Yes — a DeWalt 20V battery may fly in carry-on; spares are banned in checked bags, and 101–160 Wh packs need airline approval.
Power-tool packs travel all the time. The trick is knowing where each battery goes and what size crosses a limit. This guide lays out the rules in plain terms, shows you how to read the label, and gives packing steps that pass screening without drama.
Quick Rules For Power-Tool Batteries
Airlines look at watt-hours (Wh). That number sits on the pack label. It decides whether you just walk through, need approval, or can’t fly with a pack at all.
| Battery Size | Carry-On (Spares) | Checked Bag |
|---|---|---|
| ≤ 100 Wh | Allowed in carry-on. | Spare packs banned. Installed in a tool only, fully off and protected. |
| 101–160 Wh | Up to two spares per person with airline approval. | Spare packs banned. Installed only when the airline permits and the tool stays off. |
| > 160 Wh | Not allowed on passenger flights. | Not allowed. |
These limits come from official guidance. See the FAA’s PackSafe page and the TSA pages on lithium batteries for the exact language and any carrier notes. We link both later for easy reference.
Taking A DeWalt 20V Battery On A Plane — Rules That Matter
Carry-On Only For Spares
Loose DeWalt 20V packs count as spare lithium-ion batteries. Spares must ride in the cabin. Never put a loose pack in a checked bag. If a gate agent checks your carry-on at the door, pull the packs out and take them with you to your seat.
Installed In A Tool?
Many travelers check the drill, saw, or driver and keep the batteries with them. That setup keeps sharp bits out of the cabin and keeps packs where crews can respond if one misbehaves. If you do ship a tool with a battery installed, power it off, prevent activation, and pad it so the trigger can’t move. Tool heads and blades should be packed safely in the case.
When Approval Is Needed
Packs labeled 101–160 Wh need airline approval before you fly. Most carriers allow up to two such spares per person. Approval usually takes a short call or chat; agents add a note to your booking. Ask the agent to record “up to two spares, 101–160 Wh, in carry-on” and keep a screenshot of the chat or a note in your phone. Show it if staff ask at the counter or gate.
Over 160 Wh? Leave It Home
Packs over 160 Wh don’t fly on passenger planes. Some large packs fall in this zone, including certain FLEXVOLT sizes. If your label shows over 160 Wh, pick a smaller pack for the trip or ship tools by ground.
Find Your DeWalt 20V Watt-Hours
You don’t need a spec sheet. The number is usually printed on the battery. If it’s missing, use the formula: Wh = Volts × Amp-hours (Ah). For 20V packs, a 5Ah reads around 100 Wh; a 6Ah reads around 108–120 Wh depending on series; a 9Ah sits near 162–180 Wh. That’s why size class, not brand, decides the rule.
Where To Read The Label
Look for a small box near the barcode or safety icons. You’ll see “Wh” right after a number. Some packs show “Nominal 18V” with “20V MAX*” branding above it. The watt-hour line still gives you the value that matters at the checkpoint.
Label Missing? Mark It Yourself
If the label is worn, do the math and mark the figure on a strip of painter’s tape. Write the pack size, the Wh number, and a note like “carry-on spare.” Set the tape next to the contacts so an officer can spot it fast.
What About FLEXVOLT?
FLEXVOLT packs switch between 20V and 60V. The label lists a single Wh figure for the whole pack. A 9Ah FLEXVOLT often shows 180 Wh, which crosses the 160 Wh line. A 12Ah FLEXVOLT can be even higher. Those won’t pass as spares, and many airlines refuse them entirely.
Packing Steps That Screen Smoothly
Protect The Terminals
Cover the exposed contacts on every spare. Use the original cap, a battery sleeve, or non-conductive tape over each set of terminals. Then place each pack in its own pouch or plastic bag so metal can’t bridge the contacts.
Keep Packs Separate From Tools
Put tools and bits in checked baggage. Carry spare packs in your personal bag or carry-on. If you must travel with one pack clipped in, set the tool to lock, and pad the trigger. The safer move is still to remove packs and carry them in the cabin.
