FedEx lithium battery shipping policy is based on international dangerous goods regulations rather than independently defined rules. All lithium battery shipments handled by FedEx must comply with global aviation safety standards due to their classification as Dangerous Goods (Class 9).

FedEx enforces compliance primarily through:

• International Air Transport Association (IATA) Dangerous Goods Regulations (DGR)
• International Civil Aviation Organization (ICAO) Technical Instructions
• United Nations Dangerous Goods Model Regulations

This guide explains FedEx lithium battery acceptance rules, restrictions, and compliance requirements for 2026.

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1. FedEx Lithium Battery Shipping Overview

FedEx classifies lithium batteries as hazardous materials (Dangerous Goods Class 9). Acceptance depends on:

• Battery chemistry (lithium-ion or lithium metal)
• Configuration (standalone or contained in equipment)
• Watt-hour (Wh) rating
• Compliance with IATA Packing Instructions

Source: FedEx
Dangerous Goods Guidelines: https://www.fedex.com/en-us/shipping/dangerous-goods.html

FedEx only accepts lithium battery shipments that fully comply with applicable international regulations.

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2. Types of Lithium Battery Shipments Accepted by FedEx

FedEx categorizes lithium battery shipments into three main groups:

2.1 Lithium-ion batteries alone (UN3480)

• Strictest acceptance conditions
• Often limited to cargo aircraft operations
• Requires full DG documentation approval

2.2 Lithium-ion batteries contained in equipment (UN3481 – PI967)

• Most widely accepted category
• Lower regulatory restrictions

2.3 Lithium-ion batteries packed with equipment (UN3481 – PI966)

• Requires protective packaging separation
• Moderate restriction level

Source: International Civil Aviation Organization (ICAO)
https://www.icao.int/safety/DangerousGoods/Pages/default.aspx

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3. Regulatory Framework Behind FedEx Lithium Battery Policy

FedEx does not establish independent lithium battery classification rules. Instead, it operates under:

• UN Dangerous Goods classification system
• ICAO Technical Instructions (legal aviation standard)
• IATA Dangerous Goods Regulations (operational standard)

Source: United Nations Economic Commission for Europe
UN Model Regulations: https://unece.org/transport/dangerous-goods/un-model-regulations

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4. IATA Packing Instructions Used by FedEx

FedEx applies the following IATA Packing Instructions:

• PI965 → UN3480 (lithium-ion batteries alone)
• PI966 → UN3481 (packed with equipment)
• PI967 → UN3481 (contained in equipment)
• PI968–PI970 → Lithium metal batteries (UN3090 / UN3091)

These instructions define:

• Packaging requirements
• Quantity limits
• Labeling standards
• Acceptance conditions for air transport

Source: International Civil Aviation Organization (ICAO)
https://www.icao.int/safety/DangerousGoods/Pages/default.aspx

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5. State of Charge (SoC) Requirements

For lithium-ion batteries shipped via air:

• UN3480 batteries are generally restricted to ≤30% State of Charge
• Applies mainly to cargo aircraft shipments
• Subject to FedEx operational and route-specific restrictions

Source: International Air Transport Association (IATA)
https://www.iata.org/en/programs/cargo/dgr/

SoC limitation is a critical safety measure to reduce thermal runaway risk during transport.

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6. FedEx Packaging Requirements for Lithium Batteries

FedEx requires all lithium battery shipments to comply with IATA-compliant packaging standards, including:

• Rigid outer packaging with impact resistance
• Protection against short circuits
• Insulation of battery terminals
• Prevention of accidental activation
• Compliance with PI965–PI967 requirements

Improper packaging is a leading cause of shipment rejection.

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7. Labeling Requirements

FedEx requires proper hazardous materials labeling, including:

• Lithium Battery Handling Label
• UN number marking (UN3480 / UN3481 / UN3090 / UN3091)
• Class 9 Dangerous Goods label (where applicable)
• Cargo Aircraft Only label (for restricted shipments)

Incorrect or missing labels will result in shipment refusal.

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8. Documentation Requirements

FedEx lithium battery shipments typically require:

• UN38.3 Test Report (mandatory compliance requirement)
• Material Safety Data Sheet (MSDS)
• Dangerous Goods Declaration (DGD) if applicable
• Commercial Invoice
• Packing List
• Air Waybill (AWB)

Source: International Air Transport Association (IATA)
https://www.iata.org/en/publications/dgr/

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9. FedEx Restrictions on UN3480 Shipments

UN3480 (lithium-ion batteries alone) is subject to the strictest FedEx controls:

• Limited acceptance depending on origin/destination
• Cargo Aircraft Only (CAO) restrictions in many cases
• Prior approval required for Dangerous Goods handling
• Higher inspection and rejection probability

These restrictions reflect elevated fire risk during air transport.

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10. FedEx vs Global Regulatory Framework

FedEx lithium battery policy is fully aligned with international frameworks:

• UN classification system defines hazard categories
• ICAO Technical Instructions define aviation safety law
• IATA DGR defines operational airline procedures

Source: International Civil Aviation Organization (ICAO)
https://www.icao.int/safety/DangerousGoods/Pages/default.aspx

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11. Common FedEx Shipment Failures

Most FedEx lithium battery shipment issues occur due to:

• Incorrect UN classification (UN3480 vs UN3481)
• Missing or invalid UN38.3 documentation
• Non-compliant packaging design
• Incorrect or incomplete DG labeling
• Attempting to ship restricted batteries without approval

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• Correct UN classification (UN3480 / UN3481 / UN3090 / UN3091)
• IATA Packing Instructions (PI965–PI967)
• Valid UN38.3 certification
• Proper packaging and labeling requirements
• ICAO/IATA global aviation safety regulations

Failure to comply may result in shipment rejection, delays, or regulatory penalties.