How close are we to a lithium-ion battery catastrophe in the skies?

With lithium-ion batteries powering everything from smartphones to electric scooters, the volume of these high-risk items moving through air cargo has never been greater, and so has the danger. As regulators and industry leaders scramble to stay ahead of the risks, concerns are mounting over undeclared shipments, inconsistent enforcement, and the growing potential for mid-air incidents.

The global air cargo industry must intensify its vigilance and collaboration to address rising threats to safety and security, urged Brendan Sullivan, Global Head of Cargo at IATA, during the opening of the World Cargo Symposium (WCS) held in Dubai last month.

In a striking anecdote that set the tone for the symposium, Sullivan recounted a recent close call at an East Asian airport that highlighted the dangers posed by undeclared lithium-ion batteries in air cargo. A routine inspection flagged a shipment labelled “mobile phone accessories,” which was later discovered to contain damaged and undeclared lithium-ion batteries, just hours before it was due to be loaded onto a flight.

"The inspector," Sullivan explained, “had just completed IATA’s dangerous goods training. He was helped by DG AutoCheck which caught the mismatch between what was declared and what was in the box. And the airline’s station was CEIV Lithium Batteries-certified, meaning strong, consistent processes were in place."

With the growing global appetite for lithium ion-powered devices—from smartphones and e-bikes to industrial tools and drones—the number of lithium ion battery shipments continues to surge. Sullivan warned that with increased volume comes increased risk, and the industry cannot afford complacency.

He laid out a clear agenda: “Too many lithium battery shipments enter the system undeclared or mis-declared. That’s unacceptable. It puts aircraft at risk. It puts lives at risk. Civil aviation authorities must take firm enforcement action against non-compliant shippers. And we need governments to actively support ICAO’s work to strengthen Annex 18—the global framework for the safe transport of dangerous goods by air.”

The call for heightened safety came with a strong push for training and accountability. In 2024 alone, over 85,000 professionals were trained through IATA’s Competency-Based Training and Assessment (CBTA) Center for Dangerous Goods, and 121 organisations have adopted CEIV Lithium Batteries certification.

"It’s not just manufacturers who fail to declare batteries—often, everyday people unknowingly ship used items with compromised batteries that haven’t been quality-checked. These go unnoticed, as forms are signed without realising a battery is inside."
Chris Daniels, Global K9 Protection Group

Sullivan's warning was not just a theoretical concern—it was a clarion call echoed across the air cargo industry, where frontline experts are already grappling with the mounting challenges posed by lithium-ion batteries. Among them is Chris Daniels, Chief Strategy Officer at Global K9 Protection Group, whose work puts him squarely in the path of the threat every day. 

“The lithium-ion battery problem is very real,” warns Daniels. “It's also growing. It’s going to continue to grow as more and more battery-powered products move through the supply chain.”

The danger isn’t hypothetical. Lithium-ion batteries are known to be flammable, and if damaged, improperly packed, or manufactured defectively, they can ignite and cause uncontrollable fires, sometimes mid-air. The FAA has recorded hundreds of incidents involving smoke, fire, or extreme heat caused by lithium batteries in air transport.

And as Daniels puts it, “It’s not a matter of if it happens—it has already happened. The only question is: how well are we identifying, isolating, and mitigating the risk before it gets airborne?”

One major concern is the improper declaration of lithium-ion battery shipments. Often, shippers fail to declare batteries correctly, either through ignorance or willful evasion to save costs or avoid scrutiny. 

"It’s not just manufacturers who fail to declare batteries—often, everyday people unknowingly ship used items with compromised batteries that haven’t been quality-checked. These go unnoticed, as forms are signed without realising a battery is inside."

He adds, “That creates a blind spot in the screening process. You could have a pallet of e-bikes with batteries still inside, or bulk-packed batteries hidden within general cargo. If nobody declares it, it’s like a ticking time bomb in the hold.”

That places greater emphasis on documentation, regulatory enforcement, and intelligence-led inspections. But enforcement is often uneven across jurisdictions. “Some countries have rigorous checks and advanced tech. Others don’t. That gap can be exploited,” says Daniels.

He also sees potential in integrating AI and data analytics into the screening process to flag high-risk shipments before they get near a plane. “We need to get better at predictive targeting—using shipping patterns, consignee history, route profiles—to identify suspicious cargo,” he explains. “It’s about combining traditional screening with smarter systems.”

