Yes, you can ship power tools with USPS, including cordless tools with their lithium-ion batteries, as long as the package stays within 70 lbs. and 130 inches in length plus girth. Under USPS Publication 52, each battery in a domestic package can be up to 100 watt-hours, with no more than two batteries per package. A new tool with its batteries installed or packed with it can go by air or ground. A used cordless tool must go by ground and be marked “Restricted Electronic Device.”
Corded tools with no battery and no fuel ship like any other heavy item. The rest of this guide covers the battery rules, gas-powered tools, packing, the best USPS service for a tool, and international shipping.
What Are the USPS Rules for Shipping Power Tools?
USPS treats a power tool as ordinary merchandise unless it contains something hazardous. In practice, two things can make a tool a regulated item: a lithium battery and fuel. A corded drill, sander or saw with no battery and no fuel residue only has to meet the size and weight limits and be packed well.
| Type of tool | Mailable with USPS? | Key rule |
|---|---|---|
| Corded tool (no battery, no fuel) | Yes | Normal size and weight limits apply |
| New cordless tool, battery installed or in the box | Yes, air or ground | Each battery up to 100 Wh, no more than 2 batteries; lithium battery mark (UN3481) on the address side |
| Used cordless tool with its battery | Yes, ground only | Mark “Restricted Electronic Device” and “Surface Transportation Only” |
| Spare battery shipped without a tool | Yes, ground only | Up to 100 Wh, package no more than 5 lbs., originally sealed packaging, UN3480 mark |
| Damaged, defective or recalled battery | No | Prohibited unless USPS Product Classification approves it |
| Gas-powered tool with fuel or fuel residue | No | Drain and clean it or use another option |
The size limits are the same for every domestic USPS package service: a maximum of 70 lbs. and 130 inches in combined length and girth. Our USPS frequently asked questions page covers the general mailing rules.
Can You Ship a Cordless Tool With the Battery in It?
Yes. Publication 52 allows lithium-ion batteries installed in equipment, or packed in the same box as the equipment, by both air and ground. You don’t have to remove the battery. The domestic limits are:
- Battery size: each lithium-ion battery may be up to 100 Wh, and each cell up to 20 Wh.
- Quantity: no more than 2 batteries (or 8 cells) per package.
- Marking: the package needs the DOT lithium battery mark showing UN3481 on the address side. USPS doesn’t require the mark when the tool has no more than 2 batteries installed in it.
- Condition: damaged, defective or recalled batteries are prohibited.
To check a battery against the 100 Wh limit, look for the watt-hour rating on its label, or multiply its voltage by its amp-hours. An 18V, 5.0Ah pack works out to 90 Wh and fits the limit. Larger high-capacity packs can go over 100 Wh, and those can’t be mailed with USPS.
When a battery travels in the box but outside the tool, protect it from short circuits. Cover the terminals with tape or a terminal cap, put it in its own bag or compartment, and pack it so it can’t touch metal parts or shift.
What Changes When the Tool Is Used?
Publication 52 has a separate rule for “used, damaged, or defective electronic devices” that contain lithium batteries, meaning any device that isn’t new in its original packaging and isn’t manufacturer-certified new or refurbished. A used cordless drill you sold online fits that description. These devices can’t go by air, so ship them with USPS Ground Advantage, and mark the address side “Restricted Electronic Device” and “Surface Transportation Only.”
Can You Mail a Spare Battery on Its Own?
Yes, but only by ground. A lithium-ion battery shipped without the tool must be under the same 100 Wh limit, in its original sealed packaging, in a package of 5 lbs. or less. The package needs the UN3480 lithium battery mark and the statement “Surface Mail Only, Lithium-ion Batteries – Forbidden for Transportation Aboard Passenger Aircraft.” For household batteries, our guide on shipping AA batteries with USPS covers the smaller cells.
Can You Ship Gas-Powered Tools With USPS?
Not with fuel in them. Gasoline is a flammable liquid that USPS won’t carry, and a tool that has run on it can hold fuel and vapor in the tank, lines and carburetor. Before you mail a used chainsaw, trimmer or blower, check Publication 52 or ask at the Post Office counter. If you can’t confirm that it’s completely free of fuel, choose another way to send it.
The same caution applies to other flammable items people pack with tools, such as fuel cans, lubricant sprays and torch gas. Our guide on whether you can ship matches with USPS explains how USPS handles small flammable items.
How Should You Pack a Power Tool for USPS?
Power tools are heavy, dense and have hard edges, so poor packing is the most common cause of damage. Follow these steps:
- Clean the tool and remove blades, bits and other sharp attachments. Wrap them separately.
- Use the original case or box if you have it, then place it inside a sturdy outer box. Double-wall corrugated boxes are the best choice for heavy tools.
- Leave 2 inches of cushioning on every side. Foam or large-cell bubble wrap absorbs impact better than loose fill alone.
- Block the tool so it can’t move. Shake the closed box. If anything shifts, add more fill.
