Battery thermal runaway incidents aboard both passenger and cargo aircraft have reached a record high, according to data from the Undeclared Lithium Battery Shipments and Incidents Report published by the UL Safety Institute (ULSE). The report highlights the growing dangers associated with the transport of lithium-ion batteries, especially undeclared and improperly tested units. These incidents present significant risks, not only to the aircraft and its passengers but also to global supply chains dependent on safe battery transport.
The Alarming Rise of Thermal Runaway Incidents
In 2023, there were 188 reported incidents of overheating, smoke, fire, or explosions related to lithium batteries on aircraft, marking a sharp increase from previous years. The majority of these incidents occurred on cargo aircraft, where undeclared shipments of lithium-ion batteries—often from consumer devices or industrial applications—pose a hidden risk.
According to the ULSE report, many of these batteries failed to comply with IATA (International Air Transport Association) regulations, bypassing essential testing and packaging requirements. For instance, in one case, an undeclared lithium-ion battery caused an in-flight fire that forced an emergency landing of a cargo plane.
In passenger aircraft, incidents often stem from personal devices, such as laptops or smartphones, overheating in overhead bins or seatback pockets. These thermal runaway events can lead to cabin fires or require immediate action from flight crews, compromising safety.
What is Battery Thermal Runaway?
Thermal runaway is a condition in which a lithium-ion battery overheats uncontrollably, causing a rapid release of energy, heat, and gases. This can occur due to physical damage, manufacturing defects, overcharging, or exposure to high temperatures. Once initiated, the chain reaction spreads from one cell to another, often resulting in smoke, fire, or explosions.
On aircraft, the confined space, pressurized cabins, and high-altitude conditions amplify the risk. The consequences of thermal runaway can be devastating, leading to emergency landings, cargo destruction, and potential loss of life.
Undeclared Lithium Battery Shipments: A Major Culprit
The ULSE report identifies undeclared shipments of lithium-ion batteries as the primary driver of these incidents. Many of these batteries are shipped without proper testing, labeling, or compliance with UN 38.3 and IEC 62133 standards, which are designed to mitigate risks during air transport.
Undeclared batteries often arrive mixed with other consumer goods, making detection difficult. Without proper packaging, these batteries are prone to physical damage, increasing the likelihood of thermal runaway.
In 2023, ULSE found that 90% of thermal runaway incidents were tied to undeclared batteries, underscoring the critical need for stringent testing and compliance before shipping.
The Role of Battery Testing in Reducing Incidents
Contract laboratories play a vital role in ensuring that batteries meet rigorous safety standards before they are shipped. A wide range of testing protocols can help manufacturers ensure compliance and reduce the risks of thermal runaway. These include:
- Thermal Runaway Testing: Evaluating the battery’s response to high temperatures and potential failure modes.
- Vibration and Shock Testing: Simulating the mechanical stress batteries experience during transportation.
- Overcharge and Short-Circuit Testing: Assessing how batteries react under failure conditions, ensuring they don’t enter thermal runaway.
- UN 38.3 Testing: A series of tests, including altitude simulation and thermal testing, that batteries must pass to be deemed safe for transport.
- Packaging Compliance Testing: Verifying that batteries are properly packaged according to IATA guidelines, reducing the risk of damage during transit.
Contract laboratories are crucial in providing the necessary expertise, equipment, and regulatory knowledge to carry out these tests. Many of these labs work closely with manufacturers and logistics companies to ensure that batteries are compliant with international regulations before they are shipped by air.
Why Manufacturers Must Prioritize Testing
The rise in thermal runaway incidents highlights the importance of testing for any company involved in the manufacturing, packaging, or shipment of lithium-ion batteries. Non-compliance not only puts lives at risk but can also lead to costly fines, product recalls, and damage to brand reputation. Companies must prioritize battery testing through certified laboratories to ensure their products meet the stringent requirements set by organizations like IATA and IEC.
Contract Laboratory: Connecting You to Trusted Battery Testing Labs
With the increase in incidents and the urgent need for compliance, manufacturers and suppliers must turn to expert battery testing labs. Contract Laboratory offers a seamless platform to connect you with third-party laboratories specializing in battery safety testing. Whether you’re shipping consumer electronics or industrial-grade batteries, our network of certified labs can help you ensure compliance with UN 38.3, IEC 62133, and other international standards.
Our testing partners offer:
- Thermal runaway testing to assess safety under real-world stress conditions.
- UN 38.3 compliance testing for batteries destined for air transport.
- IATA packaging and shipping compliance to mitigate risks during transit.
- Cycle and aging testing to ensure long-term battery stability.
With over 188 thermal runaway incidents in 2023 alone, the rise in battery-related incidents aboard aircraft is a call to action for all manufacturers, suppliers, and logistics companies. Thorough and rigorous battery testing is the most effective way to mitigate risks, ensuring safe and compliant transport of lithium-ion batteries across the globe.
At Contract Laboratory, we help companies access expert testing services to protect both their products and their reputations. If you’re involved in the manufacture, shipment, or use of lithium-ion batteries, ensure your products are tested to the highest safety standards. Visit ContractLaboratory.com to find the right lab for your needs and take the first step toward safer battery transport.
