The growing use of smartphones, laptops, power banks, smartwatches and other battery-powered gadgets is creating a new safety challenge for the aviation industry, with lithium-ion batteries increasingly being linked to incidents involving smoke, overheating and fires on aircraft. Airlines and aviation authorities are consequently stepping up warnings to passengers about how such devices should be carried and handled during flights.
Technology journalist Ben Wodecki recently witnessed the danger first-hand while flying into Las Vegas. During what had been a routine flight, members of the cabin crew suddenly rushed towards the rear of the aircraft, appearing visibly concerned. Wodecki said their reaction suggested that the situation was far more serious than a passenger simply falling ill.
The reason soon became apparent when smoke and distressed passengers began emerging from the rear of the aircraft. A passenger’s battery pack had overheated and caught fire, with the flames spreading to a seat. Cabin crew responded quickly, placing the device in a container of water to cool it down. The aircraft subsequently made a rapid landing at Harry Reid International Airport in Las Vegas, where emergency fire crews were waiting on the runway.
The incident highlights why passengers are increasingly being warned not only about carrying lithium-ion batteries but also about how they use and store battery-powered devices during a flight. Airlines frequently advise travellers not to place such devices in checked baggage and warn passengers against attempting to retrieve phones or other gadgets that become trapped in the gap around aircraft seats.
Jonathan Nicholson of the UK’s Civil Aviation Authority said lithium-ion batteries had remained among the aviation industry’s most significant risks for several years. According to him, a recent US study indicated that the global airline industry was experiencing around two lithium-ion battery-related incidents every week. These incidents vary in seriousness, from passengers discovering that a battery-powered device has accidentally been placed in checked baggage to devices beginning to smoke or catch fire in airport baggage areas or inside aircraft.
Some incidents, however, have had devastating consequences. In January 2025, an Air Busan aircraft was destroyed while parked at Gimhae Airport in South Korea. Investigators concluded that a power bank left in an overhead luggage compartment was responsible for the fire. The incident prompted the International Air Transport Association to launch a global campaign urging passengers to travel safely with lithium batteries.
Experts stress that flying itself does not make lithium-ion batteries inherently more dangerous. The difficulty is that dealing with a battery fire becomes considerably more complicated when an aircraft is thousands of feet above the ground. Nicholson attributed the increasing number of incidents largely to the growing number of passengers, flights and electronic devices being carried.
The US Federal Aviation Administration has also identified battery safety as a priority, with its records continuing to show an increase in confirmed incidents. It recorded 51 verified battery-related incidents in the year up to July 15.
Pierre Kubiak, a principal engineer specialising in battery technology at the UK’s National Physical Laboratory, said the range of devices using lithium-ion technology was expanding rapidly. Apart from familiar products such as mobile phones, laptops, tablets and power banks, passengers are increasingly carrying smartwatches, smart glasses and electronic vaping devices.
According to Kubiak, the lithium itself is not what primarily fuels the flames. Instead, organic materials and plastics within the battery system can burn, while a failing battery can generate extremely high temperatures in a very short period. This combination can make a damaged or overheating battery particularly difficult to control.
Concerns over lithium-ion battery safety became widely known about a decade ago after a series of fires involving mobile phones. Kubiak said many of those problems were associated with design flaws that manufacturers subsequently addressed. South Korea, he noted, has emerged as a leader in improving battery safety.
However, the widespread availability of inexpensive battery packs and electronic devices manufactured with varying levels of quality control remains a concern. Consumers can also contribute to battery problems by using unsuitable charging cables, mishandling devices or failing to maintain them properly.
For airlines, this means prevention and rapid response remain critical. Cabin crews are trained to react quickly when a battery begins overheating or catches fire. Nicholson said cooling the device with water was among the most important measures, although some airlines also use specialised containment equipment.
Keeping battery-powered devices in the passenger cabin is therefore considered essential. If an incident occurs, crew members can identify and deal with it much more effectively than if the device is buried inside checked baggage in the aircraft’s hold. Passengers are also encouraged to remain alert to the condition of their devices and report any signs of overheating, smoke or unusual odours immediately.
Despite the growing restrictions and warnings, aviation officials say passengers have generally responded positively. The bigger challenge is that many travellers do not realise how many everyday products around them contain lithium-ion batteries.
Experts say replacing the technology is not currently a practical economic option because the electronics and personal-device industries are deeply dependent on lithium-ion batteries. Sodium-ion technology is one possible alternative, but it remains significantly more expensive for consumers.
The aviation industry is therefore likely to focus on improving safety around existing battery technology rather than attempting to prohibit battery-powered devices altogether. With electronic gadgets becoming an increasingly integral part of modern travel, better battery design, stronger quality controls, responsible consumer use and effective emergency procedures are expected to remain central to keeping passengers safe in the skies.
