The Federal Aviation Administration (FAA) has issued a new Safety Alert for Operators (SAFO 25002) in response to a sharp rise in lithium battery-related incidents aboard commercial aircraft.
The advisory, titled “Managing the Risks of Lithium Batteries Carried by Passengers and Crewmembers”, comes after 50 reported cases of overheating, smoke, or fire involving lithium-ion devices on US flights in 2025 alone.
While many incidents were contained by cabin crew using thermal containment bags and water-based suppression methods, several resulted in passenger injuries and aircraft damage. Notably, a mobile phone fire aboard an American Airlines flight from Madrid to Dallas in August caused burns and floor damage during taxiing. Another incident in April forced a United Airlines flight to divert to St Louis after a battery pack ignited mid-air.
The FAA’s alert reinforces existing PackSafe guidelines, which restrict spare batteries to the cabin and mandate protective measures such as terminal covers. However, SAFO 25002 goes further, urging airlines to integrate lithium battery risks into their safety risk management (SRM) frameworks. This includes reassessing where devices are stored—particularly in overhead bins or obscured carry-ons—and how quickly crew can detect and respond to overheating.
Firefighting protocols are also under scrutiny. While Halon extinguishers suppress flames, they do not cool the battery core, which can reignite once oxygen is reintroduced. The FAA recommends using large volumes of water to fully extinguish thermal runaway events and prevent re-ignition. Crew training must now include recognising early signs of overheating and deploying containment tools effectively.
Passenger education is another key focus. Airlines are encouraged to use safety videos, website messaging, and onboard announcements to inform travellers about safe device storage, the risks of packing lithium-powered items in checked luggage, and the importance of alerting crew at the first sign of smoke or heat.
According to UL Standards & Engagement, the average passenger boards with four rechargeable devices, including smartphones, laptops, and e-cigarettes. In 2023, e-cigarettes accounted for 35% of reported battery incidents, followed by power banks at 16%. Alarmingly, 27% of passengers still pack these items in checked baggage, where fires are harder to detect and contain.
To mitigate these risks, airlines are equipping aircraft with advanced containment kits such as AvSax, HOT-STOP ‘L’, and Aircare Firesock—each designed to isolate and cool overheating devices. These kits are now considered essential safety equipment, especially as thermal runaway temperatures can exceed 1,000°C and release toxic gases under pressure.
While SAFOs are advisory and not legally binding, SAFO 25002 serves as a critical reminder that lithium battery fires remain one of aviation’s fastest-growing safety threats. With passengers carrying more devices than ever, airlines must act swiftly to update protocols, train crews, and educate travellers—or risk serious consequences in the cabin.