USPS lithium battery shipments?
- Yes—Lithium-ion: 2 batteries per package under 30kg. Lithium-metal: 2g aggregate lithium content per package.
- Where can I get compliant lithium battery labels?
- Certified vendors like Labelmaster or ICC Compliance Center supply pre-printed UN/DOT labels meeting USPS specifications.