How to Ship Lithium Batteries Internationally in 2026 (Regulations, Packaging and Costs Guide)

Lithium batteries power almost everything we ship today, from phones and laptops to e-bikes, power tools, and electric vehicles, which is exactly why learning how to ship lithium batteries safely and legally matters so much. They are also one of the most tightly regulated products in freight, because a damaged or poorly packed battery is a genuine fire risk. This guide explains the regulations, packaging, labels, carrier policies, and costs for shipping lithium batteries internationally, so your shipment moves without delays, fines, or rejection.

1. Can You Ship Lithium Batteries Internationally?

Yes, you can ship lithium batteries internationally, but they are Class 9 dangerous goods and must follow IATA, IMDG, and DOT rules for packaging, labeling, and documentation.

Lithium batteries are not banned, but they are restricted. Whether a shipment is straightforward or heavily regulated depends on two things: the type of battery and how it is shipped. Batteries shipped on their own are treated more strictly than batteries installed inside a device, because a loose battery carries a higher risk of short circuit. Small batteries below certain watt-hour limits qualify for lighter requirements, while larger ones are fully regulated dangerous goods.

The mode of transport matters just as much. Standalone lithium-ion batteries are forbidden on passenger aircraft and can only travel on cargo aircraft, while ocean and ground transport allow more flexibility. Because lithium batteries are dangerous goods, shipping them also overlaps with wider hazmat rules.

For the broader picture on dangerous goods, see our guide to shipping hazardous materials.

2. Are Lithium Batteries Hazardous Materials? Classes and UN Numbers

Yes. Lithium batteries are hazardous materials in Class 9 (miscellaneous dangerous goods), and they are assigned one of four UN numbers depending on type and packing.

Every lithium battery shipment must be identified with the correct United Nations (UN) number and proper shipping name. This is the single most important step in classifying your shipment, because it drives the packaging, labels, and paperwork that follow. There are four UN numbers for lithium batteries.

Lithium-ion batteries are the rechargeable type found in phones, laptops, and e-bikes. Lithium metal batteries are usually non-rechargeable, such as the coin cells in watches and small electronics. Getting the UN number right is the foundation of a compliant lithium battery shipping process, so confirm it before you package or label anything.

3. Lithium Battery Shipping Regulations by Mode, Air, Sea and Road

Lithium battery shipping is governed by the IATA DGR for air, the IMDG Code for sea, and DOT 49 CFR for US road, each with its own restrictions, with air being the strictest.

There is no single global rulebook. Instead, each transport mode has its own regulations, all built on the UN Model Regulations. Understanding which set applies to your shipment is essential.

These frameworks come from official sources. For US ground and general guidance, the PHMSA Lithium Battery Guide (2024) is the authoritative reference, and for air transport the IATA lithium battery guidance sets the standard. Always work from the current edition, because thresholds and packing instructions are updated regularly.

4. Lithium Battery Shipping Restrictions and Watt-Hour Limits

The main lithium battery shipping restrictions are watt-hour (Wh) limits, a 30% state-of-charge cap for air cargo, quantity limits per package, and a ban on damaged batteries.

Size is what separates a lightly regulated shipment from a fully regulated one. Lithium-ion capacity is measured in watt-hours (Wh), and lithium metal by the grams of lithium it contains. Batteries at or below the thresholds in the table qualify for reduced requirements, while anything above is fully regulated Class 9.

* Widely published thresholds for reference; confirm the current IATA and DOT values before shipping.

Two more restrictions matter for air shipments in particular. First, standalone lithium-ion batteries must be shipped at a state of charge (SoC) of 30 percent or less, which reduces fire risk in transit. Second, there are limits on how many batteries and how much net weight you can put in each package. And in every mode, batteries that are damaged, defective, or recalled face separate, much stricter rules, covered later in this guide.

5. How to Package Lithium Batteries for Shipping

To package lithium batteries for shipping, use UN38.3-tested cells, protect every terminal against short circuits, use strong non-metallic inner packaging, and use UN-specification outer packaging for fully regulated shipments.

Packaging is where most lithium battery shipments succeed or fail an inspection. The goal is simple: prevent short circuits, movement, and crushing. Good packaging follows a few clear rules.

• UN38.3 testing: every battery must pass the UN38.3 test, a series of eight safety tests covering altitude, thermal, vibration, shock, short circuit, impact, overcharge, and forced discharge. Keep the test summary on file.
• Short-circuit protection: cover terminals with tape or caps and package each battery so it cannot touch another battery or metal object.
• Inner packaging: place batteries in sturdy non-metallic inner packaging that holds each unit securely in place.
• Outer packaging: for fully regulated shipments, use UN-specification tested outer packaging rated for the weight and hazard.
• Equipment protection: batteries installed in equipment must be protected from accidental activation during transport.

A test summary confirming UN38.3 compliance has been required to be available for lithium battery shipments since 2022, so make sure your supplier can provide it. Well-packaged batteries not only pass inspection, they also protect the rest of your cargo.

6. Lithium Battery Shipping Labels and Documentation

Lithium battery shipments require the Class 9 lithium battery hazard label, the lithium battery mark, the UN number and proper shipping name, and, for fully regulated shipments, a Shipper's Declaration for Dangerous Goods.

Correct marks and paperwork tell every handler what is inside and how to treat it. The requirements scale with how regulated your shipment is, but the core elements are consistent.

• Class 9 hazard label: required on fully regulated shipments to show the goods are miscellaneous dangerous goods.
• Lithium battery mark: applied to packages that qualify for reduced requirements, showing the UN number and a contact phone.
• UN number and proper shipping name: the correct UN number (UN3480, UN3481, UN3090, or UN3091) and proper shipping name on the package and documents.
• Shipper's Declaration: a signed Shipper's Declaration for Dangerous Goods for fully regulated air shipments, prepared by trained staff.
• Test summary and SDS: keep the UN38.3 test summary and a Safety Data Sheet (SDS) available on request.