- Tape every seam with 2-inch packing tape in an H pattern, and reinforce the bottom.
- Add the required marks for any lithium battery, flat on the address side.
Our USPS packaging guidelines explain what USPS accepts as packaging. For small tools, a USPS flat rate box can be a convenient option because it’s priced the same up to 70 lbs.
Which USPS Service Is Best for Power Tools?
USPS Ground Advantage is the usual choice for power tools. It carries packages up to 70 lbs. in 2–5 days, includes tracking and up to $100 of insurance, and it’s the USPS service for items that can only travel by ground, such as used cordless tools and spare batteries. Priority Mail is faster, at 1–3 business days, and also includes up to $100 of insurance.
| Service | Delivery time | Max weight | Insurance included | Best for |
|---|---|---|---|---|
| USPS Ground Advantage | 2–5 days | 70 lbs. | Up to $100 | Most tools, used cordless tools, spare batteries |
| Priority Mail | 1–3 business days | 70 lbs. | Up to $100 | New tools that need to arrive faster |
| UPS Ground | 1–5 business days | 150 lbs. | Declared value coverage | Tools or kits heavier than 70 lbs. |
Our guide to how long Priority Mail takes covers its delivery times. For a big kit or a table saw over 70 lbs., use UPS, which takes packages up to 150 lbs., and look at UPS Ground discounts with ParcelPath. Shop equipment on a pallet can go LTL freight through PalletPath, and you can get an LTL freight quote online.
ParcelPath is free to use, with up to 89% off USPS and up to 85% off UPS and no subscription or per-label fee. You can compare live USPS and UPS rates for your tool before you buy, and schedule a free USPS pickup so you don’t have to carry a heavy box to the Post Office.
How Do You Insure and Track a Power Tool Shipment?
Every Ground Advantage and Priority Mail label includes tracking and up to $100 of insurance. For a more valuable tool, buy extra coverage for its full value: USPS sells additional insurance up to $5,000 for merchandise, and ParcelPath offers Shipsurance coverage when you buy a label. Our guides on how USPS insurance works and how to check whether your USPS package has insurance explain coverage and claims.
Take photos of the tool and the packed box before you ship, and keep your receipt. If the tool arrives damaged, keep the box and packing material for the claim. If it never arrives, here’s what happens if USPS loses your package and how the search and claim work.
Can You Ship Power Tools Internationally With USPS?
Yes, with tighter battery rules. For international and APO/FPO/DPO mail, Publication 52 allows lithium-ion batteries only when they’re installed in the tool they power:
- No more than 2 batteries (or 4 cells) per shipment, each battery up to 100 Wh.
- Batteries packed loose in the box with the tool, and spare batteries on their own, are prohibited.
- Used, damaged or defective devices with lithium batteries are prohibited, so a used cordless tool can’t be mailed abroad.
- No lithium battery marks are permitted on the package, and Global Express Guaranteed doesn’t accept lithium batteries.
- The destination country must accept lithium batteries, and you’ll need a customs form with an accurate description and value.
A corded tool with no battery has none of these battery limits, but it still has to meet the destination country’s import rules. If the battery rules rule out USPS, our roundup of shipping services and solutions compares other options.
Frequently Asked Questions
Can I ship a cordless drill with the battery in it through USPS?
Yes, within the U.S. USPS Publication 52 allows lithium-ion batteries installed in the equipment they power, up to 100 Wh per battery and two batteries per package, by air or ground. If the drill is used rather than new or manufacturer-refurbished, ship it by ground only and mark the box “Restricted Electronic Device” and “Surface Transportation Only.”
What is the maximum weight for shipping a power tool with USPS?
70 lbs., with a maximum size of 130 inches in combined length and girth. That limit applies to USPS Ground Advantage, Priority Mail and Priority Mail Express. A heavier tool, kit or saw has to go by UPS, which accepts packages up to 150 lbs., or as LTL freight on a pallet.
Can I mail a spare power tool battery by itself?
Yes, but only by ground. A lithium-ion battery shipped without its tool must be 100 Wh or less, in its original sealed packaging, in a package that weighs 5 lbs. or less. The package needs the UN3480 lithium battery mark and the “Surface Mail Only” statement. International mail doesn’t accept spare batteries.
Can I ship a gas-powered tool with USPS?
Not if it contains fuel or fuel residue. Gasoline is a flammable liquid that USPS doesn’t carry, and engines can hold fuel and vapor after use. Check Publication 52 or ask at the Post Office before mailing a used gas tool, and choose another way to send it if you can’t confirm it’s free of fuel.
Sources
- USPS Publication 52, 349: Miscellaneous Hazardous Materials (Class 9), lithium batteries
- USPS Publication 52, Packaging Instruction 9D: Lithium Batteries, Domestic
- USPS Publication 52, Packaging Instruction 9E: Lithium Batteries, International and APO/FPO/DPO
- USPS: USPS Ground Advantage
Part of our USPS Packaging Guidelines guide. Related: Shipping Resources, USPS Flat Rate Boxes.
