Why airlines are warning over lithium-ion batteries

In late June, a technology journalist observed something unusual while flying into Las Vegas – flight crew members rushing to the rear of the plane with fear in their eyes. Smoke and distressed passengers soon emerged, revealing a battery pack had overheated and burst into flames, catching a seat on fire. The plane landed quickly and aggressively at Harry Reid International Airport, where fire crews were on standby.

This incident highlights the increasing concerns over lithium-ion batteries on flights, leading to frequent warnings from airlines.

Jonathan Nicholson of the UK's Civil Aviation Authority (CAA) states that lithium-ion batteries are now within the top three risks for the industry, with two incidents occurring weekly globally, according to a recent US study. These incidents can range from passengers realizing they left a device in checked luggage to fires in baggage halls or on flights.

The most extreme example was in January 2025 when an Air Busan plane was destroyed on the tarmac in South Korea due to a power bank battery pack left in an overhead luggage compartment.

The increase in lithium-ion-related incidents is attributed to more people, more flights, and more devices. The US Federal Aviation Administration reports a rise in confirmed incidents, with 51 verified cases up to July 15. Pierre Kubiak, a battery technology specialist at the UK's National Physical Laboratory, explains that lithium itself doesn't burn, but the organic material and plastic surrounding it can heat up rapidly, often exceeding 700 to 1000 degrees Fahrenheit.

The dangers of lithium-ion batteries gained public attention following phone-related fires about a decade ago, often due to flawed designs. Manufacturers have since addressed these concerns, but South Korea's proliferation of cheap battery packs from East Asia, as well as vapes and other powered devices with questionable quality controls, remains a challenge. Passengers also contribute to the issue by using unsuitable cables and not properly caring for their devices.

To mitigate these risks, airlines emphasize keeping devices in the cabin, not overhead compartments, and avoiding checked luggage. The CAA recommends using water to cool down devices in case of a fire. While sodium-ion batteries are an alternative, their higher cost currently hinders widespread adoption. Both technical and societal solutions are needed to address the issue, including better safeguards around existing lithium-ion technology.