Documentation errors are one of the most common reasons a lithium battery shipping request is delayed or rejected, so it is worth having a dangerous goods-trained person prepare and check the paperwork.

7. How Carriers Handle Lithium Batteries, UPS, USPS, FedEx and DHL

Major carriers accept lithium batteries under their dangerous goods programs, but policies differ: USPS is the most restrictive, while FedEx, UPS, and DHL accept fully regulated shipments under a dangerous goods agreement.

Even when a shipment meets the regulations, each carrier applies its own policy on top, and these change often. The table below is a general guide only.

* General guidance only; carrier rules vary by service, route, and change frequently. Always confirm current policy directly with the carrier or your freight forwarder before booking.

A dangerous goods experienced forwarder can route your shipment through the carrier and mode that will actually accept it.

8. Shipping Damaged, Defective, or Used Lithium Batteries

Damaged, defective, or recalled lithium batteries are forbidden on aircraft and are subject to special, much stricter rules for any transport, because they carry the highest fire risk.

A battery that is swollen, leaking, overheating, or has been recalled is treated very differently from a new, compliant one. These batteries are prohibited from air transport entirely, and moving them by other modes requires special provisions, approved packaging designed to contain a thermal event, and often prior approval.

Used and second-hand lithium batteries can usually be shipped if they are undamaged and still meet the standard rules, but you must confirm their condition and, where required, their UN38.3 status. If you are unsure whether a battery is safe to ship, treat it as damaged and get expert advice rather than risk a dangerous, non-compliant shipment.

9. How Much Does It Cost to Ship Lithium Batteries?

Shipping lithium batteries typically adds a dangerous goods surcharge of about $100 to $250 per shipment by air (or roughly $150 to $500 per container by sea), plus $20 to $60 for UN-specification packaging and $50 to $150 for documentation, on top of the base freight rate.

There is no flat rate, because the total cost depends on the battery type, quantity, transport mode, and how regulated the shipment is. As a reference, the extra costs specific to lithium batteries usually break down like this:

* Indicative US reference ranges only, not a quote. Actual pricing varies by carrier, route, battery type, quantity, and current fuel and DG rates.

The main extra costs to plan for are:

• DG surcharge: a dangerous goods handling fee added by the carrier on top of the base freight rate.
• Compliant packaging: UN-specification packaging, terminal protection, and inner packaging that cost more than standard cartons.
• Documentation: preparation of the Shipper's Declaration and related paperwork, sometimes billed as a service.
• Mode limits: fully regulated standalone batteries must move by cargo aircraft or by sea, which changes the rate and transit time.

As a general rule, ocean freight is the most economical option for large or bulk lithium battery shipments, while air is faster but carries the highest surcharges. Because the variables are so specific, the only accurate figure is a quote for your exact shipment.

10. Real-World Lithium Battery Shipping Scenarios

Beyond the rules, the same practical situations come up again and again. Here is how each is typically handled.

• Moving abroad with battery-powered devices: relocating internationally often means moving devices that contain lithium batteries, such as laptops, power tools, and e-bikes. Batteries installed in equipment are easier to move than loose spares, and loose batteries usually must travel separately under dangerous goods rules rather than in a household-goods container.
• An individual shipping one battery overseas: individuals often struggle to find a carrier that will accept a single loose battery internationally, because most consumer services restrict standalone lithium. The usual solution is to ship through a dangerous goods-capable forwarder, or to keep the battery installed in its device where the rules allow.
• A business importing batteries in bulk: companies importing batteries or battery-powered products at scale usually ship by ocean freight under full dangerous goods compliance, with UN38.3 documentation from the manufacturer and a forwarder handling classification and paperwork.

Shipping a battery already installed in a device, such as an e-bike, follows its own guidance, covered in our guide to shipping an electric bike.

11. How to Choose a Lithium Battery Shipping Partner

Choose a freight forwarder with proven dangerous goods experience, trained staff who can classify and document lithium batteries, and the carrier and mode options to actually move your shipment.

Because lithium batteries are dangerous goods, the partner you choose matters more than with ordinary freight. Judge candidates on these points:

• Dangerous goods expertise: does the forwarder handle Class 9 dangerous goods regularly and employ trained, certified staff?
• Classification and documentation: can they correctly classify your batteries, prepare the Shipper's Declaration, and provide compliant packaging?
• Carrier and mode access: do they have the carrier relationships and mode options, including cargo air and ocean, to move restricted batteries?
• Customs and import handling: can they manage customs and import requirements on your trade lane, such as Asia to the United States?

Worldcraft Logistics moves regulated and general cargo across global trade lanes, with air, ocean, and customs services that support dangerous goods shipments handled in accordance with applicable rules. If you are importing batteries or battery-powered products, the right forwarder turns a complex, high-risk shipment into a predictable one.

Conclusion

Learning how to ship lithium batteries comes down to a few essentials: classify the battery with the correct UN number, respect the watt-hour and state-of-charge limits, package to prevent short circuits, apply the right labels and documentation, and work within each carrier's policy. Get those right and lithium batteries move safely and legally around the world. Get them wrong and you risk fines, rejection, or a genuine safety incident. When in doubt, verify the current regulations and lean on a dangerous goods experienced partner.

*Sources and Further Reading: This guide references official regulatory sources. Always confirm the current edition before shipping: US PHMSA Lithium Battery Guide (2024) and IATA: What to know about how to ship lithium batteries.