How to ship electronics with lithium batteries
Almost every gadget has a lithium battery in it, and USPS has rules for that. The big one most resellers miss: used electronics can only travel by ground. Here's what that means, plus how to pack a device so it can't get crushed or switch on.
- Used electronics ship by ground only. A used phone, laptop, or tablet goes USPS Ground Advantage, not Priority Mail or a Flat Rate box, and the box needs "Restricted Electronic Device" and "Surface Transportation Only" written on the label side.
- New in the original box? Sealed new devices and manufacturer-certified refurbished ones can use any domestic service.
- Power banks and loose batteries are stricter. Ground only, and USPS only takes them in their original sealed packaging.
- Always a rigid box. No bubble or poly mailers for anything with a lithium battery, and never ship a swollen or damaged battery.
Phones, laptops, tablets, headphones, smartwatches, handheld game consoles, and controllers are some of the fastest-selling items on eBay, Mercari, and Facebook Marketplace. Nearly all of them run on lithium-ion batteries, which the Postal Service treats as hazardous material. Most of the time that's not a problem, but there's one rule resellers trip over constantly: used electronics aren't allowed to fly.
Here's how the rules sort out, then how to pack a device so it gets there in one piece.
The rules: new, used, or loose battery?
USPS splits electronics into three groups, and the group decides which services you can use.
| What you're shipping | Ground Advantage | Priority Mail, Express, Flat Rate | What else |
|---|---|---|---|
| New device, in its original packaging (or manufacturer-certified refurbished) | Yes | Yes | Battery has to be installed in, or packed with, the device. |
| Used device (phone, laptop, tablet, console, earbuds) | Yes | No | Mark the box "Restricted Electronic Device" and "Surface Transportation Only." |
| Power bank or loose battery | Yes, sealed only | No | Must be in its original sealed packaging, with a lithium battery mark. 5 lb max. |
| Damaged, swollen, or recalled battery | No | No | Not mailable. |
There are size limits too: each battery can be up to 100 watt-hours, and one package can hold up to two batteries. That covers practically every phone, tablet, and laptop. The full rules are in USPS Publication 52, Packaging Instruction 9D.
Vapes are a different story. Vapes and e-cigarettes fall under separate federal rules and generally can't be mailed through USPS at all, battery or not. Don't list them as "ships anywhere."
How to buy the label
- Used device? Pick USPS Ground Advantage. Even if Priority Mail looks only a dollar more, it's an air service and a used device isn't allowed on it.
- Answer the hazmat question honestly. When your label tool asks whether the package contains hazardous materials or batteries, say yes and pick the lithium battery option that matches. Undeclared hazmat can bring a $50 USPS fee on commercial labels.
- Add the markings. For a used device, write "Restricted Electronic Device" and "Surface Transportation Only" in big, clear letters on the address side. Packages with loose batteries also need the lithium battery mark.
- Watch prepaid labels. If a marketplace emails you a prepaid Priority Mail label for a used device, check its battery instructions before you ship on it.
How to pack electronics so they arrive working
Step 1. Power the device completely off.
Step 2. Wrap it in bubble wrap.
Step 3. Center it in a rigid box and fill every gap.
Step 4. Add the markings on the label side.
- 1Powered fully off and wrapped. Off, not asleep, so it can't switch on and heat up in the box.
- 2A rigid box with padding on every side. Required for lithium batteries, and it keeps screens from cracking.
- 3Markings on the label side. Where USPS staff will see them.
- Wipe it and photograph it powered on. Show it working, then do a factory reset and remove accounts so it isn't activation-locked when the buyer gets it.
- Turn it fully off. Hold the power button and shut it down. Sleep mode doesn't count.
- Protect the screen. Lay a soft cloth or a piece of foam over the screen, or use the original box insert if you have it.
- Wrap it. Two layers of bubble wrap, taped closed. Wrap chargers and cables separately so the plug can't scratch the screen.
- Box it with padding. At least 2 inches of padding under, over, and around the device. Shake test: nothing should move.
- Tape, mark, and label. Tape every seam, add the markings on the label side, and buy the right service.
What size box to use for electronics
| Device | Box to look for |
|---|---|
| Phone, earbuds, smartwatch | 8 x 6 x 4 in. Leaves room for 2 inches of padding around a phone. |
| Game controller, handheld console | 10 x 8 x 6 in. |
| Tablet | 12 x 10 x 4 in, screen side padded with foam or cardboard. |
| Laptop | 18 x 14 x 4 in, or 16 x 12 x 4 in for smaller laptops. Pad the corners extra. |
| Home console (PlayStation, Xbox) | 18 x 14 x 8 in. At this size, carriers may bill by box size instead of weight, so don't go bigger than you need. |
Measure your wrapped device and the BoxSizeFit calculator will match it to the smallest box that fits. Choose "Box only," since mailers are off the table for batteries.
Common electronics shipping mistakes
- Sending a used phone Priority Mail. It's the most common battery mistake, and it's an air service.
- Using a bubble mailer. Not allowed with lithium batteries, and phones crack in them.
- Shipping a puffy or swollen battery. If the case bulges or the screen lifts, the battery is damaged. It can't be mailed.
- Leaving the device on or in sleep mode. Alarms and wake-ups heat batteries.
- Forgetting to remove the account lock. Not a shipping rule, but it's the top reason used phones get returned.
Supplies checklist
- Small and medium rigid shipping boxes
- Bubble wrap
- Foam sheets for screens
- Packing paper or air pillows
- Lithium battery labels
- Packing tape and a thick marker
Not sure which mailer or box it fits in? Measure your packed item and drop the numbers into the free BoxSizeFit calculator. It matches you to the smallest USPS, UPS, or FedEx box or bubble mailer that fits, for eBay, Etsy, Poshmark, and Depop.
Open the box size calculatorFrequently asked questions
Can I ship a used phone or laptop with Priority Mail?
Not through USPS. Since used, damaged, or defective electronics with lithium batteries aren't allowed on air transportation, a used phone or laptop has to go USPS Ground Advantage. Devices that are new in their original packaging, or manufacturer-certified refurbished, are the exception.
What does Restricted Electronic Device mean on a package?
It's a marking USPS requires on packages holding used, damaged, or defective electronics with lithium batteries. Write or stick "Restricted Electronic Device" and "Surface Transportation Only" on the address side of the box so it stays on the ground network.
Can I mail a power bank through USPS?
Only by ground, and only in its original sealed packaging. USPS treats a power bank as a loose lithium battery, so the box also needs a lithium battery mark. A used or opened power bank generally can't go through USPS, so check UPS or FedEx rules instead.
Can I ship electronics in a bubble mailer?
No, not if they have a lithium battery inside. USPS requires a rigid box for lithium batteries. The only exception is equipment with a tiny button-cell battery, like a watch or a calculator.
Can I ship a phone with a swollen battery?
No. Damaged, defective, or recalled lithium batteries are prohibited in the mail. Sell it as parts with the battery removed, or check with a recycler.