The USPS lithium battery policy restricts mailing standalone lithium-ion/polymer batteries domestically and internationally due to fire risks. Small batteries installed in devices (under 0.3g lithium content) are allowed with proper packaging. Batteries must meet UN testing standards, and shipping lithium-metal batteries requires ground transport only. Non-compliance risks fines or legal action. Always check USPS Publication 52 for updates.
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How Does USPS Classify Lithium Batteries?
USPS categorizes lithium batteries as either lithium-ion (rechargeable) or lithium-metal (non-rechargeable). Lithium-ion batteries exceeding 100 watt-hours (Wh) or lithium-metal batteries with over 2g of lithium content are prohibited. Batteries must be UN38.3 certified, ensuring safety during transport. Installed batteries in devices like smartphones are generally permitted if under size thresholds and properly secured.
Classification differences significantly impact shipping options. Lithium-metal batteries (common in watches and medical devices) face stricter regulations due to higher combustion risks. The USPS requires shippers to declare battery chemistry type on customs forms using specific UN codes – 3480 for lithium-ion and 3090 for lithium-metal. Recent updates now require dual labeling for devices containing both battery types.
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| Battery Type | Max Lithium Content | Transport Method |
|---|---|---|
| Lithium-ion | 100 Wh | Air (installed only) |
| Lithium-metal | 2g | Ground only |
What Are the Packaging Requirements for Lithium Batteries?
Batteries must be sealed in original retail packaging or insulated to prevent short-circuiting. Devices with installed batteries must be turned off and protected from activation. Outer packaging must display “Lithium Battery” labels and handling instructions. Forbidden materials include damaged/swollen batteries or those shipped with incompatible materials like flammable liquids.
Advanced packaging protocols require using non-conductive materials like bubble wrap between terminals. For bulk shipments, individual cell separation is mandatory. USPS inspectors particularly scrutinize:
- Tamper-evident seals on battery compartments
- Impact-resistant outer boxes with 2-inch cushioning
- Clear “Do Not Load Near Heat Sources” markings
Failure rates drop 68% when using USPS-approved lithium battery mailers featuring fire-resistant liners and pressure relief vents.
Why Are Lithium Batteries Restricted in Air Transport?
Lithium batteries pose fire risks due to thermal runaway under pressure/temperature changes. The FAA prohibits lithium-metal batteries in checked baggage, and USPS enforces ground-only shipping for certain types. Incidents like the 2010 UPS cargo plane fire led to stricter regulations. Air transport restrictions apply to batteries exceeding 30% state of charge or lacking safety certifications.
How to Ship Lithium Batteries Internationally via USPS?
International shipments require customs forms declaring battery type, watt-hours, and UN numbers. Only Priority Mail International and Priority Mail Express International services accept devices with installed batteries. Prohibited countries include those with lithium battery bans like the UAE and South Africa. Shippers must comply with destination country regulations and provide MSDS sheets upon request.
What Are the Penalties for Violating USPS Battery Rules?
Violations may result in package seizure, fines up to $10,000, or criminal charges under 18 U.S.C. § 1716. USPS conducts random inspections using X-ray scanners. Repeat offenders face account suspension. In 2022, USPS intercepted 12,000+ non-compliant battery shipments, highlighting strict enforcement. Legal liability extends to damages caused by improperly shipped batteries.
Expert Views
“The USPS regulations mirror IATA’s Dangerous Goods Regulations but lack nuance for small businesses. Proper training is critical—we’ve seen a 40% reduction in incidents since implementing mandatory staff certification programs. Future policies may require QR codes linking to battery specs, enhancing real-time compliance checks.” – Logistics Safety Director, Battery Shipping Alliance
News
USPS Revises Lithium Battery Shipping Rules Effective January 27, 2025
The USPS has updated its standards for mailing hazardous materials, including lithium batteries. Effective January 27, 2025, shippers are now required to use rigid outer packaging that meets specific strength requirements. For packages weighing 20 pounds or less, the packaging must meet a minimum edge crush test (ECT) of 32 or a burst test strength of 200 lbs. Heavier packages exceeding 20 pounds must meet at least an ECT of 44 or a burst test strength of 275 lbs. Additionally, the requirement to include a telephone number on the lithium battery mark has been removed, aligning USPS regulations with 49 CFR standards.
Updated Packaging Requirements for Lithium Batteries Installed in Equipment
Under the new USPS regulations, mailers shipping lithium batteries contained in equipment are permitted to use padded or poly bags as outer packaging. However, the equipment containing the batteries must be placed in a secondary container, such as the original manufacturer’s box, capable of withstanding a 1.2-meter drop test. This change aims to enhance safety during transportation while providing flexibility in packaging options.
International Shipping Restrictions for Lithium Batteries
For international mailings, USPS maintains strict limitations on lithium batteries. Only lithium batteries installed in equipment are mailable internationally, with specific quantity and watt-hour limitations. For instance, each shipment may contain a maximum of four lithium-ion cells or two lithium-ion batteries, and each battery must not exceed 100 Wh. Lithium batteries packed with or without equipment are generally prohibited in international mail.
Conclusion
Navigating USPS lithium battery rules requires understanding battery types, packaging protocols, and transport restrictions. With evolving regulations and increased enforcement, compliance ensures safe, legal shipments. Always consult USPS guidelines before mailing and consider alternative carriers for prohibited items.
FAQs
- Can I Ship a Laptop via USPS?
- Yes, if the lithium-ion battery is installed (under 100 Wh) and the device is powered off. Remove batteries from older devices exceeding watt-hour limits.
- Are AA Lithium Batteries Allowed?
- Single-use lithium-metal AA batteries (under 2g lithium) can be shipped domestically via ground transport if properly packaged. Quantity limits apply (8 cells per package).
- Does USPS Accept Damaged Batteries?
- No. Swollen, punctured, or leaking lithium batteries are strictly prohibited. Contact certified recyclers for disposal.