Can You Ship Lithium Batteries Through FedEx: Rules, Step-by-Step Packing Guide

November 28, 2025 Austin Jones Fedex Shipping Restrictions

Introduction: Why this matters and what you will learn

Shipping lithium batteries is one of the riskiest moves in e commerce and logistics. Batteries can catch fire from a single short circuit, thermal runaway, or damage in transit; that is why carriers like FedEx enforce strict rules. If you ignore those rules you risk package refusal, hefty fines, shipment delays, or worse, liability for a damaged aircraft or facility.

This guide answers the question can you ship lithium batteries through FedEx, and gives a practical, step by step packing guide. You will learn how to classify cells and batteries, pack and label correctly, complete required paperwork, and follow international limits. Read this if you sell power banks, ship drone batteries, handle e bike cells, or manage warehouse fulfillment. Follow the checklist and you will ship compliant and avoid costly mistakes.

Quick answer and a practical checklist

Yes, you can ship lithium batteries through FedEx, but only if you follow FedEx and international hazardous materials rules exactly. Ship incorrectly and your package will be refused, delayed, or fined.

Printable checklist:
Identify the battery, write the type and UN number: lithium ion UN3480, lithium metal UN3090, or batteries packed with equipment UN3481/UN3091.
Check capacity: note Watt hour rating for lithium ion, cell weight for lithium metal, and quantity limits per package.
Limit state of charge for lithium ion to 30 percent for air shipments unless otherwise authorized.
Protect terminals with non conductive caps or tape, isolate cells so they cannot contact each other.
Use inner packaging that prevents movement, then a strong outer box with cushioning.
Apply required labels and marks, include shipping declaration if FedEx requires it.
Choose the correct FedEx service and get preapproval for dangerous goods when required. Call FedEx if unsure.

Understand lithium battery types and classifications

Short answer: yes, but it depends on battery chemistry and how the battery is packaged. Lithium ion batteries are rechargeable cells found in phones, laptops, power banks. Lithium metal batteries are nonrechargeable cells found in coin cells and some camera batteries. FedEx follows international UN classifications, which determine rules and paperwork.

Key UN numbers to know: UN3480 covers lithium ion batteries shipped loose, UN3090 covers lithium metal batteries shipped loose. There are companion numbers for batteries shipped with or inside equipment: UN3481 is lithium ion packed with or contained in equipment, and UN3091 is the equivalent for lithium metal. Use the correct UN number on your shipping papers and labels, because mis declaring leads to refusal or fines.

Three packaging types matter, and they change allowed quantities and labeling requirements. Contained in equipment means the battery is installed in the device, for example a phone or a laptop. Packed with equipment means the battery is separate from the device but accompanies it in the same box, for example a spare laptop battery shipped with the laptop. Standalone, or loose, means the battery is shipped by itself, for example bulk coin cells.

Practical tip, when deciding whether you can ship lithium batteries through FedEx, identify the chemistry and packaging first, then pick the matching UN number and label before booking the shipment.

FedEx rules and service restrictions explained

If you searched can you ship lithium batteries through fedex, here is the short version. FedEx Express follows strict air transport rules, so most spare lithium batteries and large capacity cells require airline approval or are not accepted. FedEx Ground within the U.S. is more flexible, but DOT and FedEx packaging, labeling, and documentation rules still apply. International shipments must meet IATA and destination country rules, so many cross border shipments are restricted or need prior authorizations.

Concrete examples to watch for:

  1. Prohibited without approval, or often banned: damaged or recalled batteries, lithium metal cells with more than 2 grams of lithium, lithium ion batteries above 300 watt hours.
  2. Require special handling or paperwork: spare lithium ion cells between 100 and 300 watt hours, bulk quantities, or batteries shipped separately from the device. FedEx will ask for a Dangerous Goods declaration, a shipper with dangerous goods training, and preapproval for certain air routes.

Practical tip, use the FedEx Service Guide and call Dangerous Goods support before booking. Labeling, terminal protection, and original or tested packaging will prevent rejections and delays.

Step-by-step packing and labeling guide

If you Google can you ship lithium batteries through FedEx, this checklist gives the exact packing steps to avoid delays and refusals. Follow the order, and double check FedEx rules for your service and shipment type.

  1. Identify the battery. Confirm chemistry, cell versus battery, watt hour or lithium content, and whether it is a spare or installed battery. Keep the manufacturer label and MSDS handy.

  2. Insulate terminals. Cover terminals with non conductive tape or use terminal caps. For loose cells, put each one in its own small plastic bag to prevent contact.

  3. Inner packaging. Place each insulated battery in individual compartments or foam pockets so they cannot touch each other or shift. Example, use perforated foam inserts or corrugated dividers.

  4. Cushioning. Add at least 1 inch of cushioning on all sides, more for larger packs. Use foam, bubble, or molded inserts, not loose fill that allows movement.

  5. Inner box to outer box. Use a strong corrugated inner box if shipping multiple units, then place inside an outer box rated for shipping. Tape all seams with packing tape.

  6. State of charge. For air shipments, set lithium ion batteries to no more than 30 percent charge unless FedEx allows a higher limit for your service. Document the state of charge on the paperwork.

  7. Labels and marks. Attach the appropriate lithium battery handling label, the UN number or Excepted Lithium Battery label if qualified, and Cargo Aircraft Only if required. Include the proper shipping name and emergency contact phone number.

  8. Documentation. Include UN 38.3 test reference or declaration if required, and complete the FedEx dangerous goods forms or shipper certifications before tendering.

Required documentation and how to complete it

If you asked "can you ship lithium batteries through FedEx" the paperwork is as important as the packing. Small domestic shipments that meet limited quantity rules may only need the FedEx waybill and the lithium battery handling label. For international or higher risk shipments you will need a Shipper’s Declaration for Dangerous Goods, completed in full on FedEx Electronic Dangerous Goods Note or on paper.

On the declaration include the proper shipping name, the UN number (common ones are UN3480 for lithium ion, UN3481 for lithium ion packed with or in equipment, UN3090 and UN3091 for lithium metal), the class 9 notation, packing instruction code, net quantity, and an emergency contact phone number. Add the lithium battery handling label and, if applicable, the limited quantity LQ mark.

Place labels on the same face as the airway bill and commercial invoice, flat and unobstructed, not over seams or corners. If you ship more than one package, label each package. Always check the latest FedEx Dangerous Goods guide before sending.

Common mistakes, enforcement, and how to avoid penalties

Many shippers ask, can you ship lithium batteries through FedEx and still get hit with penalties? Yes, if you make common mistakes. Frequent errors include failing to declare lithium batteries, packing loose cells without inner packaging, using non approved outer cartons, and missing UN numbers or required labels like UN3480 or UN3091. Regulators and FedEx can refuse the shipment, return it at your cost, levy administrative fines, or even involve law enforcement for severe violations.

Quick pre drop off checklist

  1. Confirm battery type and correct UN number, and declare it on the waybill.
  2. Verify packaging and labels meet FedEx requirements and IATA rules.
  3. Take photos of packaging, weigh the box, and keep documentation handy.
  4. Call FedEx customer service when in doubt, get confirmation, keep the reference number.

Conclusion and final insights

You can ship lithium batteries through FedEx only when they meet classification, packaging, labeling, and documentation requirements; if not, use ground couriers like UPS or DHL, arrange freight, or recycle nonshippable batteries at local hazardous waste or battery recycling centers.