Can You Ship Lithium Batteries Through UPS? Step by Step Guide

Introduction: why this matters

If you are asking "can you ship lithium batteries through UPS", the stakes are real. Improperly packed lithium ion cells can ignite, causing package fires, rejected shipments, and thousands in fines. At the same time, getting it right unlocks clear benefits, like selling batteries online, returning devices for repair, and meeting warranty logistics without surprise delays.

This guide is for e commerce sellers, repair shops, hobbyists, and operations managers who move batteries regularly. If you ship single cells, packs, or devices with batteries installed, this matters.

Promise: you will get step by step rules that work with UPS policies, including how to classify batteries, protect terminals, choose inner and outer packaging, apply labels, and file required documentation. No legal fluff, just practical, checkable steps.

Quick answer: can you ship lithium batteries through UPS

Yes, you can ship lithium batteries through UPS, but only if you follow strict rules. Small batteries installed in devices, like a laptop or phone, are usually the easiest to ship. Spare batteries and power banks are more restricted and often need special packaging, labels, and documentation.

Top three caveats:

1. Classification matters, know whether it is lithium ion or lithium metal, and if it is packed with equipment, contained in equipment, or shipped alone; each has different UN numbers and rules.
2. Packaging, labeling, and state of charge limits, for example many batteries must be packaged in UN tested boxes, protected against short circuits, and sometimes limited to about 30 percent charge for air transport.
3. Transport mode and destination affect acceptance; some shipments are ground only, some need a Shipper’s Declaration, and international routes follow different regulations.

When in doubt, call UPS Hazardous Materials support before shipping.

Essential rules and regulations to know

Regulatory landscape is layered, and you need to satisfy multiple rule sets before you ask, can you ship lithium batteries through UPS. UPS policies add company limits on top of federal and international law, so always check UPS Dangerous Goods rules first. UPS generally accepts lithium ion and lithium metal batteries when packaged and declared correctly, but they prohibit damaged or recalled cells.

For air transport, IATA rules govern packaging, state of charge, labeling, and documentation. Common limits include 100 watt hour for most lithium ion cells, 100 to 160 watt hour with airline approval, and a 30 percent state of charge requirement for many cargo shipments. UN numbers are UN3480 for lithium ion and UN3090 for lithium metal, with UN3481 or UN3091 when packed with equipment.

For ground, DOT 49 CFR treats these as Class 9 hazardous materials, requiring proper packaging, labels, and training; UPS Ground still requires declaration and marking. Special permits or exceptions apply when quantities exceed thresholds, when batteries are defective, or when shipping bulk cells, so secure regulatory approval before moving large or abnormal shipments.

How to determine battery type and capacity

First, find the label. Look for wording like "Li ion", "lithium metal", "Wh", "V", or "mAh". If you see "Li ion" or "lithium ion", it is rechargeable. If you see "Li" or "lithium metal" it is primary, nonrechargeable.

Second, calculate capacity. If the label gives watt hours, you are done. If it gives milliamp hours, convert to amp hours by dividing by 1000, then multiply by volts, example: Wh = V × Ah. A phone cell marked 3.7 V and 2700 mAh is 3.7 × 2.7 = 9.99 Wh. A laptop pack at 11.1 V and 5600 mAh is 11.1 × 5.6 = 62.16 Wh. An e bike battery at 36 V and 10 Ah is 360 Wh, too large for most carriers.

Finally, compare to UPS rules. Small consumer lithium ion batteries under about 100 Wh are usually accepted with packing rules; 100 to 160 Wh need approval; over 160 Wh will be refused. For lithium metal, check the manufacturer for lithium content in grams, or consult UPS Dangerous Goods pages before shipping.

Packing and labeling requirements

If you asked can you ship lithium batteries through UPS, nail the packing and labeling first. Follow these steps exactly.

