Lithium batteries power millions of products — from cameras and sensors to smart meters and flashlights. As their use expands worldwide, shipping safety regulations have become increasingly strict, especially in the United States.
If you plan to ship lithium batteries by USPS (United States Postal Service), it’s essential to understand the rules, packaging standards, and labeling requirements.
At Jiangmen Hongli Energy Co., Ltd., we specialize in 3V primary lithium batteries (such as CR123A, CR2, CR14505, CR17450, and CRP2) that meet UN38.3, CE, and RoHS certifications, ensuring they are safe and compliant for international transport — including USPS shipments.
1. Can You Ship Lithium Batteries by USPS?
Yes, you can — but strict regulations apply. USPS follows U.S. Department of Transportation (DOT) and International Air Transport Association (IATA) guidelines for lithium battery shipping.
The rules depend on battery type and configuration:
| Battery Type | USPS Status | Example |
|---|---|---|
| Lithium-ion (rechargeable) | Allowed with restrictions | Phone or laptop batteries |
| Lithium metal (non-rechargeable) | Allowed with restrictions | CR123A, CR2, CR14505 |
| Damaged or recalled batteries | ❌ Prohibited | Any defective or swollen cell |
Hongli Energy’s 3V primary lithium batteries are non-rechargeable lithium metal cells, which can be shipped safely under USPS and international air transport rules when properly packaged and labeled.
2. Key USPS Lithium Battery Shipping Rules
When shipping lithium batteries with USPS, three factors determine what’s allowed:
2.1 Battery Type
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Lithium-ion (rechargeable): up to 100 Wh per cell, 300 Wh per package.
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Lithium metal (non-rechargeable): up to 2 grams of lithium content per cell, 8 grams total per package.
All Hongli lithium cells comply with this limit — for example, a CR123A battery contains approximately 0.6 grams of lithium.
2.2 Battery Configuration
USPS classifies batteries as:
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Installed in equipment (e.g., inside a camera or sensor)
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Packed with equipment (separate but in same package)
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Batteries only (shipped individually)
Each category has specific labeling and packing rules.
2.3 Destination
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Domestic shipping: Allowed by air or ground with correct labeling.
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International shipping: Only allowed when batteries are installed in or packed with equipment — not as standalone cells.
3. Packaging Requirements for USPS Lithium Battery Shipments
Proper packaging ensures both regulatory compliance and transport safety.
3.1 For Batteries Installed in Equipment
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The equipment must be switched off and protected from accidental activation.
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Secure batteries firmly inside the device.
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Use strong outer packaging that prevents movement or crushing.
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Mark package with:
“Lithium Metal Batteries — in Compliance with Section II of PI 970.”
3.2 For Batteries Packed with Equipment
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Each battery must be in its own inner packaging to prevent contact.
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Cushion with non-conductive material (foam, plastic, or cardboard).
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Total lithium content must remain under 8 grams.
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Label as:
“Lithium Metal Batteries — Packed with Equipment.”
3.3 For Batteries Shipped Separately
USPS allows lithium metal batteries alone only by ground transport (Surface Mail) under USPS Publication 52, Section 349.
Packages must include:
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Lithium Battery Handling Label with the “Class 9” symbol
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Proper shipping name: “Lithium Metal Batteries, UN3090”
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Documentation proving UN38.3 testing compliance
Hongli Energy provides all necessary documentation for safe ground and international shipments.
4. USPS Labeling and Documentation Guidelines
Correct labeling is crucial for acceptance at USPS facilities.
| Requirement | Description |
|---|---|
| UN Number | UN3090 (batteries alone) or UN3091 (with/inside equipment) |
| Class 9 Hazard Label | Black and white lithium battery symbol |
| Handling Label | Includes phone number for additional info |
| Documentation | Proof of UN38.3 test summary |
| Marking Size | At least 120×110 mm for full labels |
If labels are missing or incorrect, USPS will reject the shipment.
5. Testing and Certification Requirements
Before lithium batteries can be shipped legally, they must pass UN38.3 testing, which verifies safe performance under extreme conditions.
UN38.3 Tests Include:
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Altitude simulation
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Thermal test (−40°C to +75°C)
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Vibration and shock
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Overcharge and short-circuit tests
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Impact and crush resistance
Hongli Energy’s lithium batteries fully comply with UN38.3 standards, and our factory provides complete test reports upon request — giving distributors and OEM customers confidence in international logistics compliance.
6. Safety Tips for Shipping Lithium Batteries
Even when regulations are met, handling care ensures product and personnel safety.
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Use new packaging materials — avoid reused boxes or bubble wrap.
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Separate battery terminals with non-conductive tape.
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Avoid extreme heat during storage or transit.
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Do not ship damaged batteries.
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Include manufacturer information (e.g., Hongli Energy) and emergency contact.
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Retain documentation for at least 90 days after shipment.
Following these practices minimizes the risk of shipping delays or damage claims.
7. Why Choose Hongli Energy Lithium Batteries for Safe Shipping
7.1 UN38.3 Certified and Globally Compliant
All Hongli products — including CR123A, CR2, CR14505, CR17450, CR17500, CRP2, and 2CR5 — are certified for air and ground shipment under UN, CE, and RoHS standards.
7.2 Leak-Proof and Explosion-Proof Design
Our batteries use hermetic stainless-steel sealing and multi-layer safety vents, ensuring stability during long-distance transportation.
7.3 OEM & ODM Service
We support customized packaging and labeling for clients who need private branding or compliance-specific formats.
7.4 Annual Production Capacity
With over 40 million batteries produced yearly, Hongli guarantees fast delivery and consistent supply for global distributors.
8. Quick Checklist: Shipping Lithium Batteries with USPS
✅ Verify battery type (metal or ion)
✅ Confirm lithium content under legal limits
✅ Ensure UN38.3 certification
✅ Use strong, non-conductive packaging
✅ Apply proper USPS lithium battery labels
✅ Include documentation and emergency contact
✅ Choose ground transport for standalone lithium metal cells
Following this checklist ensures your shipment arrives safely, legally, and on time.
Conclusion
So, how do you ship a lithium battery with USPS?
You must follow specific USPS and UN38.3 guidelines covering battery type, packaging, labeling, and transport mode.
With Hongli Energy’s certified 3V lithium batteries, compliance is simple — every product is tested, sealed, and documentation-ready for safe delivery worldwide.
To learn more about our UN38.3-certified lithium batteries or discuss OEM/ODM cooperation, visit www.honglienergy.com today.