Seen a few ideas out there to carry batteries effectively through airport security in carry-on. My recent trip to Japan was plagued with small containers of batteries jiggling about in a small carry bag. I decided to do something about it.

The outer case is from Amazon. https://amzn.asia/d/0FsoNPo

I 3d printed the inner two sections in PETG or ASA (either/or - doesnt matter). Optimised for the range of batteries i may typically take with me. My camera batteries are in a different holder in my camera backpack.

I keep track of spent batteries by turning them upside down (-ve facing up).

The top section holds the random usb cables in have.

Much better than a bag of random boxes of batteries.

Nice box.... but for sure in Zurich / CH you will have some problems at the security check... that is to many batterie ... the rules are strict....

2 x 16 AA bat... is allready to much for a person. I was lucky to be with my wife I gave him one set... other wise ... :(

10 minutes ago, CaolIla said:

2 x 16 AA bat..

It might be hit and miss. I've travelled with a lot of batteries before and never had any confiscations... plenty of questions though.

14 hours ago, foetusmachine said:

plenty of questions though.

More or less every time I start my trip from Zurich airport... they have very strict rules... it is CH...

I travel with 2 box of 16 AA
1 box of 6x32650 small box of 6 AAA

and the drone with 3 batteries.

I try now to separate the boxes in different backpack to avoid to have all in one and with that avoid "to much questions"

4 hours ago, CaolIla said:

I travel with 2 box of 16 AA
1 box of 6x32650 small box of 6 AAA

and the drone with 3 batteries.

You've given me an idea to help with 20 battery quotas.

I'm going to make sets of sealed battery "banks". For example, I'll have 8x AA batteries in one bank. It will have a single hex or Philips screw that holds a lid on so it can't be opened by airport staff. The "bank" will have 8x 2450mAh x nom 1.5v = 29400Wh "capacity". This will be under the maximum 100Wh limit for single pack.

I'll do a similar thing for the 21700 and other lithium cells, ensuring I stay under the 100Wh capacity.

I'll get some professional looking stickers printed that indicate the battery capacity in total, so the airport staff can easily read the numbers and confirm they meet international rules.

I'll just open the lids when I get to my destination and use the batteries as I normally would.

Will report soon on an update to the design, including STL files. Welcome anyone with further input that will help everyone here.