Can You Ship Lithium Batteries Through USPS: A Practical Guide

November 29, 2025 Austin Jones USPS Shipping Restrictions

Introduction: Why this question matters and what you will learn

If you have ever tried to mail a spare phone battery, a power bank, or a laptop cell, you know the rules are confusing. So, can you ship lithium batteries through USPS? The short answer is sometimes. It depends on the type of battery, its watt hour or lithium content, whether it is installed in equipment, and how it is packaged and declared.

In this guide you will get clear, practical answers, not legalese. You will learn which lithium ion and lithium metal batteries USPS allows, which shipments are banned, how to package and label batteries to meet USPS lithium battery rules, and which forms or carrier choices trigger extra requirements. You will also see concrete examples, for instance sending a spare iPhone battery, mailing a power bank, and shipping a laptop with its battery installed. Follow the simple checklist here and you will avoid delays, rejection, and potential fines.

Quick answer, and the short rules you must know

Yes, with caveats. You can ship lithium batteries through USPS in many common situations, but the rules depend on the battery type, watt hour or lithium content, and whether the cell is installed in equipment, packed with equipment, or shipped alone. For example, AA lithium metal cells inside a flashlight are usually fine, a laptop with its battery installed is normally accepted if well protected, while spare phone batteries often need terminals taped and may be limited to low state of charge. International and air shipments face stricter limits or bans. Always confirm battery type and capacity, follow USPS packaging and labeling rules, and when unsure, ask your local post office or consult USPS Publication 52.

What counts as a lithium battery, and the key types

Broadly, there are two families to know, lithium ion and lithium metal. Lithium ion cells are rechargeable, found in phones, laptops, power banks, and most camera batteries. Lithium metal cells are nonrechargeable coin cells and some specialty batteries, like CR2032 watch cells. Why care, because chemistry drives risk; lithium metal tends to be more reactive, and regulators treat it more strictly.

USPS classifies shipments three ways, and the differences matter. Batteries installed in a device, for example a smartphone or laptop with the battery inside, face the fewest restrictions because the device reduces short circuit risk. Batteries packed with a device, such as a spare battery boxed alongside a laptop, require extra packaging and labeling. Standalone batteries shipped by themselves are the most regulated, especially lithium metal coin cells and loose lithium ion cells.

So can you ship lithium batteries through USPS? Generally yes, but the allowed method, required documentation, state of charge limits, and packaging depend on type and how the battery is packaged. Practical tip, whenever possible ship batteries installed in the device, insulate terminals, use original packaging, and always verify current USPS guidance before mailing.

USPS rules at a glance, domestic versus international

Short answer, yes with strict limits. USPS follows DOT hazardous materials rules and FAA air safety regulations, so what you can mail depends on battery type, packing, testing, and whether the item goes by air or ground. Look for UN numbers such as UN 3480, UN 3481, and UN 3090, and make sure cells meet UN 38.3 testing.

DOT sets hazardous materials rules for all transport, FAA adds extra controls for air shipments, so some lithium batteries are allowed only if at 30 percent state of charge or approved for air transport. USPS applies those rules to domestic and international mail.

Domestically you can usually mail devices with batteries installed, and some spare batteries under limited quantity rules with proper labeling. International shipments are far stricter, many countries ban spare batteries in mail or require airline approval. Practical tip, check USPS Publication 52 and the DMM before you ship, or use a courier for complex cases.

Packaging and labeling requirements you must follow

If you are wondering can you ship lithium batteries through USPS, follow these exact packaging and labeling steps to avoid delays or refusals.