Watch For Heat And Damage
Do not fly with a cracked case, a swollen cell, or a pack that smells odd or runs hot while idle. Crews can and do deny unsafe packs at the checkpoint or gate. Recycle damaged packs before the trip.
Mind The Gate-Check Moment
Overhead space fills up. If staff tag your bag, take out every spare battery and any power bank before they roll it to the hold. Keep those items with you in the cabin.
Pack Chargers And Bits Smart
Chargers, cords, and bit sets can ride in checked bags. Wrap sharp bits. A small tool roll keeps things tidy. Keep the charger’s cord away from the battery contacts so nothing rubs or snags.
Approved Sources For The Fine Print
For precise limits, read the FAA’s PackSafe lithium battery page and the TSA’s page for 101–160 Wh batteries. Those pages spell out carry-on only for spares, the two-spare cap for larger packs, and the hard stop above 160 Wh.
Airline And Route Nuances
Domestic carriers usually mirror FAA and TSA language. Some list extra packaging lines or ask you to seek written approval for larger packs. International legs may add their own rules. If your trip crosses borders, match the strictest policy on the itinerary to avoid a repack at the gate.
If You’re Changing Planes
Keep spares in the same small case across every leg. If staff move you to a different aircraft or check a bag mid-journey, you won’t need to shuffle gear. A compact case also makes security bins faster on tight connections.
What Screeners Look For
They look for three things: a clear Wh value, no loose metal across terminals, and a sane pack count. If you’re under 100 Wh, the chat is brief. If you bring one or two packs in the 101–160 Wh range, show approval when asked and move along.
Common Travel Setups That Work
Short Job With Two Packs
Check the tool case and bits. Carry two 5Ah packs in a small pouch. Each sits under 100 Wh, so no prior approval needed. Keep the pouch handy for screening.
Site Work With One Large Pack
Traveling with one 6Ah pack marked around 108–120 Wh? Ask the airline to note approval for up to two spares in that range. Carry the pack in the cabin, with terminals taped and capped.
FLEXVOLT-Only Rig
Large FLEXVOLT packs often run past 160 Wh. Swap to smaller 20V MAX packs for the flight, or ship the FLEXVOLT by ground freight. That avoids a last-minute refusal at the counter.
How To Get Airline Approval Fast
Call Script You Can Use
“Hi, I’m flying on [date]. I’ll carry DeWalt 20V lithium-ion packs in the 101–160 Wh range. May I have approval for up to two spares in my carry-on? Please note it on my booking.” Agents handle this often. Ask for a reference number or take a screenshot of the chat.
What To Have On Hand
Have the Wh figure for each pack, a photo of the label, and your flight number. If you’re unsure which packs you’ll bring, ask the agent to note “up to two” within the range. That covers a swap on packing day.
Second Look: Where DeWalt 20V Packs Land By Size
These figures are common examples. Always trust the exact Wh printed on your label.
| DeWalt 20V Pack | Typical Wh (approx.) | Rule Triggered |
|---|---|---|
| 2Ah | ~36–40 Wh | Carry-on spares allowed. |
| 4Ah | ~72–80 Wh | Carry-on spares allowed. |
| 5Ah | ~90–100 Wh | Carry-on spares allowed. |
| 6Ah | ~108–120 Wh | Needs airline approval; limit two spares. |
| 8Ah | ~144–160 Wh | Likely needs approval; watch the label. |
| 9Ah FLEXVOLT | ~180 Wh | Over the limit; not allowed on passenger flights. |
| 12Ah FLEXVOLT | ~216 Wh+ | Over the limit; not allowed. |
Fast Checklist Before You Go
- Confirm the Wh number on each pack.
- Carry spares in the cabin; never in checked bags.
- Tape or cap every set of terminals.
- Pack tools in checked luggage; keep packs with you.
- Get approval for any pack labeled 101–160 Wh.
- Skip any pack over 160 Wh on passenger flights.
- Remove spares from a bag that gets gate-checked.
- Leave damaged or recalled packs at home.
With the label in hand, the right bag choice, and simple packing steps, DeWalt 20V batteries fly without hassle. Follow the watt-hour lines, give officers a clean view, and you’ll get back to work on schedule.