In 2025, more people are flying with guns than ever before. The Supreme Court’s Bruen decision and the spread of permitless carry laws in many states have encouraged lawful gun owners to travel armed. Whether you shoot competitions, hunt, or just want your firearm with you, flying with a gun is completely legal under federal law — as long as you follow the rules. Break them, and you’ll face big fines or missed flights.
This guide covers the latest 2025 TSA and airline rules, clears up the biggest myths about “TSA-approved” cases, and shows you solid hard cases that actually work.
Section 1 – The Basic TSA Rules for Flying with Guns in 2025
It’s simpler than most people think. Here are the current TSA requirements:
- The gun must be unloaded when you get to the airport.
- It must go inside a hard-sided, locked container.
- You declare the firearm at the airline counter, never at the regular TSA checkpoint.
- Ammo has to be in boxes or original packaging. Loose rounds are not allowed.
- You can bring up to 11 pounds (5 kg) of ammunition total.
- Magazines must be out of the gun, even if empty.
New in 2025: Most airlines now inspect the case right at the check-in counter before they accept your bag.
Official TSA page (always check for last-minute changes): TSA.org/firearms
Section 2 – The Huge Myth: “TSA-Approved” Gun Cases and Locks
Let’s kill this myth once and for all:
- There is no official “TSA-approved” gun case list.
- Those little red TSA travel locks that agents can open? You are NOT allowed to use them on firearm containers.
- Only regular padlocks or built-in locks that ONLY YOU can open are permitted.
You’ll still see tons of Amazon and eBay listings that say “TSA-approved.” Most are wrong. In 2025 this confusion is worse than ever. Double-check your locks.
Section 3 – What Actually Makes a Case Legal in 2025
Locks and Security
- Look for cases with at least four padlock holes. Airlines and TSA like them because the case stays locked on every corner.
- No zippers. No TSA-access locks. Just normal locks you control.
Material and Strength
- Go for tough plastic (polypropylene), aluminum, or a mix.
- Cases rated IK08 for impact resistance handle rough baggage handlers well.
Weather Protection
- IP67 or higher is ideal. That means fully waterproof and dustproof even in bad conditions.
Size and Weight
- Make sure the case fits your airline’s checked-bag limits.
- Small pistol cases usually count as normal luggage. Long rifle cases often cost extra because they’re oversized.
Inside Padding
- Pick a case with pick-and-pluck foam or pre-cut foam. It keeps the gun from moving and proves it’s packed safely.
Section 4 – Best Real-World Gun Cases for Flying in 2025
Best Overall Rifle Case
Model: YFGB-64 Shockproof Long Rifle Gun Case
- Outside: 134.6 × 40.6 × 15.5 cm
- Inside: 128.2 × 34.3 × 13.3 cm
- Empty weight: 9.8 kg
- Six reinforced padlock points, IP67, IK08 shock rating, pressure valve, customizable foam. Perfect for scoped rifles or shotguns.
Best Value Wheeled Rifle Case (most popular on forums right now)
Model: YF-S1378 Wheeled Heavy-Duty Rifle Case
- Outside: 137.8 × 38.3 × 17.5 cm
- Inside: 130 × 32 × 14 cm
- Empty weight: 10.8 kg
- Six lock points, wheels, pull handle, thick walls, IP67, three-layer foam. Great for full-length rifles or broken-down ARs.
Best Premium Wide-Body Wheeled Case
Model: YF-S1187 Large Wheeled Rifle Case
- Outside: 118.7 × 52.5 × 20.9 cm
- Inside: 112 × 46.2 × 18.2 cm
- Empty weight: 11.8 kg
- Wide enough for two rifles side-by-side, heavy-duty wheels, telescopic handle, tons of foam options, IP67.
All three IFSTAR Cases models check every 2025 box: hard sides, owner-only locks, IP67 sealing, strong padlock holes, thick injection-molded plastic, and customizable foam.
Section 5 – How Check-In Actually Works in 2025
- Walk up to the airline counter and say calmly: “I need to declare a firearm.”
- They hand you an orange declaration tag. Sign it and put it inside or on the case.
- They’ll probably ask you to open the case so they can confirm it’s unloaded.
- Once they’re happy, the bag goes to TSA screening behind the counter.
- Keep your keys or combo with you the whole time. Sometimes TSA pages you to come open it again — totally normal.
Remember just three things:
- Hard case
- Regular locks only (no red TSA locks)
- Declare it at the airline counter
Do that and you’ll be fine. Always peek at your specific airline’s webpage — Delta, United, Southwest, etc., each have small differences in 2025.
Need a solid case? Check out the full gun cases lineup at IFSTAR Cases. Sign up for restock alerts if something is sold out.
FAQ
Q: What is a TSA approved gun case?
A: A hard-sided, lockable case that meets TSA rules for flying with firearms.
Q: Do I need a TSA approved gun case to fly with a firearm?
A: Yes. Every U.S. airline and TSA require an unloaded gun to be in a hard, locked case in checked baggage.
Q: Can TSA agents open my TSA approved gun case?
A: No. Only you have the key or combination. That’s why regular padlocks are mandatory.
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