A mid-air fire involving a passenger’s power bank forced a Chennai-bound IndiGo flight to make an emergency landing at Hyderabad’s Rajiv Gandhi International Airport on Sunday.
The incident has renewed concerns over the safety of lithium-ion batteries on aircraft and the risks posed by portable charging devices during air travel.
According to reports, the passenger’s power bank caught fire during the flight, filling the cabin with smoke. The crew intervened and extinguished the fire before the aircraft landed safely. Authorities have launched an investigation to determine the cause of the incident.
A similar incident occurred in May when a power bank reportedly exploded aboard a Chandigarh-bound IndiGo flight after landing, prompting an emergency evacuation. The device was reportedly kept in a seat pocket when it caught fire, alerting passengers and cabin crew to the danger.
Power banks typically contain lithium-ion battery cells, including Lithium Cobalt Oxide (LCO) cells. These batteries store significant energy in a compact space, but manufacturing defects, poor-quality components, physical damage and overheating can increase the risk of fire.
Sagar Mitra, a professor at IIT Bombay, said the use of low-quality or counterfeit battery cells could be a likely explanation for the October 11 incident. Poor manufacturing standards and defects within battery cells can make them vulnerable to overheating and combustion.
Other factors may also trigger battery fires. Explaining the May incident, Mitra said vibrations caused by an aircraft’s landing could potentially have contributed to a mechanical disturbance in the power bank. Combined with the condition of a fully charged LCO battery, this may have triggered an internal short circuit.
Experts also identify internal leakage between a battery’s positive and negative terminals, damaged insulation, manufacturing defects and electrolyte leakage as possible causes. Electrolyte leakage can occur when a battery is physically damaged or its internal protective materials deteriorate over time.
Consumer habits can also affect battery safety. Vivek Panchal, managing director of battery manufacturing company Powertron, said exposure to high temperatures, overcharging and continued use of damaged devices could increase the risk of battery failure.
Experts recommend avoiding unnecessary heat exposure and following the manufacturer’s charging instructions. Keeping a battery at a moderate charge level, rather than constantly charging it to full capacity, may also help reduce stress on the cells.
Overheating, swelling, leakage, unusual smells and visible damage are important warning signs. Users should stop using a power bank if any of these symptoms appear and avoid charging or carrying a damaged device on a flight.
Most airlines in India prohibit power banks in checked-in baggage while permitting them in cabin baggage subject to applicable safety limits and restrictions.
Aviation expert Jai Rao explained that lithium batteries can malfunction and catch fire. Keeping permitted devices in the cabin allows the crew to identify and respond to a potential fire more quickly. A battery fire in the cargo hold would be considerably harder to access and contain.
In November 2025, the Directorate General of Civil Aviation (DGCA) issued an advisory prohibiting passengers from using or charging power banks during flights. It also prohibited storing them in overhead bins, citing concerns that inaccessible devices could delay emergency responses. Airlines were directed to educate passengers about lithium-battery risks and precautions against short circuits.
These measures followed several battery-related incidents around the world. In June 2024, a power bank reportedly exploded aboard an Air Arabia flight travelling from Abu Dhabi to Kozhikode, causing panic among passengers. In March 2025, a fire linked to a portable power bank severely damaged a South Korean aircraft before take-off.
The International Civil Aviation Organization (ICAO) had also introduced restrictions on lithium-ion battery shipments as cargo on passenger aircraft in 2016 amid concerns about fire hazards.
Experts advise consumers to prioritise battery-cell quality, reliability, warranty and safety protections when purchasing power banks. Many modern devices include a battery management system (BMS) designed to monitor battery health and protect against overcharging, excessive discharge and overheating. However, the level of protection varies by product.
Panchal said products with better reliability and a higher Mean Time Between Failures (MTBF) generally offer a longer operational life. Consumers should choose reputable products that meet applicable safety standards rather than relying solely on capacity or price.
Mitra advised users to discontinue using any power bank that becomes unusually hot during charging or discharging. Swelling, fluid leakage, unusual odours and excessive heat should be treated as warning signs that the battery may be unsafe.
The latest incident highlights the importance of battery quality, proper handling and compliance with aviation safety rules. As portable chargers become increasingly common, safe manufacturing and responsible use remain essential to reducing the risk of battery fires during air travel.
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