FAA warns airlines of rising lithium battery fire risks in passenger cabins 

The Federal Aviation Administration (FAA) has issued a new safety alert to airlines, warning that lithium batteries carried by passengers and crew continue to pose a growing fire risk aboard commercial flights. 

The FAA Safety Alert for Operators (SAFO) urges airlines to take immediate steps to tighten procedures, review crew training, and communicate more clearly with passengers about how to safely handle electronic devices. The FAA says thermal runaway events — when a battery overheats uncontrollably and can ignite — remain a major hazard in passenger compartments and cargo holds. 

“Operators should consider lithium battery hazards in their safety risk management processes,” the FAA wrote in SAFO 25002. The agency called on US air carriers to update firefighting protocols, refresh crew training, and expand publicity campaigns so passengers understand what to do if a device poses a potentially dangerous condition in flight. 

The timing of the alert reflects a rise in reported lithium battery fire incidents. According to FAA data cited by Reuters, US airlines and cargo operators have logged about 50 smoke, fire, or overheating events involving lithium-ion batteries in 2025. Several cases forced flight diversions or caused passenger injuries. 

One recent example came on August 5, 2025, when a passenger’s cellphone overheated on an American Airlines flight from Dallas to Madrid. Smoke filled part of the cabin, the FAA said, and the passenger was injured, while damage to the aircraft floor delayed the flight. Less than a month earlier, a laptop overheated on a flight from Chicago to Portland, Oregon. The crew moved the device into a bag in a lavatory, but the situation grew serious enough that the pilots diverted to Casper, Wyoming. 

Lithium batteries are now so common, powering everything from smartphones to e-cigarettes to medical devices, that airlines face a constant challenge in mitigating risks. Most incidents involve passenger electronics in the cabin. Others stem from cargo shipments that contain undeclared or poorly packaged batteries. In January 2024, FedEx workers in California discovered flames in a package that had arrived from Seoul. Investigators later determined it contained five lithium-ion batteries shipped without proper declaration.  

The latest SAFO outlines three main areas where airlines should act. First, carriers must update their safety risk assessments under federal regulations to account for where passengers stow devices, especially in places like overhead bins where a fire may not be detected quickly. Second, flight crews must understand how lithium battery fires differ from other cabin fires. Halon fire extinguishers, which are effective for use on many types of flames, cannot stop a runaway battery from overheating. The FAA stresses that cooling with water is essential to prevent re-ignition. Finally, the alert directs airlines to boost passenger awareness, using announcements, safety cards, and websites to explain why lithium batteries should remain accessible during flight and what to do if one begins to overheat. 

Industry experts note that while cabin crews train regularly on battery fire scenarios, passengers often remain unaware of the dangers.

“Many people still don’t realize how serious a smoking laptop or phone can be,” said aviation safety consultant John Cox, quoted in a 2023 USA Today report on battery fires. “The key is rapid recognition and immediate action.” 

The FAA has been tracking lithium battery events since 2006 and maintains a public database of incidents. The numbers show a steady climb as the devices have become more powerful and more prevalent. Regulators worldwide have already banned spare lithium batteries from checked baggage, requiring them to be carried into the cabin where crews can intervene. 

For now, the FAA is pressing airlines to raise their vigilance. “Thermal runaway can occur without warning,” the agency said in its alert. “Effective mitigation requires preparation, training, and clear communication with passengers.” 

The agency has not proposed new regulations, but the tone of the SAFO suggests mounting concern inside the FAA about the hazards batteries can pose. With dozens of serious events this year alone, regulators appear determined to keep the pressure on airlines, manufacturers, and passengers to reduce the risk of in-flight fires.The post FAA warns airlines of rising lithium battery fire risks in passenger cabins  appeared first on AeroTime.

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