TSA flags 5 types of electronics in carry-ons: lithium batteries, power banks and vapes

What TSA scrutinizes in carry-ons

The US Transportation Security Administration (TSA) flags five categories of electronics in carry-on luggage: lithium batteries, power banks, electronic cigarettes, smart luggage, and devices with non-removable batteries. These items are subject to specific restrictions to mitigate fire hazards and security risks.

Lithium batteries, including those in power banks and smart luggage, must remain in carry-on luggage due to their potential to overheat. Devices powered by lithium batteries, such as smartphones, tablets, and laptops, may need to be removed from bags during security checks. The TSA may also require travelers to power on devices to confirm functionality.

Power banks and spare batteries: size and placement rules

Portable power banks are only permitted in carry-on luggage and must not exceed 100 watt-hours (Wh) without prior airline approval. Power banks like the 25K Anker model are often marketed as "flight approved" because they meet the 100Wh limit. Travelers can carry up to two lithium-ion batteries exceeding 100Wh, but larger capacities require airline clearance.

Non-rechargeable lithium metal batteries, such as CR2032, are allowed in carry-on luggage if they contain no more than 2 grams of lithium per battery. Spare batteries of any type are prohibited in checked luggage.

Smart luggage and trackers: what flies and what doesn’t

Smart luggage with integrated lithium batteries is permitted in carry-on luggage only if the batteries can be removed. If batteries are non-removable, the luggage may be prohibited, even if it meets size requirements. Some airlines, including Delta and Air Canada, ban motorized rideable luggage, such as electric skateboards, airwheels, and battery-assisted bikes, regardless of battery type.

Tracking devices like Apple AirTags are allowed in both carry-on and checked luggage. Their batteries contain less than 0.1 grams of lithium and do not exceed 0.7Wh, making them exempt from most restrictions.

Restrictions on vapes, toothbrushes, and banned devices

Electronic cigarettes and vapes must be carried in carry-on luggage and are banned from checked bags. Airlines like Southwest limit passengers to two devices per person and prohibit their use or charging onboard. Laser pointers are also restricted; Air Canada, for example, requires them to be packed in checked luggage.

Electric toothbrushes are treated similarly to other lithium-battery devices and must be kept in carry-on luggage. Devices with a history of safety incidents, such as the Samsung Galaxy Note 7, are banned from all flights, including in carry-on luggage.

What this means

Lazyfounder analysis — our interpretation, not reported fact.

For founders and operators in consumer electronics, travel tech, or hardware startups, TSA’s rules are a design constraint. Products like power banks, smart luggage, or wearable tech must comply with airline restrictions to avoid being banned or confiscated. For example, if your startup sells portable chargers, ensure they stay under 100Wh or risk alienating travelers. If you’re building smart luggage, removable batteries are no longer optional—they’re a requirement for market access.

These rules also signal broader regulatory scrutiny of lithium batteries, which are increasingly common in consumer products. Startups in this space should anticipate stricter guidelines in other markets, including India, where aviation authorities often adopt TSA-like policies. Operators should also consider how these restrictions might affect product testing or demos abroad—shipping prototypes with lithium batteries via air freight may require special permits or alternative logistics.