  1. Prepare batteries, tape or cover all terminals with non conductive tape, place each cell or battery in its own plastic bag or pouch to prevent contact, cushion with foam so nothing shifts inside the box.
  2. For batteries installed in equipment, secure the device so the battery cannot become loose, and pad around the item with at least two inches of shock absorbing material.
  3. Use a strong outer box with no previous shipping labels, do not overstuff, and make sure the package shows no signs of damage.
  4. Labeling, for lithium ion cells use UN 3480, for lithium ion packed with equipment or contained in equipment use UN 3481, for lithium metal use UN 3090 or UN 3091 when applicable.
  5. Add the appropriate lithium battery handling label, include the emergency contact phone number, and declare watt hour or lithium content when required.
  6. Never ship damaged, defective, or recalled batteries. When in doubt contact USPS or follow 49 CFR guidance.

Documentation and declarations explained

If you are asking can you ship lithium batteries through USPS, documentation matters. Small consumer batteries shipped with or contained in equipment often qualify for the Section II exception, which means no shipper declaration is required, but the package must bear the lithium battery mark with the words Section II nearby, and include basic handling statements. If batteries exceed the Section II limits, or are shipped alone as hazardous material, you must complete a Shipper’s Declaration for Dangerous Goods and follow IATA or 49 CFR packing instructions. Always keep supporting documents, for example the manufacturer’s UN test summary, MSDS, the completed shipper declaration, and the self declaration of compliance. Retain these records for at least two years and have them available if USPS or DOT requests them.

Common mistakes that cause rejected shipments

Many mistakes cause rejected shipments when shippers ask can you ship lithium batteries through USPS and then mess up. Common errors include wrong battery classification, missing hazard labels, exposed terminals, and packing that allows shorts. Carriers reject packages that exceed watt hour limits, lack documentation, or contain damaged batteries. Consequences include returned parcels, fines, or seizure. Quick fixes: confirm whether the cell is lithium ion or lithium metal and check the Wh rating, tape terminals, wrap batteries separately, use outer boxes with nonconductive fillers, and add required lithium battery markings and paperwork. When in doubt, call your local post office.

Step-by-step checklist to prepare a USPS lithium battery shipment

  1. Assess the battery, check label for watt hour or lithium content, confirm type (lithium ion or lithium metal). If you cannot find rating, stop and look up the device model.

  2. Verify limits, consult the USPS website or Publication 52, and note that many carriers use a 100 Wh guideline for consumer lithium ion cells; if above that, do not attempt regular mail.

  3. Protect terminals, tape exposed contacts, and place batteries in individual insulated bags or original packaging.

  4. Use sturdy outer packaging, add cushioning so the battery cannot move, and measure dimensions and weight for correct postage.

  5. Affix required lithium battery handling labels and include any manufacturer documentation requested by USPS.

  6. Call your local post office to confirm they accept the package, then hand it to the clerk at the counter; do not drop it in a collection box.

  7. Keep tracking and a photo of the sealed package until delivered.

When USPS is not the right choice and alternatives

If you ask can you ship lithium batteries through USPS, note that USPS will refuse service for large or damaged cells, improperly packaged batteries, recalled units, and shipments above allowed watt hour limits. For e bike packs, power stations, bulk spare cells, or batteries over 100 Wh, use UPS or FedEx DG services, or a certified hazmat carrier. These providers handle proper packaging, labeling, and paperwork. Tip: check the battery’s Wh rating, call the carrier before booking, and use a hazmat specialist for commercial or high capacity shipments.

Conclusion and final insights for safe, compliant shipping

Short answer, yes, but only when you follow strict rules. To ship lithium batteries through USPS safely and legally, do these things first: verify battery type and rating, confirm it meets USPS and DOT limits, and read the device manufacturer’s shipping guidance. Practical checklist you can use right now:

  1. Measure or find the Wh or gram rating on the battery, and compare it to USPS limits.
  2. Protect terminals with tape or a non conductive cap, place each battery in its own plastic bag, and cushion inside a strong outer box.
  3. Label and document the shipment if required, and never misdescribe hazardous contents.

If you are unsure, call your local post office or consult USPS Publication 52 and DOT resources before dropping the package. For large quantities or high capacity cells, use a hazmat specialist or freight carrier. When in doubt, remove the battery and ship the device instead.