Lithium-ion batteries have, over the past decade, evolved from an electronics component into the foundation of entire infrastructure: they are used in smartphones and laptops, electric vehicles, micromobility devices, energy storage systems, and increasingly in more complex automated systems. But as batteries become more widespread, so do the risks associated with their operation, accidents, and recycling.

According to UL Standards & Engagement (ULSE), 98% of Americans own at least one battery-powered device, and on average each person has nine rechargeable devices. At the same time, 43% of U.S. residents do not know that a lithium-ion battery is the power source for their devices, Axios reports.

The problem becomes especially noticeable where battery failure can affect not just one person, but an entire system — from an aircraft to urban infrastructure.

A battery on board an aircraft can become a serious threat

One of the most challenging situations arises when lithium-ion batteries catch fire on airplanes. According to ULSE, 123 cases of battery thermal runaway were recorded on passenger flights in 2025, compared with 107 a year earlier. That represents growth of about 15% and an average of 2.36 incidents per week.

Thermal runaway is an uncontrolled process in which a battery rapidly heats up and may begin to emit smoke before catching fire. On an aircraft, such a situation is especially dangerous: space is limited, and access to the source of the fire is difficult.

At the same time, far from all passengers are aware that such a threat exists. According to ULSE, only 9% of Americans have ever heard of a battery fire occurring during a flight.

The organization recommends that passengers keep devices with lithium-ion batteries within reach so that any potential problem can be noticed as early as possible. A UL 5800 standard has also been developed for aircraft, covering systems for containing battery fires, smoke, and fumes.

E-bikes have shown the dangers of use without proper rules

Another example is electric bicycles and electric scooters. In 2024, bike- and scooter-sharing programs operated in more than 350 U.S. cities, and the number of trips exceeded 170 million.

But the batteries in such devices create risks inside homes as well. According to a ULSE study, 49% of e-bike users who charge them at home admit that they leave the device near an exit or block evacuation routes with it. Another 53% leave the battery plugged in after it is fully charged, and 41% charge it overnight.

New York provides a telling example. In 2023, 18 deaths linked to fires involving e-bikes and other micromobility devices were recorded there. After the city required relevant products to comply with ULSE safety standards and strengthened educational programs and inspections, the number of fatalities fell to one person in 2025.

This example shows that battery safety depends not only on the design of the battery itself. Product requirements, rules for use, owner awareness, and enforcement of standards also matter.

An old battery does not necessarily become waste

Another issue arises after a battery reaches the end of its primary service life. Electric vehicle batteries typically retain about 70–80% of their original capacity after automotive use. They can therefore be reused — for example, in energy storage systems, backup power supplies, and microgrids.

However, recycling such batteries remains a separate challenge. Only 38% of Americans believe that electric vehicle batteries are recycled in a way that recovers valuable materials. Just 15% are sure they are reused in home or grid energy storage systems.

In practice, a spent battery can be disassembled and individual components reused — for example, cell modules, cooling systems, and electronic units. Lithium, nickel, cobalt, and copper can also be extracted from it. Various recycling methods are used for this, including hydrometallurgical and pyrometallurgical processes, as well as direct recycling technologies.

But each stage requires its own safety measures. Batteries need to be designed with future disassembly and reuse in mind, and facilities must be prepared to safely disassemble, recycle, and repurpose batteries.

Safety must become part of the entire chain

The spread of batteries is changing the scale of potential accidents. A smartphone fire is a problem for an individual user. A faulty battery in an aircraft, electric vehicle, energy storage system, or other critical infrastructure can lead to far more serious consequences.

That is why battery safety must be viewed not as a separate stage of manufacturing, but as a continuous process — from battery design and production to operation, reuse, and recycling.

The more areas of life switch to rechargeable energy sources, the more important it becomes to account for failure scenarios in advance. This makes it possible not only to reduce the likelihood of accidents, but also to build trust in technologies that are gradually becoming part of both everyday life and critical infrastructure.