An electronic toy with a battery inside is a dangerous-goods shipment, and the rules apply to the toy, not just the cell. This guide covers the classification, the testing the cell needs, and how the requirements differ between air freight, sea freight and express carriers.
The classification
- Alkaline cells installed in equipment. Usually shipped as non-dangerous if the equipment is protected against short circuit and accidental activation. The toy itself becomes the equipment in the classification.
- Lithium ion cells installed in equipment. Classified as UN 3481, lithium ion batteries contained in equipment, with the cell's watt-hour rating determining the package limits.
- Lithium metal cells. UN 3091, with stricter limits because lithium metal is not rechargeable and has a higher energy density per gram.
- Loose cells shipped with the toy. UN 3480 or 3090, which is a stricter classification than installed cells and attracts higher packaging requirements.
UN 38.3 is the gate
Any lithium cell used in a shipped product needs a UN 38.3 test summary from an accredited lab, covering altitude simulation, thermal cycling, vibration, shock, external short circuit, impact or overcharge, and forced discharge. The summary travels with the shipment documentation, and the carrier will ask for it. A factory that cannot produce a UN 38.3 summary for the specific cell it installed is shipping a toy it cannot legally put on an aircraft.
State of charge for air freight
Lithium ion cells shipped by air must be at a low state of charge, typically no more than 30 percent, to reduce the fire energy in a containment failure. This is a packing-station requirement: the toy is either shipped with a partially charged cell or with the cell separate and the buyer charging on arrival. Factories that ship fully charged cells by air are either misdeclaring or will have the shipment refused.
Practical differences by carrier
- Air freight. Strictest. Section A and B packaging, state-of-charge limit, UN 38.3 summary, and a lithium battery marking on the outer package. Batteries installed in toys are permitted, but loose cells are restricted.
- Sea freight. Less strict on state of charge but still requires IMDG classification, the UN number on the dangerous goods declaration, and stowage away from heat sources. The practical advantage is that fully charged installed cells are acceptable.
- Express carriers. The most restrictive in practice. Each carrier maintains its own accepted-state list, and several will not accept lithium cells in toys to certain destinations at all. Always check the destination-specific rule, not the general one.
What to specify in the purchase order
- The cell's UN 38.3 summary reference, and a commitment to use the same cell model in production.
- The shipping mode, because it determines the state-of-charge requirement.
- Whether spare cells ship with the toy, since this changes the classification.
- That the battery compartment is secured against accidental activation, with a physical interlock or a taped contact.
Related reading
Our RC chassis programme ships without cells installed by default, and the export regulations section covers labelling and classification for the same shipments.
Related product categories
The materials and part types discussed above are grouped in our sourcing directory:
