Planning to take your Foil Drive on a flight? This guide covers how to prepare your Foil Drive system for airline travel, including packing your equipment, travelling with your battery, and what to expect at the airport.

Important: Airline and dangerous-goods requirements can vary between airlines, routes and countries. Always check the requirements of every airline on your itinerary before travelling and obtain any required approval before arriving at the airport.

This guide is based on current 2026 airline and Australian aviation guidance and is intended as a general guide only.

Before You Travel

Before packing your Foil Drive, allow enough time to:

• Check your airline's current baggage and dangerous-goods requirements.
• Confirm whether your Foil Drive battery is permitted for passenger travel.
• Obtain airline approval for your batteries.
• Check the battery's Watt-hour (Wh) rating.
• Inspect the battery for any signs of damage, swelling, leakage or overheating.
• Ensure all batteries are safely disconnected from the Foil Drive system.
• Pack batteries separately from other equipment where required.
• Have your battery specifications and supporting documentation available if requested.

Do not attempt to travel with a damaged, swollen, leaking or overheating lithium battery.

Travelling with Your Foil Drive Battery

Foil Drive batteries are lithium-ion batteries and are subject to dangerous-goods regulations when travelling by air.

The battery's Watt-hour (Wh) rating determines which category it falls into for air travel.

As a general guide:

Spare batteries must be individually protected against short circuits and must not be placed in checked baggage. Current CASA guidance requires batteries between 100 Wh and 160 Wh to be individually protected, approved by the airline and carried in the cabin.

IATA also recommends that spare lithium batteries are carried in hand baggage, with their terminals protected against short circuits.

For more information on travelling with your batteries, see:

Travel Batteries - MAX and SLIM Travel Battery Guide

Assist PLUS Small Battery - Airline Travel & Y Lead Guide

Do not assume that a battery is permitted simply because its capacity is below 160 Wh. Airline approval and airline-specific restrictions may still apply.

Packing Your Foil Drive

Separate your Foil Drive equipment into batteries, electronic equipment and other equipment.

Batteries

Foil Drive batteries should be:

• Disconnected from the Foil Drive system
• Carried in your carry-on baggage where permitted
• Individually protected against short circuits
• Protected from physical damage
• Kept separate from metal objects or other items that could contact the terminals
• Packed so the battery cannot move around excessively

Never place spare lithium batteries in checked baggage. If your carry-on bag is taken from you at the gate and placed in the aircraft hold, remove all lithium batteries and keep them with you in the cabin.

Electronics Box and Controller

The Electronics Box and Controller do not need to be treated in the same way as a loose spare battery.

Before packing:

1. Disconnect the battery from the system.
2. Ensure the Electronics Box and Controller are completely dry.
3. Leave the nose cone disconnected from the electronics box 
4. Protect the equipment from impact and damage.
5. Pack the Controller so that the buttons or triggers cannot be accidentally activated.
6. Keep the Electronics Box and Controller easily accessible if you expect security screening.

If the airline or security staff ask about the equipment, explain that it is part of an electric hydrofoil propulsion system.

Motor and Mast

The motor, mast and associated components can generally be packed with your sporting equipment, subject to your airlines baggage allowance and security requirements.

Before packing:

• Remove the propellers.
• Protect the motor and propeller from impact.
• Protect exposed connectors and cables from damage.
• Coil the motor cable without tight bends or kinks.
• Keep small components and hardware contained so they cannot become loose in your luggage.

Foils and Sharp Equipment

Foils, masts, propellers and other sharp or pointed equipment may be subject to additional airline or airport-security restrictions. These items are best packed in checked baggage to avoid confiscation at security. 

At the Airport

Allow additional time when travelling with a Foil Drive.

Your battery or equipment may require additional inspection by airport security or airline staff.

Keep the following information readily available:

• Battery model
• Battery Watt-hour rating
• Manufacturer information
• Battery label
• Airline approval, if required
• Relevant battery documentation or SDS, if requested

Do not hide, relabel or modify a battery to make it appear compliant with an airline's requirements.

If asked to declare the battery or equipment, provide the correct information.

Battery Protection During Travel

Before leaving home, inspect each battery carefully.

Do not travel with a battery that is:

• Swollen
• Cracked
• Leaking
• Physically damaged
• Showing exposed cells or wiring
• Overheating
• Showing signs of significant impact damage

Damaged lithium batteries can present a fire risk and should not be taken onto an aircraft. CASA specifically advises passengers to stop using or charging batteries that show signs of damage, overheating or swelling.

Airline Approval

Always obtain airline approval for your batteries before travelling to the airport.

Do not rely on airport staff to approve the battery at check-in.

Keep a copy of the approval available on your phone and, where practical, retain a printed copy with your travel documents.

Airline approval requirements can vary, and an approval from one airline does not necessarily mean another airline will accept the same battery.

Quick Travel Checklist

Before leaving home

☐ Check every airline on your itinerary
☐ Check the battery Watt-hour rating
☐ Obtain airline approval prior to flight departure
☐ Inspect batteries for damage or swelling
☐ Disconnect batteries from the Foil Drive
☐ Individually protect battery terminals
☐ Pack batteries in carry-on baggage
☐ Pack the mast, foil and other sharp equipment according to airline requirements

☐ Remove the nose cone from the electronics box
☐ Protect the electronics box, controller and motor from damage
☐ Have battery documentation available

At the airport

☐ Declare batteries at check-in
☐ Keep spare batteries with you in the cabin
☐ Remove batteries if your carry-on is gate-checked
☐ Allow additional time for security screening
☐ Follow the airlines instructions if they inspect your equipment

During the flight

☐ Keep batteries protected and with you
☐ Do not charge or use batteries during the flight
☐ Follow all instructions from the cabin crew

Important

Airline and dangerous-goods regulations can change and may vary between airlines, countries and routes.

The information in this article is based on current 2026 guidance and is provided as a general guide for Foil Drive customers. The airline operating your flight has the final say on what it will accept for carriage.

Always check directly with your airline before travelling.