How to Ship Electronic Devices Without Damage: Complete Guide

Updated for 2026

Shipping electronic devices - a laptop bought on eBay, a smartphone sold on Vinted, a tablet to send to a relative abroad - is one of the operations that generates the most doubts and concerns. The risk of damage in transit is real, the rules on lithium batteries are specific, and choosing the wrong courier can be costly.

This guide answers everything: how to pack every type of device correctly, what regulations apply to batteries, which courier company to choose and what to do if the package arrives damaged. At the end you will find the complete checklist to use every time you ship electronics.

Why shipping electronics is different from shipping anything else

Electronic devices share three characteristics that make them particularly delicate to ship:

1. Internal components sensitive to mechanical stress. Screens, motherboards, HDDs and connectors are designed to operate in static conditions, not to absorb repeated shocks from conveyor belts and automated sorting centres.
2. Lithium batteries subject to international regulations. Almost all modern devices contain lithium batteries, the shipment of which is regulated by IATA standards (for air transport) and ADR (for road transport). Ignoring them can lead to the shipment being blocked or, in the worst cases, to fires during transport.
3. High economic value. A laptop or smartphone often represents hundreds or thousands of euros. Inadequate packaging that leads to damage means a significant financial loss - and a complaint to the courier without the right precautions may lead to nothing.

The rules on lithium batteries: what you need to know before shipping

Every electronic device with a lithium battery is subject to specific transport regulations. Failure to comply with them is one of the most common reasons why electronics shipments are blocked or refused by the carrier.

Batteries integrated in the device (non-removable)

Smartphones, tablets, laptops and most modern devices have a built-in battery. They can be shipped without additional restrictions, provided that:

• The battery do not exceed 100 Wh (for multiple cells) or the 20 Wh (for single cells) - limits met by all standard consumer devices
• The device both protected against accidental activation (aeroplane mode activated or power button locked)
• The battery is charged to the maximum at 30% for international shipments by air
• The device has no visible damage to the battery (swelling, leakage)

Separate lithium batteries (not installed in the device)

Spare batteries, power banks and single cells not installed in a device are subject to much stricter restrictions:

• They cannot be sent by air in most cases
• For shipment by land, require specific packaging with terminal protection and dangerous goods declaration
• Contact us before shipping separate batteries: we will evaluate together the most suitable solution

Devices with defective or damaged batteries

They are not dispatchable via any carrier. Swollen batteries, electrolyte leakage or damage caused by short circuits pose a fire risk during transport. Always check the condition of the battery before shipping a used device.

ShippingComoda recommends: Before shipping a used device, take a photo of the battery. If it is even slightly swollen, do not send it: no courier will accept it and you risk having your shipment blocked.

How to pack electronic devices: the correct procedure

The main cause of damage to electronics during shipment is not the courier: it is inadequate packaging. Here is the correct procedure for each type of device.

Golden rule: always use the original packaging if you have it

The original manufacturer's box is designed specifically for that device, with polystyrene or foam moulded to its exact measurements. If you still have it, it is the best protection available. Then place it in an outer box with additional padding on all sides.

If you do not have the original packaging: step-by-step procedure

Step 1 - Prepare the device

• Switch the device off completely (not just standby)
• Remove any attached accessories (memory card, cables, covers)
• Activate the screen protector with a sheet of paper or soft cloth
• Wrap cables separately

Step 2 - Primary Protection

Wrap the device with at least 3 layers of bubble wrap with medium bubbles (ø 10-25 mm), covering every surface, corner and edge. Secure with packing tape. Do not use paper sheets as the only protection: they do not absorb shocks.

For screens and displays (TV, monitor, tablet): use a rigid sheet of honeycomb cardboard o foam on the surface of the screen before bubble wrap, to avoid direct pressure that could cause damage to the panel without leaving external marks.

Step 3 - Boxing and immobilisation

Choose a new box at double wall slightly larger than the wound device. Position the device in the centre with at least 5 cm of padding on all sides (bubble wrap, foam or polystyrene chips). The object must not move an inch - do the shake test: no noise, no movement.

Step 4 - Box-in-box for high-value devices

For laptops, high-end smartphones, cameras and consoles: use the double box method. Place the device wrapped in an inner box, then place that in an outer box with 5 cm of additional padding between the two walls. This double barrier protects against serious shocks even if the outer box falls.

Step 5 - Sealing and Labelling

• Seal with “H” tape above and below
• Apply labels FRAGILE on all sides
• Insert sender and addressee also inside the box
• Take photos of the completed packaging

ShippingComoda recommends: never use a padded envelope to send a laptop, even for short distances. It offers zero protection against drops in sorting centres.

Device-specific instructions

How to ship a laptop

The laptop is probably the most shipped electronic device between private individuals, thanks to the sale of used equipment on eBay and Subito.it. The main risks are damage to the screen, keyboard and power connector.

• Close the laptop and lock it in the closed position with a cardboard sheet inserted between the screen and keyboard
• Wrap with bubble wrap starting from the corners (the areas most vulnerable to impact)
• Never send your laptop in a padded envelope: it does not offer sufficient protection against drops
• Use a rigid double-walled cardboard box, not a suitcase or soft box
• Remove any power adapters and ship them separately or wrapped in the same box

How to ship a smartphone

Small does not mean light to ship: smartphones are dense, with glass screens vulnerable to side pressure and temperature-sensitive batteries.

