A new safety technology for air transport of lithium batteries has been successfully tested in China, addressing a long-standing challenge for exporters. With China producing over 1.2 trillion yuan ($169.7 billion) worth of lithium batteries in 2024 and air transport volumes reaching 645,000 tons, this breakthrough could significantly improve supply-chain speed and reliability for overseas buyers relying on just-in-time deliveries of battery-powered goods.
Technology breakthrough
A 250 kg power lithium battery was flown from Ezhou, Hubei, to Shenzhen, Guangdong, in under two hours—cutting transport time by nearly 80% compared with road shipping. The shipment used a protective case made of specialized materials that provide thermal insulation, flame retardancy, pressure reduction, toxin mitigation, and fire suppression. During tests, when batteries caught fire, no flames escaped and surface temperature stayed below 100°C.
Real-time monitoring and AI warning
The system monitors 12 core indicators—including temperature, pressure, and gas levels—in real time. AI-based early warning algorithms can detect subtle abnormalities such as minor gas leakage. Third-party testing shows an average warning response time of 5.38 seconds and accuracy exceeding 96%, allowing supervisors to intervene before thermal runaway occurs.
China sourcing context
China remains the world's largest lithium battery producer, with installed capacity rising 48% year-on-year to over 645 GWh in 2024. Currently, more than 90% of lithium batteries are shipped by land or sea, and only 2–3% by air for export. The new technology, developed under China's 14th Five-Year Plan and approved by the Ministry of Transport and Ministry of Science and Technology, is expected to gradually expand nationwide.
What buyers should watch
"Cross-border air transportation of lithium batteries offers an irreplaceable advantage in meeting overseas delivery timelines," said Du Meng of SF Holding. Shipping fees vary by destination and season, but each flight can carry 5–30 tons of batteries and related equipment. Overseas importers should monitor regulatory acceptance of this protective-case technology and potential cost reductions as air transport becomes a more viable option for urgent orders.
Source: Read the original report | Published: December 10, 2025