Are Power Tools Allowed on Planes? Essential Guide

Yes, some power tools are allowed on planes, but with strict regulations regarding batteries and specific tool types. Always check with your airline and the TSA before flying to ensure compliance and avoid confiscated items.

Heading out on a trip and wondering if you can bring your trusty power drill or that handy sander? It’s a common question for DIYers and contractors alike! Traveling with power tools can be a bit of a puzzle, and the last thing you want is to have your essential gear confiscated at security. Don’t worry, though! We’re here to break down exactly what you need to know about flying with power tools, from the TSA’s rules to the best ways to pack them. Get ready to travel smarter and keep your tools in your hands, not left behind!

Understanding the Rules: What the TSA Says About Power Tools

When it comes to air travel, the Transportation Security Administration (TSA) has specific guidelines for what you can and cannot bring. For power tools, the primary concern revolves around the power source, particularly batteries. Lithium-ion batteries, commonly found in cordless power tools, are classified as a hazardous material due to their potential to overheat and cause fires. This is why they are subject to stringent regulations.

Generally, cordless power tools are permitted in both carry-on and checked baggage, but with a crucial caveat: the batteries. The TSA’s rules often focus on the watt-hour (Wh) rating of lithium-ion batteries.

Batteries in Use: If the battery is installed in the tool, it’s usually allowed, but often with restrictions on the size of the battery.
Spare Batteries: Spare lithium-ion batteries, including those for your power tools, must be carried in your carry-on baggage. They cannot be placed in checked luggage. This is a critical safety measure to allow for immediate attention if a battery shows signs of thermal runaway.
Battery Size Limits: There are typically limits on the watt-hour rating for lithium-ion batteries. Batteries up to 100 Wh are generally allowed in carry-on baggage without airline approval. Batteries between 100 Wh and 160 Wh may be allowed with airline approval, usually limited to two per passenger. Batteries over 160 Wh are generally prohibited.

It’s important to note that while the TSA sets the overarching security guidelines, individual airlines may have their own specific policies, which can sometimes be more restrictive. Always double-check with your airline before you fly.

Key Takeaways for Power Tool Batteries:

Carry-on for Spares: Never pack spare lithium-ion batteries in checked luggage.
Installed Batteries: Tools with installed batteries are usually permitted, but check battery size limits.
Watt-Hour (Wh) Matters: Understand your battery’s Wh rating. This is often printed on the battery itself.
Airline Policies: Confirm with your specific airline for any additional restrictions.

What About Corded Power Tools?

Corded power tools, like those that plug into a wall outlet, generally do not pose the same battery-related risks. This means they are usually permitted in both carry-on and checked baggage. However, there are still a few things to consider:

Size and Weight: Very large or heavy power tools might be impractical or even prohibited due to size and weight restrictions imposed by airlines, especially for carry-on baggage.
Sharp Components: While not usually an issue for most power tools, if your tool has exposed sharp blades or bits, it’s wise to ensure they are securely protected to prevent accidental injury during handling.
Packaging: Proper packaging is essential to protect both the tool and other items in your luggage.

Navigating Different Types of Power Tools

The type of power tool you’re traveling with can also influence whether it’s allowed and how you should pack it. Let’s break down some common categories:

Cordless Power Tools (Drills, Drivers, Saws, Sanders)

These are the most common types of power tools for DIYers and homeowners. As mentioned, the main concern is their lithium-ion batteries.

Allowed: Generally yes, in both carry-on and checked baggage, provided batteries comply with TSA and airline regulations.
Best Practice:
Carry-on: If you have spare batteries or batteries that might be borderline on size, carry the tool and its installed battery in your carry-on. Keep spare batteries in their original packaging or use protective covers.
Checked Baggage: If the tool has a smaller, compliant battery installed and you’re not carrying spare batteries, checked baggage is an option. Ensure the tool is powered off and ideally the battery is removed if possible and stored safely.
Battery Removal: If your tool allows for easy battery removal, consider removing it and packing it separately in your carry-on baggage to ensure compliance.

Pneumatic Tools (Nail Guns, Air Sanders)

Pneumatic tools use compressed air. While the tools themselves are generally allowed, the associated components might require attention.

Air Compressors: Large portable air compressors are unlikely to be permitted on passenger aircraft due to their size, weight, and the pressurized air tank.
Air Tanks/Cylinders: Empty, compressed air cylinders are generally prohibited. If you need to transport such tools, you might need to arrange for local rental or purchase.
Hoses and Fittings: These are usually fine and can be packed in either carry-on or checked luggage.

Electric/Corded Tools (Circular Saws, Routers, Grinders)

These tools plug into a standard electrical outlet.

Allowed: Generally yes, in both carry-on and checked baggage.
Considerations:
Size and Weight: Larger tools might be too bulky for carry-on.
Cords: Ensure cords are neatly coiled and secured to prevent tangling.
Accessories: Blades, bits, and other sharp accessories should be securely protected.

Handheld Power Tools with Rechargeable Batteries (e.g., Dremel, Rotary Tools)

These smaller tools often use smaller lithium-ion batteries.

Allowed: Generally yes, similar to larger cordless tools.
Battery Limits: Pay close attention to the Wh rating of the batteries. Smaller batteries are less likely to exceed limits.
Carry-on Recommendation: Due to their size and the prevalence of spare batteries for these tools, carrying them in your carry-on is often the most convenient option.

Specialty Tools

Soldering Irons (Cordless): If they use lithium-ion batteries, the same rules apply. Check battery Wh.
Heat Guns: Generally allowed, but be mindful of potential heat residue if the tool was recently used. Ensure it’s completely cool.
Glue Guns (Cordless): Again, it’s all about the battery.

