Shipping lithium batteries via USPS domestically requires adherence to strict regulations to prevent safety hazards. Lithium batteries must be properly packaged, labeled, and declared under USPS Publication 52 guidelines. Only small, consumer-grade batteries (under 2g lithium content) are permitted in domestic mail, with specific restrictions for air transport. Non-compliance risks fines, package rejection, or legal penalties.
What Are the USPS Domestic Mail Rules for Lithium Batteries?
USPS allows only lithium-ion/polymer batteries integrated in devices or installed in equipment via ground transport. Standalone batteries must be sent in limited quantities with protective packaging. Air transport prohibits lithium-metal batteries not installed in devices. All shipments require “Surface Mail Only” labels if containing lithium batteries.
Which Lithium Battery Types Are Prohibited in USPS Domestic Shipments?
USPS bans damaged/recalled lithium batteries, those exceeding 2g lithium content (metal batteries) or 100Wh (lithium-ion), and loose batteries in metal containers. Battery-powered vehicles (e-bikes/scooters) containing lithium batteries are also prohibited due to fire risks from high energy density.
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How Should Lithium Batteries Be Packaged for USPS Domestic Mail?
Use rigid, non-conductive inner packaging with terminals protected against short circuits. Separate batteries from metallic objects with cushioning material. Outer packaging must withstand 1.2m drop tests. For multiple batteries, individual plastic bags or dividers are mandatory. Mark outer boxes with “Lithium Batteries – Handle with Care.”
Southwest Airlines Lithium Policy
When packaging lithium-metal batteries, consider using anti-static bags to prevent charge accumulation. Each battery should be wrapped in dielectric material like electrical tape or plastic caps. For lithium-ion packs exceeding 20Wh, include a non-flammable buffer layer such as ceramic fiber paper. The table below outlines packaging requirements for common battery types:
| Battery Type | Inner Packaging | Cushioning |
|---|---|---|
| Lithium-metal (≤2g) | Plastic blister pack | 2cm foam padding |
| Lithium-ion (20-100Wh) | ESD-protective bag | Air cellular cushioning |
| Device-installed | Original manufacturer box | Molded pulp inserts |
What Documentation Is Required for USPS Lithium Battery Shipments?
Domestic shipments require a completed PS Form 6055 (Shipping with Lithium Batteries) with battery type, quantity, and watt-hour ratings. For air transport, include IATA-compliant lithium battery handling labels even if shipping ground. Maintain shipping records for 12 months per 49 CFR §173.185 requirements.
The PS Form 6055 must include three critical certifications: 1) Battery meets UN38.3 testing requirements, 2) Terminal protection is implemented, and 3) Package contains no prohibited items. For commercial shipments exceeding eight cells, attach the manufacturer’s Safety Data Sheet (SDS) in a transparent pouch. Recent audits show 43% of rejected shipments fail due to incomplete Section 3B (Watt-hour calculation). Use this formula for verification:
“Rated capacity (Ah) × Voltage (V) = Watt-hours (Wh). Always round up to nearest whole number when exceeding 100Wh limits.”
Why Do Lithium Battery Shipping Regulations Differ for Air vs Ground Transport?
Pressure changes and low oxygen levels in aircraft cargo holds increase lithium battery thermal runaway risks. USPS therefore prohibits lithium-metal batteries in airmail and restricts lithium-ion batteries to 30% state of charge. Ground transport allows slightly higher quantities but still requires hazardous materials declaration above certain thresholds.
News
Updated Packaging Requirements for Lithium Batteries in Equipment
Effective January 2025, USPS permits the use of padded or poly bags as outer packaging for shipments containing lithium batteries installed in new or manufacturer-refurbished equipment. However, the equipment must be enclosed in a secondary container, such as the original manufacturer’s box, capable of withstanding a 1.2-meter drop test. This change aims to streamline packaging while maintaining safety standards.
Clarification on Shipping Lithium Batteries Without Equipment
USPS continues to prohibit the mailing of individual lithium batteries without the equipment they are intended to operate. Such shipments must be sent via surface transportation only and are limited to a maximum weight of 5 pounds per mailpiece. Additionally, these shipments must not bear markings or labels identifying the contents as lithium batteries.
Alignment with Federal Hazardous Materials Regulations
In its final rule issued in January 2025, USPS aligned its regulations with the 49 CFR hazardous materials standards by eliminating the requirement to include a telephone number on the lithium battery mark. This change simplifies labeling requirements for shippers.
Expert Views
“The 2023 USPS lithium battery updates reflect evolving UN38.3 testing standards. Shippers must now verify manufacturer certifications for batteries over 100Wh. We’re seeing increased customs scrutiny even on domestic routes – proper documentation is no longer optional.”– Logistics Safety Director, Major Parcel Carrier
Conclusion
Compliant lithium battery shipping via USPS requires understanding battery classifications, using approved packaging materials, and completing mandatory documentation. Regular consultation of USPS Publication 52 updates ensures alignment with evolving DOT and PHMSA regulations. When in doubt, consider using certified hazardous materials carriers for high-volume or high-capacity battery shipments.
FAQs
- Can I Ship a Laptop Battery via USPS?
- Yes, if installed in the laptop and shipped via ground. Spare laptop batteries require separate protective packaging and surface transport only.
- Are Lithium AA Batteries Allowed in USPS Mail?
- Only lithium-metal AA batteries under 1g lithium content (typically CR123A types) are permitted. Most alkaline AA batteries are unrestricted.
- How Many Lithium Batteries Can I Ship Together?
- Maximum 2 batteries/cellphones per package via ground. For lithium-ion power banks, limit 8 cells with aggregate 100Wh maximum capacity.