To ship lithium batteries internationally, you need to classify them under the right UN number, meet the packing instruction for your transport mode, and have a UN38.3 test summary for every cell and battery. In 2026 there is an important new rule for air freight. Lithium-ion batteries packed with equipment must now ship at no more than 30% state of charge (SoC), the limit that already applied to batteries shipped on their own.
Key Takeaways
- Lithium batteries are Class 9 dangerous goods: UN3480 (Li-ion alone), UN3481 (Li-ion with or in equipment), UN3090 and UN3091 (lithium metal).
- From 1 January 2026, Li-ion batteries packed with equipment (PI 966) must ship at ≤30% SoC (IATA).
- Standalone Li-ion batteries (UN3480) are forbidden as cargo on passenger aircraft and must travel on cargo aircraft only.
- Sea freight follows the IMDG Code, which is usually less restrictive on SoC. It is often the practical route for large packs.
Step 1: Classify the Shipment
Every shipment falls into one of these categories. The category decides the packing instruction (PI) for air freight:
| Shipment type | UN number | Air packing instruction |
|---|---|---|
| Li-ion batteries shipped alone | UN3480 | PI 965 |
| Li-ion batteries packed with equipment | UN3481 | PI 966 |
| Li-ion batteries contained in equipment | UN3481 | PI 967 |
| Lithium metal batteries shipped alone | UN3090 | PI 968 |
| Lithium metal batteries packed with / in equipment | UN3091 | PI 969 / PI 970 |
Next, check the size. Under the IATA Dangerous Goods Regulations, Li-ion cells up to 20 Wh and batteries up to 100 Wh can use the lighter Section II provisions (with quantity limits). Anything above that is fully regulated under Section I or IA. To find the watt-hour rating, multiply nominal voltage by rated capacity in Ah. See watts and watt-hours explained.
Step 2: Get the UN38.3 Test Summary
All lithium cells and batteries must pass the tests in Section 38.3 of the UN Manual of Tests and Criteria. Manufacturers and later distributors must make the test summary available. According to IATA’s guidance, you can do this by posting it on a website and giving the link or a QR code, instead of printing it for every consignment.
Forwarders and airlines will ask for it. No test summary means no shipment. Read more in UN38.3 certification explained.
Step 3: Meet the 2026 State-of-Charge Rules for Air
The IATA Lithium Battery Guidance Document 2026 sets out these SoC limits:
| Packing instruction | SoC requirement |
|---|---|
| PI 965 (batteries alone) | Mandatory ≤30% of rated capacity |
| PI 966 Section I (packed with equipment) | Mandatory ≤30% from 1 January 2026 |
| PI 966 Section II | Mandatory ≤30% for batteries above 2.7 Wh, from 1 January 2026 |
| PI 967 (contained in equipment) | Strongly recommended: ≤30% SoC or ≤25% indicated capacity |
Shipping above 30% needs approval from both the State of Origin and the State of the Operator. The reason for the rule is that cells at a lower SoC are less likely to go into thermal runaway. For production, build a controlled discharge-to-shipping-SoC step into end-of-line testing and record it on the batch record.
Step 4: Package, Mark and Document
- Packaging: UN-specification packaging where Section I applies. Use strong outer packaging that protects terminals from short circuit and stops movement inside the box.
- Marks and labels: the lithium battery mark for Section II. The Class 9 lithium battery hazard label and UN number for Section I. The “Cargo Aircraft Only” label where required.
- Documents: a Shipper’s Declaration for Dangerous Goods (Section I), the UN38.3 test summary, and an SDS if the forwarder asks for one.
- Training: the person preparing a Section I shipment must have valid dangerous goods training.
Step 5: Choose Air or Sea
Air is fast but limited. Standalone UN3480 batteries can’t fly on passenger aircraft, cargo-aircraft capacity is limited, and the SoC rules apply. Sea under the IMO IMDG Code (2024 Edition, mandatory from 1 January 2026) is usually the cost-effective choice for large packs and bulk orders. You still need correct classification, packaging, labelling and a dangerous goods declaration.
For shipments into or through the United States, the PHMSA Hazardous Materials Regulations apply (49 CFR 173.185). PHMSA publishes a free Lithium Battery Guide for Shippers.
Common Mistakes That Delay Shipments
- A missing or outdated UN38.3 test summary, often after a cell change
- Declaring batteries “contained in equipment” when they are actually packed loose in the box
- Shipping batteries fully charged
- Wrong watt-hour marking on the battery label
- Damaged or recalled batteries sent through normal channels (these are forbidden by air)
Frequently Asked Questions
Can I ship lithium batteries by express courier?
Yes, if you meet the carrier’s dangerous goods acceptance rules. Many couriers only accept Section II shipments, or require a dangerous goods account for Section I.
Does the 30% SoC rule apply to batteries installed in devices?
For PI 967 (contained in equipment), IATA recommends ≤30% SoC but does not require it in 2026. Check with your carrier, because some airlines apply stricter rules.
How should I store batteries before shipping?
Store them at partial charge in a cool, dry place. See how to store lithium-ion batteries safely.
Ship Compliant Packs from Day One
Jetray supplies every pack with a UN38.3 test summary and ships at compliant SoC. We can advise on air or sea routing for your order. See our certifications or contact us with your destination and volumes.