Packing Your Power Tools Safely and Efficiently

Proper packing is key to ensuring your tools arrive safely and without issue. Here’s how to do it right:

For Carry-On Baggage:

Power Tools: If you’re bringing the tool itself, ensure it’s powered off. If it has a removable battery, consider removing it and packing it separately in your carry-on.
Batteries: All spare lithium-ion batteries must go in your carry-on.
Protection: Keep batteries in their original packaging, or place them in protective cases or plastic bags to prevent short circuits. You can also tape over the terminals.
Organization: Use a small electronics organizer or a dedicated battery case to keep them tidy and prevent them from rattling around.
Accessories: Small accessories like drill bits, screwdriver bits, and sanding discs can be packed in your carry-on, but ensure they are organized and not loose.
Sharp Edges: If any part of your tool or accessories is sharp, ensure it’s well-protected. A bit of foam padding or even wrapping them in a soft cloth can help.

For Checked Baggage:

Tools with Installed Batteries: If you’re checking a tool with a compliant battery installed, ensure the tool is powered off. Some regulations may suggest removing the battery if possible, but if it’s securely installed and within limits, it might be acceptable. However, it’s generally safer to carry tools with batteries in your carry-on.
No Spare Batteries: Absolutely no spare lithium-ion batteries are allowed in checked baggage.
Protection:
Original Packaging: If you still have the original box, it’s often the best way to pack your tool.
Tool Cases: Most power tools come with their own sturdy cases. Use these! They offer excellent protection.
Padding: If you don’t have a dedicated case, wrap the tool in bubble wrap, thick clothing, or towels to cushion it against impacts.
Secure Components: Make sure any moving parts or accessories are secured so they don’t shift during transit.

What NOT to Pack (and Why):

Spare Lithium-ion Batteries in Checked Luggage: This is the biggest no-no. They are a fire hazard if damaged or short-circuited in the cargo hold, where they cannot be monitored or extinguished easily.
Tools with Damaged Batteries: Never pack a tool with a visibly damaged or swollen battery.
Pressurized Containers: Unless specifically approved (like a small, empty personal aerosol can), avoid anything with compressed air or flammable propellants.
Tools with Large, High-Watt-Hour Batteries: If your battery exceeds the 100 Wh (or 160 Wh with airline approval) limit, it will likely be confiscated.

Checking Battery Watt-Hour (Wh) Ratings

The Watt-hour (Wh) rating is the key metric for lithium-ion batteries. It tells you the energy capacity of the battery. You can usually find this information printed directly on the battery itself.

Formula:
Watt-hours (Wh) = (Amp-hours (Ah) × Voltage (V)) / 1000

Example: A 20V, 5.0Ah battery would have a Wh rating of (20V × 5.0Ah) / 1000 = 100 Wh.

Where to find the information:

On the Battery: Look for markings like “XX Wh,” “100 Wh,” “20V Max,” “5.0 Ah,” etc.
Tool Manual: Your power tool’s user manual should also list the battery specifications.
Manufacturer’s Website: You can usually find detailed specs online.

TSA Battery Limits (General Guidelines):

| Battery Type | Limit | Allowed in Carry-on? | Allowed in Checked? |
| :——————– | :——————————————————————— | :——————- | :—————— |
| Lithium-ion (Installed in Device) | Up to 100 Wh | Yes | Yes (with restrictions) |
| Lithium-ion (Installed in Device) | 100 Wh to 160 Wh | Yes (with airline approval, max 2) | No |
| Lithium-ion (Spare) | Up to 100 Wh | Yes | No |
| Lithium-ion (Spare) | 100 Wh to 160 Wh | Yes (with airline approval, max 2) | No |
| Lithium-ion (Spare) | Over 160 Wh | No | No |
| Lithium Metal (Non-rechargeable) | Up to 2 grams of lithium content | Yes | No |

Note: These are general guidelines. Always verify with your specific airline.

Tips for a Smooth Airport Experience

To make your journey as stress-free as possible, here are some extra tips:

1. Check Airline Policies FIRST: Before you even start packing, visit the website of the airline you’re flying with. Search for their “specialty items” or “prohibited items” section. This is your most reliable source of information.
2. TSA Website is Your Friend: The TSA website (https://www.tsa.gov/travel/security-screening/whatcanibring/electrical-items) has a comprehensive list of what’s allowed and prohibited. You can even use their “What Can I Bring?” tool.
3. Label Your Batteries: If you have multiple batteries, clearly label them with their Wh rating. This can speed up the screening process if they need to be inspected.
4. Keep Tools Accessible: If you’re carrying your tools on, pack them in a way that allows for easy removal if security needs to inspect them more closely.
5. Consider Renting: If you only need a specific tool for a short period at your destination, research local tool rental shops. This can save you the hassle of packing and potential issues at the airport.
6. Power Down Completely: Ensure any tool with a battery is completely powered off. If your tool has a safety switch, make sure it’s engaged.
7. Pack Smart: Use sturdy tool cases or original packaging. Pad any empty spaces with soft items to prevent movement.

When in Doubt, Leave It Out (or Ship It!)

If you’re still unsure about a particular tool or battery, it’s always better to err on the side of caution. Confiscated items are not returned.

An alternative for larger or more sensitive tools is to ship them to your destination ahead of time via a reputable shipping service. This bypasses airline regulations entirely, though you’ll need to comply with the shipping company’s own guidelines for hazardous materials (which generally don’t apply to standard power tool batteries when shipped correctly).

Frequently Asked Questions (FAQ)