1. Prepare the cells. Insulate terminals with non conductive tape or terminal caps, and place each cell or battery in its own inner packaging to prevent contact and short circuits.
2. Cushion and separate. Use foam inserts or molded trays, at least 2 inches of cushioning on all sides, and add non conductive separators between batteries. No loose fill that allows movement.
3. Inner and outer packaging. Use UN certified inner packaging for damaged or bulk shipments, otherwise use strong rigid inner boxes inside a sturdy corrugated outer box. Double box for high value or fragile packs.
4. Close and test. Close the outer box, shake it, confirm no movement, then seal with high strength tape.

Labeling and marks, required by UPS and regulators:
Proper shipping name and UN number, for example UN 3480 or UN 3481 for lithium ion, UN 3090 or UN 3091 for lithium metal.
Class 9 hazard label when required.
Lithium battery handling label with the correct UN number and a contact phone number.
If applicable, mark "Lithium ion batteries packed with equipment" or "packed in equipment" exactly as required.

Documentation and special handling forms

If you ask can you ship lithium batteries through UPS, start with paperwork. A Dangerous Goods declaration is required whenever your shipment does not meet limited quantity or excepted package limits, or when regulations require a shipper declaration for air transport. Common triggers are UN3480, UN3481, UN3090, and batteries over statutory watt hour or lithium content limits.

How to complete the essentials, fast:

1. Identify battery type, UN number, and watt hour or lithium content.
2. Fill the Dangerous Goods declaration with proper shipping name, net quantity, shipper and emergency contact phone, and sign it.
3. Note state of charge for lithium ion batteries, for example STATE OF CHARGE 30% when limited to 30 percent.

Add handling instructions and required labels, include a copy inside the package, and retain paperwork per carrier rules.

How to book and drop off a lithium battery shipment with UPS

First, pick a UPS service that accepts your battery type, then confirm limits. Check the UPS Hazardous Materials Guide online, and if unsure call customer service with your battery type, watt hour or lithium content, and whether the battery is installed in equipment or packed separately. Next, schedule a UPS pickup at UPS.com or book a drop off at a UPS Customer Center or authorized shipper. Before you go, call the destination service center to confirm they will accept lithium battery shipments that day, this avoids refusal at the counter. At drop off, present the required paperwork and labels, state explicitly that it is a lithium battery shipment, and ask the clerk to note special handling. If you need chain of custody, request a signed receipt from the center.

Common mistakes and troubleshooting

If you wonder, can you ship lithium batteries through UPS, the good news is yes, but mistakes are common. Top causes of rejection are unlabeled packages, exposed terminals, incorrect paperwork, and using nonapproved packaging. Fix each by labeling clearly, insulating terminals with tape or plastic caps, using the manufacturer box or a UN tested pack when required, and attaching the proper documentation before tendering.

Quick checklist that prevents fines
Missing declaration: always declare hazardous batteries when required.
Damaged cells: do not ship damaged or bulging batteries, contact UPS hazardous materials support instead.
Spares: ship spare batteries with terminals protected and in their own inner packaging, or follow UPS guidance for batteries packed with equipment.
When in doubt call UPS customer service and confirm shipment classification and required markings before drop off.

Final checklist and next steps

Final quick checklist before you ask yourself can you ship lithium batteries through UPS, follow this step list.

Confirm battery type and UN number, for example UN3480 for lithium ion, UN3090 for lithium metal.
Verify UN 38.3 test certification and keep test report copies.
Ensure state of charge limits and correct packing; for many shipments keep lithium ion at 30 percent state of charge or below.
Use approved inner packaging to prevent movement, insulate terminals, and place in strong outer packaging.
Affix proper labels and complete required declarations or Shipper’s Declaration for Dangerous Goods when applicable.
Get carrier acceptance, complete required shipper training, and have emergency contact info ready.

Next steps, consult official resources: UPS Hazardous Materials page, IATA Lithium Battery Guidance, FAA Hazardous Materials and DOT PHMSA pages. If unsure, call UPS Dangerous Goods desk for a final go no go. Ship only after documentation and packaging pass this checklist.