Key Features

• Correct replacement for Size XS: BattlePlug tips are size-specific — Red tips fit only the Size XS BattlePlug stem. Using incorrect size tips will not seat properly and will not achieve rated NRR.
• Restores full NRR 20/10 performance: New foam tips restore the original NRR 20 closed / NRR 10 open rating. Worn or contaminated tips reduce effective attenuation — replace tips when performance degrades.
• Lower ongoing cost than full unit replacement: Replacing only the foam insert extends the life of the reusable BattlePlug stem housing indefinitely at a fraction of full-unit replacement cost.
• Moldex USA manufacturing: Same foam formulation as the original BattlePlug tips — PVC-free, ANSI S3.19 compliant.

When to Replace BattlePlug Tips

• Foam no longer compresses and re-expands consistently on insertion
• Visible contamination (earwax buildup, debris) that cannot be removed by wiping
• Foam surface is hardened, cracked, or deformed
• Seal quality has noticeably degraded (verify with palm-cup test after insertion)
• Tips have been used for approximately 30+ shifts of full-day wear

Do not attempt to wash foam tips — water degrades the foam. Replace the tip; clean the stem separately with a damp cloth.

Compatible BattlePlug Units

Frequently Asked Questions

Are these tips compatible with all BattlePlug sizes?

No — BattlePlug tips are size-specific. This listing (6496T) fits only the Size XS BattlePlug stem (Red tips). Using tips from a different size will not seat correctly and may fall out or fail to seal. Match the tip color to your BattlePlug stem color to confirm correct pairing.

Can I buy just the stem without the tips?

The BattlePlug stem is only sold as part of the complete unit (which includes tips). If the stem is damaged, purchase a new complete BattlePlug unit (Size XS: SKU 6496). Replacement tips (this listing) are for maintaining an existing, undamaged stem.

How many tips come in the replacement set?

Each replacement set includes one pair of tips (one left, one right) — sufficient to restore one BattlePlug unit. For programs issuing multiple BattlePlugs, purchase one replacement set per unit per replacement cycle.

How do I install replacement tips?

Remove the worn tip from the stem by gently pulling it straight off. Inspect the stem for damage before installing the new tip. Press the new foam tip onto the stem post until it is fully seated and cannot be pulled off with gentle tension. Test the seal after installation by inserting and performing the palm-cup fit check.