• Wrap the screen separately with bubble wrap with small bubbles (ø 10 mm), then add layers of larger bubbles
• Place the smartphone in the box vertically (not flat): reduces the pressure area when stacking other packages on top
• Insert foam separators between the smartphone and the walls of the box
• Do not use boxes that are too big: more movement = more risk

️ How to ship a monitor or TV

Large screens are the most difficult devices to ship safely. The panel glass is thin and sensitive to both frontal impacts and box torsion.

• If you still have the original box with the polystyrene supports: always use it, no exceptions
• Alternatively, create a front protection with a sheet of double-walled corrugated cardboard cut to the size of the screen, secured with tape, then wrap with bubble wrap
• Reinforce the four corners with cardboard or foam corner pieces: these are the statistically most at-risk points
• For TVs over 40 inches, consider a custom-made wooden case or contact us for dedicated solutions
• Always orient the package so that the screen is vertical, not horizontal

ShippingComoda recommends: if you no longer have the original box, don't improvise. Contact us before packing: we will show you the right solution for your specific model.

How to ship a game console

Consoles such as PlayStation, Xbox or Nintendo Switch are durable devices, but with delicate drives and connectors.

• Remove all disks and controllers before shipping
• Block any flaps or lids with a small piece of tape or cardboard
• Wrap the console with 2-3 layers of bubble wrap, paying attention to the side connectors
• Ship controller and accessories in a separate package or well separated in the same box

How to ship a camera or optics

SLR cameras, mirrorless cameras and especially optics (lenses) are high-precision devices that are very vulnerable to prolonged vibration.

• Always remove the lens from the camera body and ship them separately or with foam separators between the two
• Close the protective caps on the body and lens
• Use custom-cut foam templates rather than just bubble wrap: cylindrical lenses tend to roll around inside the box if not properly immobilised
• Activate the FRAGILE label and always consider additional insurance for targets worth more than 300-400 euro

Which courier to choose for sending electronics?

There is no courier that specialises only in electronics: all major operators (DHL, UPS, FedEx, TNT) transport electronic devices as standard shipments. The difference lies in the number of sorting steps and the speed of the service.

General principles:

• For valuable laptops, smartphones and tablets: you prefer the service express - less time in transit means less sorting and less risk of accumulated shocks
• DHL Express is often the most reliable choice for international electronics shipments due to its direct air network
• FedEx is preferable for the Italy-US route, where it excels in customs handling
• UPS often offers the most competitive fares for European destinations

With SpedizioneComoda you compare the rates and times of all available couriers in real time: choose the best combination of speed, reliability and price for your device and destination.

→ COMPARE COURIERS AND CALCULATE YOUR ESTIMATE

ShippingComoda recommends: for valuable smartphones and laptops, always choose the express service. The extra cost is minimal compared to the risk of an extra day in the sorting centres.

Insurance: not optional for electronics

The basic coverage included in most standard shipments is 50-100 euro - insufficient for any electronic device in daily use. For smartphones, laptops and TVs, always activate the additional insurance on the declared value.

At SpedizioneComoda you can add insurance cover directly during the booking process. Before you do so, please bear in mind:

• Coverage is only valid if the packaging is adequate (that is why pre-shipment photos are essential)
• Always declare the real value of the device: under-declaring to save on the premium means receiving a partial refund in the event of damage
• Keep the purchase receipt or any documentation of the value of the device

ShippingComoda recommends: always declare the real value of the device. Under-declaring to save a few euros on the premium means receiving a partial refund if something goes wrong.

Sending electronics abroad: what changes

For shipments intra-EU (France, Germany, Spain, Belgium, etc.) no additional customs documentation is required. Follow the same packing rules as described above.

For shipments extra-EU (USA, UK, Switzerland, Australia, etc.):

• A pro forma or commercial invoice with device description, serial number (if available) and declared value
• For second-hand devices, always declare the current market value, not the original price
• In United Kingdom declaration of the HS code of the goods is required (for consumer electronic devices the code is generally in 84xx or 85xx)
• In USA, some devices with cryptographic technology may require additional declarations: contact us for specific cases

What to do if the device arrives damaged

Despite all precautions, damage can happen. Here is how to proceed:

1. Do not open the parcel in front of the courier without documenting everything - take photos of the outer package before opening it
2. Photograph the inner packaging and then the damaged device
3. Keep all packaging materialthe courier may request it for the evaluation of the claim
4. Contact the courier or our team within 7 days from delivery for visible damage, within 14 days for hidden damage
5. Do you have the tracking number and the shipping receipt? Keep them handy: they are indispensable for starting the procedure

Complete checklist: sending electronics without errors

Before packing

• I photographed the device switched on and working
• I have checked that the battery is not damaged or swollen
• I charged the battery to the maximum at 30% (for international air freight)
• I activated the screen lock/plane mode
• I removed the memory card, SIM, cables and accessories

Packaging

• I used the original packaging (if available) or a new double-walled box
• I protected the screen with honeycomb cardboard or foam before bubble wrap
• I wrapped with at least 3 layers of bubble wrap, covering corners and edges
• I completely immobilised the content (shake test passed)
• I used the box-in-box method for valuable devices

Closure and documents

• I sealed with “H” tape above and below
• I applied FRAGILE labels on all sides
• I also entered the sender and addressee inside
• I photographed the completed packaging
• I added insurance on the declared value
• I prepared the pro forma invoice (for non-EU shipments)