Apple AirPods4 – Product Liability Lawyer

2026-03-13 – A consumer suffered a thermal burn and hearing loss after their Apple AirPods 4 experienced a severe thermal failure while charging, according to a report filed with the U.S. Consumer Product Safety Commission (CPSC) on SaferProducts.gov. The incident, involving a design defect that caused the device to smoke and melt, highlights ongoing fire and burn hazards associated with lithium-ion battery-powered electronics.

Product Details

Brand Name: Apple
Manufacturer: Apple Inc.
Model: AirPods 4
Retailer: Best Buy
Incident Report Number: 5919210
Severity Type Name: Seen by Medical Professional
Severity Type ID: 8

Incident Overview

On February 13, 2026, the consumer's Apple AirPods 4 (Serial: DJGT4TF56W) began to smoke and melt while charging using an original Apple 20W power brick and an original Apple woven USB-C cable from an iPhone box. The consumer sustained a thermal burn to their finger while attempting to disconnect the melting unit. According to the incident report, the failure left the consumer without hearing protection during a 12-hour high-noise shift in a data center, resulting in a documented 21dB hearing loss and persistent tinnitus, confirmed by Apple's Hearing Test.

The consumer reported the incident to Apple on February 16. The company repeatedly failed to meet its own safety deadlines (48-72 hours, then 2 business days). During a chat session on February 21, the consumer provided macro-photos of the original Apple cable with its serial number, proving no third-party accessories were involved. A senior advisor abruptly terminated the chat without providing a resolution or safety instructions. Another representative admitted they "don't have an exact time frame" for a response and could not guarantee that the engineering team would ever respond. As of the filing date, February 25, Apple had not addressed the fire hazard or the consumer's injuries. The report was filed to create a permanent federal record of the defect and the manufacturer's response, according to the consumer.

Safety Concerns

Immediate Dangers: Lithium-ion battery failures can trigger thermal runaway, a rapid chemical reaction that produces intense heat, smoke, and fire. The reported melting and smoking of the AirPods 4 during charging poses a direct burn risk to the user and anyone nearby, as demonstrated by the consumer's finger burn.

Long-Term Risks: Exposure to battery combustion byproducts may cause respiratory irritation or other health issues. Additionally, the loss of hearing protection due to device failure resulted in permanent hearing damage, highlighting secondary but serious consequences of product failure.

Who Might Be Affected: Users of the device are at primary risk, but bystanders, especially children or pets near charging electronics, could also be exposed to fire, smoke, or burns. The incident occurred during charging, a common usage scenario.

Warning Signs: Potential precursors include unusual heat from the device, swelling, hissing sounds, or visible smoke. The consumer reported the device began smoking and melting without prior warning, emphasizing that failures can occur suddenly. Consumers should immediately stop use and unplug if any of these signs appear.

What Our Clients Say

What Consumers Should Do

Stop Using Immediately: If your AirPods 4 or any Apple product shows signs of overheating, swelling, smoke, or melting, disconnect it from power and stop using it right away. Do not attempt to charge or operate the device.

Do Not Attempt Repairs: Do not open, puncture, or attempt to repair the device yourself. Lithium-ion batteries can rupture or ignite if mishandled.

Preserve the Product: Keep the device, charger, and cable in a safe, dry place. Do not discard them, as they may be needed for investigation or as evidence in a potential claim.

Document the Incident: Take clear photos of the damaged product, including serial numbers and any accessories used. Record the date, time, and circumstances of the failure. Save all communications with the manufacturer.

Seek Medical Attention: If you sustain a burn, hearing loss, or other injury, see a medical professional immediately. Document your injuries and treatment for your records.

Contact the Manufacturer: Report the incident to Apple's product safety team. For AirPods, you can also check Apple's battery service options at support.apple.com. Keep a log of all interactions, including names, dates, and promises made.

Report to the CPSC: File a report on SaferProducts.gov to create a federal record. Include as much detail as possible, including the product model, serial number, and description of the incident.

Check for Recalls: Visit CPSC.gov to search for any recalls related to your product model.

If you or a loved one has suffered injury or property damage from a product failure, you may want to speak with a product liability attorney to understand your legal options.

Manufacturer's Response

The manufacturer's official response to this specific incident report is not publicly available at the time of this writing. According to the consumer's narrative, Apple failed to meet its own safety deadlines, terminated a support chat without resolution, and a representative stated there was no exact timeframe for a response from the engineering team.

Legal Help Available

H Law Group is a California product liability law firm representing consumers injured by defective products. We handle cases on a contingency fee basis, meaning you pay nothing unless we recover compensation for you. Our team understands the physical, emotional, and financial toll of product-related injuries and is committed to holding manufacturers accountable. If you or a loved one was injured by Apple AirPods4 or a similar product, contact H Law Group at (888) 499-4948 for a free, no-obligation consultation.