Lithium batteries may only be exported if they comply with strict safety and transport regulations. This includes checking their physical condition, UN 38.3 certification, correct documentation and safe, UN-certified packaging. Without these checks, regular transport is not permitted.
Summary of this article
Exporting lithium batteries requires a careful inspection process due to strict international safety regulations. You must verify that your batteries comply with UN certifications, are in good condition, and that the packaging and documentation meet all requirements. Only then can lithium batteries be safely transported across borders without delay or rejection. This article covers all the essential steps for successful export control.
Lithium batteries are subject to strict international safety regulations due to their flammable properties. The most important regulations come from the United Nations, laid down in the UN 38.3 test regulations. These tests check whether lithium batteries can withstand altitude differences, extreme temperatures, vibrations, shocks, short circuits, impact and overcharging.
In addition to UN regulations, transport-specific rules also apply:
The classification of your lithium batteries determines which specific export requirements apply. A distinction is made between:
Defence applications often have additional requirements, such as MIL-STD certifications, which require extra attention when exporting batteries for military equipment such as drones and defence communication systems.
For the correct export of lithium batteries, you must collect and prepare various documents. The most important document is the UN 38.3 test certificate, which proves that your battery type has passed the mandatory safety tests. You must obtain this certificate from the battery manufacturer or through an accredited testing laboratory.
Other essential documents are:
Exemptions sometimes apply to certain battery types with low energy values, resulting in less stringent documentation requirements. Always check the latest regulations, as these are subject to frequent changes.
The condition and quality of lithium batteries are crucial factors for safe transport. Damaged or defective batteries may not be exported through regular channels. You can assess the condition of batteries using various inspection methods:
Visual inspection: Check for:
Functional tests:
Batteries are considered defective and are not suitable for regular transport if they:
Batteries that are classified as defective are subject to special transport regulations (UN3480/UN3090 SP 376) or must be excluded from transport.
Proper packaging is essential for the safe export of lithium batteries. International regulations set specific requirements for packaging materials and methods:
General packaging requirements:
Packaging marking and labelling:
Industrial applications, such as in the defence and security sectors, often require specialised, robust packaging that offers extra protection against extreme conditions. Examples include aluminium boxes, flight cases or special transport cases specifically designed for the safe transport of sensitive equipment with lithium batteries.
At Faes, we start by determining the requirements before selecting or designing the packaging. The battery type, capacity, cell configuration and intended transport conditions all influence which regulations, UN classification and packaging requirements apply.
Our engineers translate these requirements into the packaging design. This includes the choice of materials and construction, as well as the internal protection needed to keep batteries insulated, stable and protected against shock and vibration. Where the application requires it, additional protective materials can be incorporated to reduce the risks associated with damage or overheating.
When packaging needs to be validated against the applicable standards, Faes coordinates the testing process with recognised testing bodies. We arrange the packaging for testing, support the required documentation and evaluate the results afterwards. If the test results reveal opportunities for improvement, we use them to further optimise the design.
This means that export suitability is not treated as a checklist at the end of the process. The applicable regulations, practical transport conditions and certification requirements are taken into account from the start of the packaging design.
Transport restrictions vary considerably between different types of lithium batteries and transport methods. Here is an overview of the most important restrictions:
Lithium-ion vs. lithium metal:
Energy value restrictions:
State of Charge (SoC):
Quantity restrictions:
Professional applications in high-tech and defence often require special transport solutions, especially when batteries are part of sensitive or critical equipment. It is important to work with a dangerous goods expert to correctly interpret all transport restrictions.
Exporting lithium batteries requires thorough preparation and attention to detail. By carefully following all safety regulations, documentation requirements, quality controls, packaging guidelines and transport restrictions, you can ensure a safe and smooth export process.
Given the complexity and regular updates to regulations, it is wise to work with experts who specialise in dangerous goods transport. At Faes, we understand the unique challenges of transporting sensitive equipment with lithium batteries, especially for demanding sectors such as defence and security. With our expertise in industrial custom packaging, we can help you get your valuable and sensitive equipment safely to its destination.
Always request a copy of the UN 38.3 test certificate from your supplier or manufacturer. This document must refer specifically to your battery model and contain all eight mandatory tests. If you have any doubts about its authenticity, you can contact the test laboratory listed on the certificate for verification. For older batteries that you already have in your possession and for which documentation is missing, you may still need to have tests carried out at an accredited laboratory.
The most common errors are: incomplete documentation (especially the lack of UN 38.3 test certificates), incorrect classification of the battery type, incorrect packaging that does not comply with regulations, missing or incorrect labelling, and insufficient protection against short circuits. The State of Charge (SoC) limit of 30% for air transport of loose lithium-ion batteries is also often ignored, leading to immediate rejection during transport checks.
For exports outside the EU, you must take into account customs procedures and possible additional country-specific requirements. Check whether import restrictions apply in the destination country and whether special permits are required, especially for batteries in defence equipment. Some countries require additional certifications or specific declarations. Also, ensure a clear HS code classification and prepare for possible customs inspections by having all documentation readily available.
Michel Prins is Account Manager at Faes and a specialist in Safety & Security. Thanks to his background at the Ministry of Defense and years of experience in the sector, he advises organizations on reliable packaging solutions for critical applications. He combines practical knowledge with technical expertise to package sensitive equipment safely and efficiently.
More articles by Michel PrinsGood packaging doesn’t just happen by chance. Using a tried-and-tested approach, our specialists guide you step by step from the initial idea to the finished product.
