Moldex 6496T BattlePlugs Replacement Tips — Extra Small, 50 Pairs

Short answer: the moldex 6496t battleplugs replacement tips is covered below on the specifications its own listing publishes, the standards it is certified to, and who it suits.

moldex 6496t battleplugs replacement tips — what the listing actually specifies

Moldex BattlePlugs — NRR 24 Dual-Mode Reusable Earplug, 4 Sizes, Replaceable Tips

The rating on the box is a laboratory number, not the protection you will get. NIOSH derates the labelled NRR because real-world attenuation is consistently lower than the test-lab figure - the fit a trained subject achieves under supervision is not the fit a worker achieves on the fifth donning of a shift.

The Moldex BattlePlugs are NRR 24 dB dual-mode reusable earplugs with a flip-stem mechanism that switches between protected mode (channel closed, maximum attenuation) and situational awareness mode (channel open, environmental sound passes through at reduced levels) without removing the earplug from the ear. Available in four sizes: 6496 Extra Small, 6497 Small, 6498 Medium, 6499 Large. Replacement foam tips available for all sizes. For continuous passive NRR 33 protection without dual-mode capability, see the Moldex Pura-Fit or Camo Plugs.

Key Features

• Flip-stem dual-mode mechanism — instant switch between protection and awareness: The BattlePlugs stem flips between two positions — closed (acoustic channel blocked, NRR 24 protection) and open (acoustic channel open, environmental sound passes through at reduced levels). The switch is made with a single finger motion while the earplug remains seated in the ear — eliminating the need to remove, store, and re-insert earplugs when switching between noise and communication tasks. In variable-noise environments where this switch happens dozens of times per shift, the compliance and operational efficiency benefits are significant
• Four sizes with replaceable tips — long-term program economy: BattlePlugs are available in Extra Small, Small, Medium, and Large sizes to accommodate the full range of ear canal dimensions. The foam tips that create the acoustic seal are replaceable — when tips become compressed or soiled, only the tips are replaced (6487T, 6488T, 6489T, or 6496T), not the entire earplug body. This reduces per-use cost in programs where workers use the same pair daily over months or years
• NRR 24 closed — adequate for most variable-noise industrial and recreational environments: At 8.5 dB effective attenuation (OSHA 50% derating on NRR 24), BattlePlugs provide OSHA-compliant protection for environments up to approximately 98.5 dBA TWA. For high-noise environments above 100 dBA with dual-mode needs, supplement with the 6598 combo pack foam earplug for dual protection
• Latex-free: No latex in any component — appropriate for latex-sensitive workers in any application
• Combo Pack 6598 — dual protection option: The 6598 Combo Pack includes one BattlePlugs (medium) and one Camo Plugs foam earplug. The foam earplug can be worn over the BattlePlugs in extreme noise to add up to 5 dB additional attenuation beyond the BattlePlugs' closed mode rating

BattlePlugs Size Selection Guide

BattlePlugs vs. Standard Earplugs — When Dual Mode is the Right Choice

OSHA Compliance

BattlePlugs (NRR 24 closed) are rated under ANSI S3.19-1974. Under OSHA 29 CFR 1910.95, the closed-mode NRR 24 provides 8.5 dB effective attenuation (OSHA 50% derating) — appropriate for environments up to approximately 98.5 dBA TWA. For environments between 98–103 dBA, supplement with the 6598 combo foam earplug for dual protection. OSHA 1910.95(i)(4) requires training on correct fitting — all four tips must seat fully to achieve rated NRR in closed mode.

Where this sits against the alternatives is covered in 10 year sealed vs replaceable battery smoke alarms, amber vs clear lens safety glasses, best cooling gear, best disposable ear plugs, best disposable earplugs for sleeping.

To see what else meets the same specification, start with 3m ear muffs, banded ear plugs, bluetooth radio ear muffs.

Written by Steven Eaton, WC Safety editor. WC Safety is an independent PPE review site, holds no inventory and sells nothing directly; Amazon links are affiliate links that earn a commission at no cost to you and never affect the assessment. This page is not medical, legal or regulatory advice.