Shipping Regulations of Lithium Ion Batteries/Cell within the US

Came across some really good info I figured I'd share with you guys. For at least the US region, you can ship lithiums fairly easily.

Have a look at the UPS regulations here: UPS Regulations

What's nice is that you can save on shipping by doing what's called using an "overpack". Basically putting smaller boxes into 1 larger one, so as long as the total weight is below the max limit.

And here's another one: How to safely pack and ship batteries - UPS

Addendum:
Here's the USPS regulations:

Domestic Lithium-ion Cells and Batteries:
Installed in or packed withthe equipment they are intended to operate:

• The total watt-hour rating for each cell must not exceed 20 Wh.
• The total watt-hour rating for each battery must not exceed 100 Wh.
• Each mailpiece must contain no more than 8 cells or 2 batteries.

Individual batteriesmailed without equipment:

• The total watt-hour rating for each cell must not exceed 20 Wh.
• The total watt-hour rating for each battery must not exceed 100 Wh.
• The mailpiece must not exceed 5 pounds.

Click to expand...

I think this is pertinent information as we are starting to ship larger quantities of batteries/cells and we all need to be vigilant in not causing an incident that could shine a negative light on our DIY works. I would hate for the media/gov't to take away this opportunity, or start taxing us or something, because someone sent batteries and they caught fire and became a hazard on our account.

Look for the revised version for 2018

I didn't see one for 2018, but the 2nd link was posted on the UPS.com site in Jun 2017.

Now, that's UPS, not USPS. USPS has much stricter regulations. Like, no more than 3 batteries per box/container

And most of FexEx's links are broken pertaining to Lithium shipments.


Also updated main post.

Keith, I thought you said when you took a box in the post office, they just slapped a ground sticker on it. Did they ask you how many batteries or the watt-hours?

Thanks for that information. This whole forum is just excellent in my view.

Below are the rules for USPSthat I know of for shipping. And as I read them, it depends on what the definition of installed in equipment is. Does an OEM designed battery with a BMS on it fit the definition of installed in equipment? My local USPS depot seems to think so. I pack with bubble wrap, tape over the contactsand apply the appropriate sticker and feel safe. They seem to as well. Presently I do not ship used cells that I have harvested because I have not figured out a way to package them that I feel is safe and meets the rules as I see them.

I will be pursuing shipping with Fedex ground as well and if I come across anything different with them I will post about it. Although the USPS flat rate boxes packaged in the way I described seem to be the most cost efficient at this time due to the weight involved.


349.222 Secondary Lithium-ion (Rechargeable) Cells and Batteries Domestic

For domestic mailings only, small consumer-type lithium-ion cells and batteries like those used to power cell phones and laptop computers are mailable domestically under the following conditions. See622or IMM 136 when mailing batteries internationally or to and from APO, FPO, or DPO destinations.

1. General.The following additional restrictions apply to the mailability of all secondary (rechargeable) lithium-ion cells and batteries:
   1. The lithium content must not exceed 20 Wh (Watt-hour rating) per cell.
   2. The total aggregate lithium content must not exceed 100 Wh per battery.
   3. Each cell or battery must meet the requirements of each test in the UN Manual of Tests and Criteria, part III, and subsection 38.3 as referenced in DOTs hazardous materials regulation at 49 CFR 171.7.
   4. The mailpiece must not contain more than three batteries.
   5. All outer packages must have a complete delivery and return address.
2. Installed in Equipment.The following additional restrictions apply to the mailing of secondary cells or batteries properly installed in equipment they operate:
   1. The batteries installed in the equipment must be protected from damage and short circuit.
   2. The equipment must be equipped with an effective means of preventing it from being turned on or activated.
   3. The equipment must be cushioned to prevent movement or damage and be contained in a strong enough sealed package to prevent crushing of the package or exposure of the contents during normal handling in the mail. The shipment must be mailed in a strong outer package.
3. Mailed With Equipment.The following additional restrictions apply to the mailing of secondary cells or batteries shipped with (but not installed in) the device or equipment being mailed:
   1. The shipment cannot contain more batteries than the number needed to operate the device up to three batteries.
   2. The secondary lithium cells and batteries must be packaged separately and cushioned to prevent movement or damage.
   3. The shipment must be contained in a strong enough sealed package to prevent crushing of the package or exposure of the contents during normal handling in the mail.
   4. The outside of the package must be marked on the address side Package Contains Lithium-ion Batteries (no lithium metal).
4. Mailed Without Equipment.The following additional restrictions apply to the mailing of secondary cells or batteries without equipment (individual batteries):
   1. The secondary lithium cells and batteries must be mailed intheoriginally sealed packaging, and the package may contain no more than three batteries.
   2. The sealed packages of batteriesmust be separated andcushionedto prevent short circuit, movement, or damage.
   3. The shipment must be contained in a strong enough sealed package toprevent crushingof the package or exposure of the contents during normal handling in the mail.
   4. The outside of the package must be marked on the address sidePackage Contains Lithium-ion Batteries (no lithium metal).

Thanks for the added info, Headrc.

I like 1.4 ruling. It says not to include more than 3 batteries. If they go by the same definition of the UPS of a battery vs cell, then you can ship more than cell cells so as long as the total package doesn't exceed 100Wh. That can be a lot of cells in one box!

I would say that the safest way to package the cells would be to tape the ends, like you said, and then have each cell separated by the thin white foam packing material. Each cell individually wrapped. Then put a batch together and then wrap them in another white foam layer. Then placing them in the box, no cells are aligned end to end, but all are parallel to each other or at 90Deg rotation. This would prevent any movement of the cells, and they can't possibly touch each other during shipment.

Good points Korishan. My packing is close to what you have stated except for the individual packing of each cell. I will re-examine through this. When I am selling packs I am of course trying to give the buyer the best price and economical solution as well as making it worth my time and effort. I certainly do not want to be responsible for anything going boom but if I can help with the efforts here, keep these things from going to a dump and help pay for my interests in this technology hopefully it is a win-win for everyone.