Daniels believes industry and regulators must work hand-in-hand. “The regulators have to keep the pressure on, but they also need to support innovation. Industry can bring speed and agility, but we need rules that are globally consistent and enforceable.”

With the surge in e-commerce, battery-powered devices are moving faster and in greater volume than ever before. That means the problem isn’t going away. “In fact,” Daniels cautions, “it’s going to get worse before it gets better—unless we get serious, fast.”

Ultimately, the goal is to balance security with operational efficiency. “We don’t want to shut down commerce. We want to protect it,” he says. “But if we don't get ahead of the lithium-ion battery threat, the consequences could be catastrophic.”

“We’re also seeing developments in packaging that can mitigate thermal runaway events—even if a battery does fail, the right containment can prevent a catastrophe.”
David Wroth, UL Standards & Engagement

As Daniels highlights the operational blind spots and evolving tactics needed to identify hidden hazards, the conversation naturally turns to the structural backbone of battery safety: standards. That’s where David Wroth, Director, Technology and Systems at UL Standards & Engagement, comes in. While enforcement and screening are crucial, Wroth emphasises that long-term safety begins well before a package reaches the tarmac—with rigorous testing, transparent supply chains, and scientifically grounded design criteria that prevent dangerous batteries from entering the system in the first place.

Wroth highlights that the International Civil Aviation Organisation (ICAO) requires lithium batteries to be shipped at a 30% state of charge to reduce thermal runaway risks. However, he observes, “They're not actually being shipped in accordance with that stated charge requirement. It's implemented, but it's not being enforced.” 

He insists this should be a mandatory requirement, adding, “Shipping at 30% state of charge significantly reduces the risk of these thermal runaway incidents, and if they do occur, the consequences of those risks.”

The cargo hold of an aircraft is no place for fire. Yet over the past decade, airlines and regulatory agencies have grappled with numerous incidents—some fatal—linked to lithium battery shipments. These incidents have spurred new safety regulations, packaging requirements, and testing protocols, but challenges persist.

UL Standards & Engagement is a nonprofit organisation within the UL enterprise, dedicated to developing safety standards and engaging with stakeholders to promote public safety and sustainability. Since publishing its first standard in 1903, UL Standards & Engagement has developed more than 1,700 standards across various sectors, including energy, healthcare, and construction.

UL Standards & Engagement, through its global standards, has been at the forefront of developing rigorous safety frameworks for lithium battery manufacturing, testing, and transport. While lithium batteries fall under various regulatory frameworks—like IATA’s Dangerous Goods Regulations—the role of independent safety science remains critical in bridging innovation with risk management.

Beyond regulations, Wroth advocates for best practices such as using fire-resistant containers and covers. “They should be using those extensively where they are shipping lithium batteries. It contains the most significant consequences of that fire,” he says, calling this a best practice rather than a requirement.

UL is also advancing safety standards for battery containment products. Wroth notes, “We believe every aircraft should have those on board. Most of the products that are on the market today have not been tested and evaluated to that standard, and other research has shown that the products that are not certified to the standard don't perform properly.” 

Looking forward, Wroth describes the development of UL 5810, a standard for fire-resistant ULDs with built-in detection and suppression. “This is a standard that would essentially enable ULDs to withstand a lithium battery fire within the ULD and contain that fire for up to four hours,” he explains, giving pilots time to land safely.

Prevention is equally crucial. Wroth asserts, “All lithium batteries and the devices that they are in should be independently tested to performance and safety standards. This would prevent most of the thermal runaway incidents.” Yet, he acknowledges, “in most countries it's a voluntary requirement. It is not required by the government.”

Regarding certification, Wroth clarifies, “UL Solutions does certify batteries. It's just called a UL mark. Other companies like TUV, Rhineland, SGS, also certify to those standards.” 

However, he admits, “We don't know of anyone who has said that they will only transport certified batteries. That wouldn't be a very good commercial decision for them. Unfortunately.”

Wroth’s insights reveal the ongoing need for stronger enforcement, adoption of best practices, and broader certification to ensure lithium battery safety in air transport.

The skies above us remain a critical artery of global trade, but as lithium battery-powered devices surge in demand, so too does the need for unrelenting vigilance. Whether it’s through sharper inspections, smarter tech, stricter standards, or stronger global enforcement, the stakes are clear: safety must never be left to chance.

The article was originally published in the May 2025 issue of The STAT Trade Times.