Can You Bring an Electric Suitcase on a Plane? TSA and FAA Rules Explained

Electric suitcases, with features like USB charging and GPS tracking, are transforming modern travel. However, their powerful batteries are subject to strict safety regulations from the Transportation Security Administration (TSA) and Federal Aviation Administration (FAA). Before flying, it's crucial to understand these rules to avoid having your luggage confiscated or facing fines. This guide breaks down the essential 2025 guidelines for bringing an electric suitcase on a plane, ensuring your high-tech companion is a help, not a hindrance.

The Core of the Matter: Lithium-Ion Batteries and Aviation Safety

The primary concern with electric suitcases, and indeed most modern electronics, is their power source: lithium-ion batteries. While generally safe, these batteries store a significant amount of energy. If damaged, short-circuited, or defective, they can overheat in a process known as thermal runaway, which can lead to smoke, fire, and even explosions.

The risk of such an incident occurring in the cargo hold of an airplane, where it would be difficult to detect and extinguish, is a serious safety concern for the FAA.

For this reason, the regulations surrounding electric suitcases are almost entirely focused on the battery. The key takeaway for any traveler with smart luggage is this: the lithium-ion battery must be removable.

If your electric suitcase has a non-removable battery, it will not be permitted on an airplane, either as a carry-on or as checked baggage. This is a non-negotiable rule across all U.S. airlines and is strictly enforced by the TSA.

Carry-On vs. Checked Luggage

The rules for your electric suitcase differ significantly depending on whether you plan to bring it into the cabin as a carry-on or check it into the cargo hold.

Electric Suitcases as Carry-On Luggage

If your electric suitcase meets the airline's size and weight restrictions for carry-on luggage, you can generally bring it on board with you. However, there are still crucial steps to follow. Even in the cabin, many airlines will require you to remove the battery from the suitcase before stowing it in the overhead bin.

Once removed, you must keep the battery with you in the cabin. The battery should be protected from short-circuiting, which can be achieved by keeping it in its original retail packaging, a protective pouch, or by placing tape over the terminals.

The FAA has set specific limits on the size of lithium-ion batteries allowed on planes. For personal use, batteries are limited to a rating of 100 watt-hours (Wh) per battery. Most electric suitcases are designed with batteries well within this limit.

If your battery’s capacity is listed in milliampere-hours (mAh), you can calculate the watt-hours by multiplying the voltage (V) by the ampere-hours (Ah). To get ampere-hours from milliampere-hours, simply divide the mAh by 1,000. The formula is: (mAh/1000)×V=Wh.

With prior airline approval, you may be able to carry up to two larger spare batteries with a rating of 101-160 Wh. However, it is essential to contact your airline well in advance of your flight to get this approval.

Electric Suitcases as Checked Luggage

This is where the rules become even more stringent. If you need to check your electric suitcase, whether due to its size or because you simply prefer to, you must remove the lithium-ion battery. The removed battery cannot be placed in your checked luggage. It must be transported in your carry-on bag.

This is because if a fire were to occur in the cargo hold, it would go undetected by the flight crew. By keeping the battery in the cabin, any potential issues can be identified and addressed immediately.

When you are at the check-in counter, you should be prepared to demonstrate to the airline agent that you have removed the battery. Some travelers have found it helpful to take a picture of the suitcase with the battery removed as proof.

If you have a smart bag that must be gate-checked due to a full flight, the same rule applies. You will be required to remove the battery before the bag is taken to the cargo hold. Failure to do so will result in the bag not being loaded onto the aircraft.

Rideable Suitcases: A Special Category of Electric Luggage

Rideable suitcases, which allow you to sit or stand on them and glide through the airport, have their own set of considerations. While they fall under the general category of electric luggage, their use as a personal transportation device can be restricted by individual airports. Some airports have banned the riding of these suitcases in crowded terminals due to safety concerns.

From a TSA and FAA perspective, the rules for rideable suitcases are the same as for other electric luggage. The battery must be removable, and its size must fall within the permitted watt-hour limits. Given that many of these suitcases are designed as carry-ons, you'll need to be prepared to remove the battery before boarding and keep it with you in the cabin.

It’s also worth noting that some airlines, such as United, explicitly state that they do not accept devices designed to be used as a vehicle, which can include some rideable suitcases. Always check your specific airline’s policy on this before you travel.

Recommended: Rideable Electric Luggage vs. Ordinary Luggage: What Frequent Travelers Should Know

What Happens If You Don’t Comply with the Rules?

Ignoring the TSA and FAA regulations for electric suitcases can lead to a variety of undesirable consequences. The best-case scenario is that you will be required to remove the battery at the security checkpoint or gate. If the battery is not removable, your suitcase will be denied transport on the aircraft. This could mean having to abandon your expensive luggage at the airport or missing your flight while you make alternative arrangements.

In more serious cases, you could face significant civil penalties. The TSA has the authority to levy fines that can amount to thousands of dollars per violation. Furthermore, non-compliance can lead to a criminal referral to law enforcement. It is simply not worth the risk to try and circumvent these rules.

A Step-by-Step Guide to Flying with Your Electric Suitcase

To ensure a smooth journey with your smart luggage, follow these steps:

Check Your Battery: Before you even start packing, confirm that the battery in your electric suitcase is removable. If it is not, your suitcase is not compliant with current air travel regulations.

Know Your Watt-Hours: Check the watt-hour rating of your battery. Ensure it is at or below the 100 Wh limit. If it is between 101 and 160 Wh, contact your airline to seek approval for it to be carried on.

Airline-Specific Policies: A few weeks before your trip, visit your airline’s website and search for their specific policy on “smart luggage” or “lithium-ion batteries.” While the FAA sets the overarching rules, some airlines have slightly different implementations.

Packing for Security: When you pack, make sure you can easily access the battery to remove it. If you are checking your electric suitcase, remove the battery and place it in your carry-on bag, ensuring the terminals are protected.

At the Airport: If you are checking your bag, inform the check-in agent that you have an electric suitcase and that you have removed the battery and have it in your carry-on. At the security checkpoint, be prepared to present the battery for inspection if requested.

Boarding the Plane: If you are carrying on your electric suitcase, follow the flight crew's instructions. If they ask you to remove the battery, do so before placing the bag in the overhead compartment.

Recommended: How to Choose an Electric Suitcase

Conclusion

By being prepared and knowledgeable about the regulations, you can enjoy all the benefits of your electric suitcase without any of the travel-day stress. These rules are in place for the safety of everyone on board, and responsible travelers who understand and follow them are key to a secure and efficient air travel system. 

Traveling with an electric suitcase can be a fantastic experience, and a little preparation goes a long way in ensuring your journey is as smart as your luggage.