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Airline Carry-On Rules for 2025: Don’t Get Caught — Your Carry-On Will Be REJECTED

Surprising Items Banned on Flights in 2025: What You Need to Know Before You Fly

Author

Ark
May 29, 2025

Imagine this: you’re packing for your flight, tossing essentials into your carry-on, feeling like a pro because you’ve flown plenty of times before. You know the drill—no oversized liquids, no sharp objects, and definitely no fireworks (obviously). But what if I told you there are perfectly normal, everyday items that could get you stopped at security? Yes, some things you’d never suspect are actually banned on flights—and the list might surprise you. More importantly, 2025 is bringing big changes to airline carry-on rules, and if you don’t know about them, your next flight could turn into a frustrating mess.

Let’s dive into the latest updates—what’s changing, what’s staying the same, and how these new rules might cost you extra at the airport. Plus, stick around for the list of bizarre banned items—some of them are downright crazy.

New Rules in 2025: Power Banks and Smart Luggage

First, let’s talk about something almost every traveler carries: power banks. They keep our devices charged on long flights, but not all power banks are allowed on planes. Following incidents like the January 28, 2025, Air Busan flight, where a suspected portable battery fire led to an emergency evacuation at Gimhae International Airport in South Korea, authorities are tightening regulations. Anything over 160 Wh (approximately 32,000 mAh) is strictly banned on all flights, whether in carry-on or checked baggage, due to the significant fire risk.

The International Air Transport Association (IATA) allows power banks up to 100 watt-hours (approximately 20,000 mAh) in carry-on luggage only. For power banks between 100Wh and 160Wh (20,000mAh to 32,000mAh), you can carry up to two spare batteries in your carry-on, but airline approval is often required. One absolute no-go? Packing power banks in checked luggage. If a battery overheats and catches fire in the cargo hold, no one’s there to stop it.

Even approved power banks aren’t risk-free. The Busan incident proved that legally allowed batteries can still be hazardous, prompting airlines worldwide to tighten restrictions further. Always check with your airline to ensure your devices meet the latest requirements.

If you own smart luggage, here’s a rule you can’t ignore in 2025: many airlines are now banning smart suitcases if the built-in battery cannot be removed. Before heading to the airport, check your luggage. If the power bank is permanently attached, your high-tech suitcase might not make it past security—and a suitcase rejected at check-in isn’t so smart after all. Make sure the battery is removable to avoid hassle and extra expenses.

Liquid Rules: What’s Changing (and What Isn’t)

If you’ve flown to the UK recently, you might have heard the buzz—some airports have relaxed the infamous 3-1-1 liquid rule, allowing liquids in containers larger than 100 ml without a plastic bag. Sounds like a dream, right? Not so fast. As of June 2024, six UK airports—London City, Aberdeen, Newcastle, Leeds Bradford, Southend, and Teesside—have reinstated the old 3-1-1 rule over security concerns. So, if you’re flying out of the UK, don’t assume the rules are the same everywhere. Double-check your departure airport’s policy unless you want to chug your expensive skincare at security.

In the rest of Europe, the EU had plans to ditch the 3-1-1 rule by mid-2024 with new scanners to detect banned substances more accurately. But those scanners didn’t pass the test, so every EU airport is sticking to the old restrictions: 100 ml per container in a clear, resealable bag. The liquid rule, in place since 2006, is still alive and well in 2025. Stick to the 100 ml limit to breeze through security, especially on international flights.

Budget Airlines and New Fees

Flying with budget airlines in Europe like EasyJet, Ryanair, or Wizz Air? They’ve shrunk the allowed size for free carry-ons. If your bag doesn’t fit their new limits, you’ll pay extra—either for a bigger carry-on or to check it in. Many passengers are now forced to downsize their luggage or accept additional fees, which can add up quickly. Always check your airline’s latest baggage policy to avoid surprises at the gate.

Flying with Air Canada on a Basic Economy ticket? Starting January 3, 2025, passengers can only bring one small personal item for free (like a purse or backpack). A carry-on suitcase will cost $35, and additional bags could jump to $65 per piece. Previously, carry-ons were free, but now even a small one comes with a fee. Starting January 21, 2025, Basic Economy passengers will also lose free seat selection—seats will be randomly assigned unless you pay to choose your spot. Budget for baggage fees and brace for a middle seat unless you’re willing to pay for an upgrade.

The Basics: What’s Always Banned

Some items might seem obvious, but they’re worth a reminder because they’ll definitely get you stopped. Sharp objects and tools like knives, scissors, multitools, throwing stars, axes, hammers, drills, and large wrenches or pliers over 10cm long are a no-go in carry-ons. Check them in if you need to bring them.

Weapons and anything resembling one—guns, ammo, tasers, stun guns, and even toy weapons or realistic props—are banned. Firearms need proper clearance for checked luggage. Explosives and flammables, like fireworks, gas canisters, certain cleaning chemicals, and some aerosols, are completely prohibited in both carry-on and checked luggage.

Surprising Banned Items You’d Never Expect

We all know the basics—no knives, no explosives, no oversized liquids. But did you know a bag of flour could get you stopped at security? Or that your camping gear might be treated as a potential weapon? Here are some totally normal, everyday items that are banned from carry-ons.

  • Mercury Thermometers: These might seem harmless, but if they break, you’ve got a toxic spill emergency. They’re completely banned on flights. Stick to digital or alcohol-based thermometers.

  • Tent Poles and Stakes: Security sees them as sharp objects that could be used as weapons, so they’re not allowed in carry-ons. Check them in if you’re hiking.

  • Multitools and Scissors: Scissors are only allowed if the blades are shorter than 4 inches (10cm), but security might still confiscate them. Box cutters, large shears, and multitools are often banned outright—put them in checked luggage.

  • Toy Guns and Foam Swords: Even if they’re bright orange and obviously fake, they’re not making it past security. If it looks like a weapon, it’s a no-go.

  • Sports Equipment: Baseball bats, golf clubs, hockey sticks, and lacrosse sticks are banned from carry-ons. If it can be swung like a weapon, check it in.

  • Powders Over 12 Ounces (350 ml): In the U.S., baby powder, baking ingredients, or bath salts over 12 ounces could get flagged because powders can disguise explosives. Exceptions like baby formula or medications are allowed but will face extra screening.

  • Heavy Tools and Appliances: A hammer, drill, or even a toaster in your carry-on? They must go in checked luggage.

Why the Liquid Rule Exists

Ever wondered why you can’t bring a regular bottle of water on an international flight? The strict limits on liquids, sprays, and gels exist for security. These substances can be used to create explosives, making them a serious threat. The rule started in August 2006 after British authorities uncovered a terrorist plot at Heathrow Airport, where attackers planned to disguise liquid explosives in soft drink bottles and detonate them on flights to the U.S. and Canada. The U.K. and U.S. immediately banned all liquids in carry-ons, later adjusting to the 3-1-1 rule: 100 ml per container in a clear resealable bag. This restriction keeps flights safe worldwide.

Final Thoughts: Stay Prepared

Airline rules are constantly changing, and what seems innocent today could get you stopped tomorrow. Want to breeze through security without surprises? Double-check the latest restrictions before you fly. Because trust me—you don’t want to be the next “Can you believe what happened at airport security?” story.

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