The safest and most recommended way to travel with a power tool is to remove the battery and pack it in your carry-on baggage while checking the tool.

The regulated part of a power tool is the Lithium-ion battery.  Lithium-ion batteries are allowed based on watt-hours (Wh). Many newer lithium-ion batteries have the Wh rating marked on them. To calculate watt-hours, multiply the battery Voltage by the Amp hours (Ah). For milliamp hours (mAh), divide by 1000 (to get to Ah) and then multiply by the volts.

Lithium metal (non-rechargeable) batteries are limited to 2 grams of lithium per battery. Lithium-ion (rechargeable) batteries are limited to a rating of 100 watt hours (Wh) per battery. These limits allow for nearly all types of lithium batteries used by the average person in their electronic devices. With airline approval, passengers may also carry up to two spare larger lithium-ion batteries (101–160 Wh) or Lithium metal batteries (2-8 grams).

Lithium battery-powered devices like power tools can be checked only if they are completely powered off and protected from accidental activation (like in the manufacturer's hard case) while still meeting the watt-hour (Wh) restrictions above. 

Spare lithium batteries must be packed in carry-on baggage and cannot be checked. Each battery must be individually protected to prevent short circuits (e.g., by placing it in its original retail packaging, otherwise insulating terminals by taping over exposed terminals, or placing it in a separate plastic bag or protective pouch). 

See the regulation: 49 CFR 175.10(a)(18)

Damaged or recalled batteries and battery-powered devices, which are likely to create sparks or generate a dangerous evolution of heat must not be carried aboard an aircraft (e.g. carry-on or checked baggage) unless the damaged or recalled battery has been removed, or otherwise made safe. The airline may offer further public guidance on transporting individual recalled products.

For additional information on recalls, visit the Consumer Product Safety Commission, manufacturer, or vendor website.

For additional information, view our Airline Passenger and Batteries resources page or download a printable version.