20 years after introducing an air shipment guideline, which mandated that Lithium-ion batteries shipped separately from devices must have a state-of-charge less than 30%, IATA has extended the rule to include batteries that are contained within devices.
Until January 2026, government and defense organisations can ship fully charged Lithium-ion batteries inside equipment to ensure they have instantly available power when they reach their destination. However, this new rule means that all batteries will arrive partially depleted and must be quickly brought back to full capacity so they can be rapidly deployed on the battlefield.
Defense organisations operating in remote areas may not have access to AC mains and, therefore, cannot use on-grid, high-power chargers to speed up charging times. Off-grid, operators are often restricted to DC inputs from vehicles or mobile generators — systems not designed to deliver the sustained current required to recharge multiple high-capacity batteries simultaneously.
When using single-bay chargers, operators must rotate batteries one at a time, creating bottlenecks that slow deployment. A well-designed multi-bay system allows operators to replenish several batteries simultaneously at higher currents, ensuring all units have power. For government and defense applications where readiness is measured in minutes and seconds, not hours, this is vital.
There are logistical benefits, too. Rather than transporting a surplus of spare batteries to cover recharging delays, personnel can bring fewer units and replenish them more efficiently. This lightens the load and streamlines supply chains.
There’s still a place for the traditional solutions. For example, Ultralife's standard UBI-2590s continue to serve applications requiring moderate capacity because they balance performance and reliability. For larger-scale power needs, 24-volt batteries that can be stacked together to provide 10kwhrs of storage are ideal.
These units can be combined in parallel or series to deliver higher currents without external protections. This makes them well-suited for vehicle-mounted systems or mobile command posts that require flexibility and robustness.
Capacity and current are important, but so is efficiency and durability. Lithium-ion batteries should be stored in cool, dry conditions at around 15 degrees Celsius. They work best at ambient temperatures, typically between five and 20 degrees. If temperatures are too cold, capacity is lost as chemical reactions slow down. If conditions are too hot, there’s a risk of fire and explosion.
In defense settings, missions can span arctic winters to desert summers — and this brings constant challenges. Therefore, operators must manage charge and discharge rates carefully, deploying batteries designed to withstand a wider operating range. Meanwhile, manufacturers must design power systems with environmental extremes in mind, ensuring critical equipment can continue to function reliably wherever deployed.
Changing transportation regulations and advancements in electronic devices put pressure on both charging infrastructure and batteries. Meeting these demands requires cutting-edge solutions that combine efficient charging, higher-output batteries and rugged designs.
Ultralife Corporation provides durable, reliable power and communications for military applications. To find out more: