{"product_id":"moldex-battleplugs-6497-dual-mode-reusable-earplugs-small-nrr-24db-closed-nrr-12db-open","title":"Moldex 6497 BattlePlugs Dual-Mode Reusable Earplugs — Small, NRR 24dB Closed \/ NRR 12dB Open","description":"\u003caside style=\"background:#1a1a2e;border-left:4px solid #e94560;padding:1rem 1.25rem;margin-bottom:1.5rem;border-radius:0 6px 6px 0;\"\u003e\n  \u003cp style=\"margin:0;color:#a0a0b0;font-size:0.85rem;font-style:italic;\"\u003eWC Safety stocks the full Moldex BattlePlug line — all four sizes (XS, S, M, L), replacement tips, and the combo pack. Use the \u003ca href=\"\/blogs\/safety-resources\/moldex-earplug-selection-guide\" style=\"color:#e94560;\"\u003eMoldex Earplug Selection Guide\u003c\/a\u003e to compare BattlePlugs with standard disposable and reusable options.\u003c\/p\u003e\n\u003c\/aside\u003e\n\n\u003ch2\u003eMoldex BattlePlug S — NRR 24 Closed \/ NRR 12 Open | Dual-Mode Hearing Protection\u003c\/h2\u003e\n\u003ch1\u003eMoldex 6497 BattlePlug S Earplugs\u003c\/h1\u003e\n\n\u003cp\u003eThe \u003cstrong\u003eMoldex 6497 BattlePlug (Size S)\u003c\/strong\u003e is a dual-mode hearing protector that switches between a \u003cstrong\u003eclosed position (NRR 24)\u003c\/strong\u003e for maximum noise reduction and an \u003cstrong\u003eopen position (NRR 12)\u003c\/strong\u003e that attenuates harmful impulse sounds while allowing speech and situational awareness to pass through. Originally designed for military and law enforcement use, BattlePlugs are also widely used in firearms training, hunting, demolition, and any environment requiring alternating between high-noise and communication-critical conditions.\u003c\/p\u003e\n\n\u003ctable\u003e\n  \u003ccaption\u003eQuick Facts\u003c\/caption\u003e\n  \u003ctbody\u003e\n    \u003ctr\u003e\n\u003cth\u003eSKU\u003c\/th\u003e\n\u003ctd\u003e6497\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eSize\u003c\/th\u003e\n\u003ctd\u003eS\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eNRR (Closed)\u003c\/th\u003e\n\u003ctd\u003e24 dB — 8.5 dB(A) effective (OSHA derating)\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eNRR (Open)\u003c\/th\u003e\n\u003ctd\u003e12 dB — 2.5 dB(A) effective (OSHA derating)\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eMax Environment — Closed\u003c\/th\u003e\n\u003ctd\u003e≈99 dB(A)\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eMax Environment — Open\u003c\/th\u003e\n\u003ctd\u003e≈93 dB(A)\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eMode Switch\u003c\/th\u003e\n\u003ctd\u003eManual — rotate the center stem to open\/close\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eReusable\u003c\/th\u003e\n\u003ctd\u003eYes — replaceable tip system\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eTips Replaceable\u003c\/th\u003e\n\u003ctd\u003eYes — replacement tips sold separately\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eCorded\u003c\/th\u003e\n\u003ctd\u003eYes — included neck cord\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003cth\u003eOSHA Standard\u003c\/th\u003e\n\u003ctd\u003e29 CFR 1910.95 Hearing Conservation\u003c\/td\u003e\n\u003c\/tr\u003e\n  \u003c\/tbody\u003e\n\u003c\/table\u003e\n\n\u003csection\u003e\n\u003ch2\u003eKey Features\u003c\/h2\u003e\n\u003cul\u003e\n  \u003cli\u003e\n\u003cstrong\u003eDual-mode protection:\u003c\/strong\u003e Rotate the stem to switch between NRR 24 (closed, maximum protection) and NRR 12 (open, situational awareness mode). No removal needed to switch modes.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eImpulse noise attenuation in open mode:\u003c\/strong\u003e The open position uses a non-linear acoustic filter that attenuates high-intensity impulse sounds (gunshots, explosions, impacts) while allowing lower-level sounds like speech and commands to pass. This is passive acoustic filtering — no batteries or electronics required.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eReplaceable tip system:\u003c\/strong\u003e The stem and housing are reusable; only the foam-tipped insert is replaced. Replacement tip sets (sold separately) extend the life of the BattlePlug housing indefinitely.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eSize S fit:\u003c\/strong\u003e BattlePlugs come in four sizes (XS, S, M, L) to accommodate different ear canal diameters. Proper size selection is critical to achieving rated NRR — do not use an incorrect size.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eCorded:\u003c\/strong\u003e Included neck cord keeps the pair accessible during rapid transitions between protection modes or when earplugs are temporarily removed.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eNo batteries:\u003c\/strong\u003e Passive acoustic design — no electronics, no charging, no failure risk in field conditions.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003c\/section\u003e\n\n\u003csection\u003e\n\u003ch2\u003eClosed vs. Open Mode — When to Use Each\u003c\/h2\u003e\n\u003ctable\u003e\n  \u003cthead\u003e\u003ctr\u003e\n\u003cth\u003eMode\u003c\/th\u003e\n\u003cth\u003eNRR\u003c\/th\u003e\n\u003cth\u003eEffective Attenuation\u003c\/th\u003e\n\u003cth\u003eBest Used When\u003c\/th\u003e\n\u003c\/tr\u003e\u003c\/thead\u003e\n  \u003ctbody\u003e\n    \u003ctr\u003e\n      \u003ctd\u003e\u003cstrong\u003eClosed\u003c\/strong\u003e\u003c\/td\u003e\n      \u003ctd\u003eNRR 24\u003c\/td\u003e\n      \u003ctd\u003e8.5 dB(A)\u003c\/td\u003e\n      \u003ctd\u003eContinuous high-noise environments; sustained machinery noise; when communication is not required (mowing, grinding, drilling)\u003c\/td\u003e\n    \u003c\/tr\u003e\n    \u003ctr\u003e\n      \u003ctd\u003e\u003cstrong\u003eOpen\u003c\/strong\u003e\u003c\/td\u003e\n      \u003ctd\u003eNRR 12\u003c\/td\u003e\n      \u003ctd\u003e2.5 dB(A)\u003c\/td\u003e\n      \u003ctd\u003eIntermittent impulse noise (firearms, explosions, impacts); environments requiring verbal communication alongside noise hazards; military\/LE operations\u003c\/td\u003e\n    \u003c\/tr\u003e\n  \u003c\/tbody\u003e\n\u003c\/table\u003e\n\u003cp\u003eIn open mode, the acoustic filter passes steady-state sounds at or below conversational levels while mechanically limiting the peak pressure of sudden high-intensity sounds. This is not electronic noise cancellation — it is a passive valve design. As a result, open mode is most effective for impulse-type noise rather than sustained industrial noise above the Action Level.\u003c\/p\u003e\n\u003c\/section\u003e\n\n\u003csection\u003e\n\u003ch2\u003eApplications\u003c\/h2\u003e\n\u003cul\u003e\n  \u003cli\u003e\n\u003cstrong\u003eMilitary and law enforcement:\u003c\/strong\u003e Original design application — allows operatives to communicate while protected against muzzle blast, breaching charges, and other impulse noise.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eFirearms training ranges:\u003c\/strong\u003e Switch to closed for sustained fire strings; open for range commands, safety briefings, and target assessment between strings.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eHunting:\u003c\/strong\u003e Open mode preserves game-hearing acuity while protecting against muzzle blast on the shot — critical for hunters who cannot predict when a shot will occur.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eDemolition and construction:\u003c\/strong\u003e Open mode for intermittent impact tools; switch to closed for sustained equipment operation.\u003c\/li\u003e\n  \u003cli\u003e\n\u003cstrong\u003eIndustrial maintenance:\u003c\/strong\u003e Workers entering and exiting noise zones — open while walking and communicating, closed during actual equipment operation.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003c\/section\u003e\n\n\u003csection\u003e\n\u003ch2\u003eSizing Guide — Choosing the Right BattlePlug Size\u003c\/h2\u003e\n\u003cp\u003eBattlePlugs require proper size selection to achieve rated NRR. An undersized earplug will not seal; an oversized earplug will be uncomfortable and may not insert fully. Available sizes:\u003c\/p\u003e\n\u003ctable\u003e\n  \u003cthead\u003e\u003ctr\u003e\n\u003cth\u003eSize\u003c\/th\u003e\n\u003cth\u003eNRR Closed\u003c\/th\u003e\n\u003cth\u003eNRR Open\u003c\/th\u003e\n\u003cth\u003eTip Color\u003c\/th\u003e\n\u003cth\u003eSKU\u003c\/th\u003e\n\u003c\/tr\u003e\u003c\/thead\u003e\n  \u003ctbody\u003e\n    \u003ctr\u003e\n\u003ctd\u003eXS\u003c\/td\u003e\n\u003ctd\u003eNRR 20\u003c\/td\u003e\n\u003ctd\u003eNRR 10\u003c\/td\u003e\n\u003ctd\u003eRed tips\u003c\/td\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6496-battleplugs-xs\"\u003e6496\u003c\/a\u003e\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003eS\u003c\/td\u003e\n\u003ctd\u003eNRR 24\u003c\/td\u003e\n\u003ctd\u003eNRR 12\u003c\/td\u003e\n\u003ctd\u003eYellow tips\u003c\/td\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6497-battleplugs-s\"\u003e6497\u003c\/a\u003e\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003eM\u003c\/td\u003e\n\u003ctd\u003eNRR 24\u003c\/td\u003e\n\u003ctd\u003eNRR 9\u003c\/td\u003e\n\u003ctd\u003eBlue tips\u003c\/td\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6498-battleplugs-m\"\u003e6498\u003c\/a\u003e\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003eL\u003c\/td\u003e\n\u003ctd\u003eNRR 24\u003c\/td\u003e\n\u003ctd\u003eNRR 12\u003c\/td\u003e\n\u003ctd\u003eGreen tips\u003c\/td\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6499-battleplugs-l\"\u003e6499\u003c\/a\u003e\u003c\/td\u003e\n\u003c\/tr\u003e\n  \u003c\/tbody\u003e\n\u003c\/table\u003e\n\u003cp\u003eIf unsure of size, most adults fit S or M. Start with M; if the earplug does not seat fully or feels oversized, try S. XS is intended for small adult ear canals. L is for larger-than-average canals. The foam tip should compress slightly on insertion and form a firm seal without forcing.\u003c\/p\u003e\n\u003c\/section\u003e\n\n\u003csection\u003e\n\u003ch2\u003eBattlePlug vs. Alternatives\u003c\/h2\u003e\n\u003ctable\u003e\n  \u003cthead\u003e\u003ctr\u003e\n\u003cth\u003eProduct\u003c\/th\u003e\n\u003cth\u003eNRR\u003c\/th\u003e\n\u003cth\u003eDual-Mode\u003c\/th\u003e\n\u003cth\u003eReusable\u003c\/th\u003e\n\u003cth\u003eBest For\u003c\/th\u003e\n\u003c\/tr\u003e\u003c\/thead\u003e\n  \u003ctbody\u003e\n    \u003ctr\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6496-battleplugs-xs\"\u003eBattlePlug XS (6496)\u003c\/a\u003e\u003c\/td\u003e\n\u003ctd\u003e20\/10\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eSmall canals, impulse noise\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6497-battleplugs-s\"\u003eBattlePlug S (6497)\u003c\/a\u003e\u003c\/td\u003e\n\u003ctd\u003e24\/12\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eS canals, firearms\/LE\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6498-battleplugs-m\"\u003eBattlePlug M (6498)\u003c\/a\u003e\u003c\/td\u003e\n\u003ctd\u003e24\/9\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eAverage canals, impulse noise\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6499-battleplugs-l\"\u003eBattlePlug L (6499)\u003c\/a\u003e\u003c\/td\u003e\n\u003ctd\u003e24\/12\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eLarger canals, firearms\/LE\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6400-rockets-corded\"\u003eRockets Corded (6400)\u003c\/a\u003e\u003c\/td\u003e\n\u003ctd\u003e26\u003c\/td\u003e\n\u003ctd\u003eNo\u003c\/td\u003e\n\u003ctd\u003eYes\u003c\/td\u003e\n\u003ctd\u003eContinuous industrial noise\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e\u003ca href=\"\/collections\/moldex-earplugs\/products\/moldex-6604-sparkplugs-uncorded\"\u003eSparkPlugs (6604)\u003c\/a\u003e\u003c\/td\u003e\n\u003ctd\u003e33\u003c\/td\u003e\n\u003ctd\u003eNo\u003c\/td\u003e\n\u003ctd\u003eNo\u003c\/td\u003e\n\u003ctd\u003eHighest NRR, disposable\u003c\/td\u003e\n\u003c\/tr\u003e\n  \u003c\/tbody\u003e\n\u003c\/table\u003e\n\u003c\/section\u003e\n\n\u003csection\u003e\n\u003ch2\u003eNRR 24 Noise Reduction (Closed Mode) — Environmental Context\u003c\/h2\u003e\n\u003ctable\u003e\n  \u003cthead\u003e\u003ctr\u003e\n\u003cth\u003eNoise Level\u003c\/th\u003e\n\u003cth\u003eEnvironment\u003c\/th\u003e\n\u003cth\u003eEffective Exposure (Closed)\u003c\/th\u003e\n\u003cth\u003eOSHA Status\u003c\/th\u003e\n\u003c\/tr\u003e\u003c\/thead\u003e\n  \u003ctbody\u003e\n    \u003ctr\u003e\n\u003ctd\u003e85 dB(A)\u003c\/td\u003e\n\u003ctd\u003eAction Level\u003c\/td\u003e\n\u003ctd\u003e76.5 dB(A)\u003c\/td\u003e\n\u003ctd style=\"color:green;\"\u003e✓ Below Action Level\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e90 dB(A)\u003c\/td\u003e\n\u003ctd\u003ePEL\u003c\/td\u003e\n\u003ctd\u003e81.5 dB(A)\u003c\/td\u003e\n\u003ctd style=\"color:green;\"\u003e✓ Below PEL\"\u0026gt;\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e95 dB(A)\u003c\/td\u003e\n\u003ctd\u003eHeavy Industry\u003c\/td\u003e\n\u003ctd\u003e86.5 dB(A)\u003c\/td\u003e\n\u003ctd style=\"color:green;\"\u003e✓ Below PEL\"\u0026gt;\u003c\/td\u003e\n\u003c\/tr\u003e\n    \u003ctr\u003e\n\u003ctd\u003e100 dB(A)\u003c\/td\u003e\n\u003ctd\u003eHigh-Noise\u003c\/td\u003e\n\u003ctd\u003e91.5 dB(A)\u003c\/td\u003e\n\u003ctd style=\"color:red;\"\u003e✗ Dual protection needed\"\u0026gt;\u003c\/td\u003e\n\u003c\/tr\u003e\n  \u003c\/tbody\u003e\n\u003c\/table\u003e\n\u003c\/section\u003e\n\n\u003csection\u003e\n\u003ch2\u003eOSHA 29 CFR 1910.95 Hearing Conservation Compliance\u003c\/h2\u003e\n\u003cp\u003eBattlePlugs are ANSI S3.19-rated hearing protectors and satisfy OSHA 29 CFR 1910.95 hearing protection requirements when used in the closed position and when the rated NRR provides adequate attenuation for the measured TWA noise level. Key points for compliance programs:\u003c\/p\u003e\n\u003cul\u003e\n  \u003cli\u003eUse the closed position (NRR 24) for OSHA TWA calculations — do not use open-mode NRR for compliance purposes in sustained-noise environments.\u003c\/li\u003e\n  \u003cli\u003eApply OSHA 50% derating: effective = (NRR 24 − 7) ÷ 2 = 8.5 dB(A). This earplug protects to 99 dB(A) TWA (single protector, closed mode).\u003c\/li\u003e\n  \u003cli\u003eOpen-mode NRR 12 is appropriate for impulse noise environments where peak pressure — not TWA — is the primary hazard. For MIL-STD-1474 and DoD impulsive noise guidelines, consult your safety officer.\u003c\/li\u003e\n  \u003cli\u003eProper size selection is mandatory for achieving rated NRR. Include BattlePlug sizing fitting in employee training.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003c\/section\u003e\n\n\u003csection\u003e\n\u003ch2\u003eFrequently Asked Questions\u003c\/h2\u003e\n\n\u003ch3\u003eIs BattlePlug Size S right for me?\u003c\/h3\u003e\n\u003cp\u003eBattlePlugs come in XS, S, M, and L to fit different ear canal diameters. Size S is designed for average adult ear canals. If you are unsure of your size, S and M are the correct starting point for most adults. Insert the earplug — it should seat firmly with the outer flange flush to the canal opening. If it seats loosely or falls out, try a larger size. If it cannot be fully inserted, try a smaller size.\u003c\/p\u003e\n\n\u003ch3\u003eHow is the open-mode acoustic filter different from electronic hearing protection?\u003c\/h3\u003e\n\u003cp\u003eThe BattlePlug open mode is entirely passive — it uses a mechanical valve and acoustic pathway that physically limits peak sound pressure without any electronics. This means no batteries, no delay between sound and protection, no failure risk due to dead batteries in the field, and no electronic artifacts in the sound. The tradeoff is that passive open-mode NRR (12) is lower than what electronic level-dependent earmuffs can achieve. For law enforcement or military use where battery failure is unacceptable, BattlePlugs are often preferred over electronic alternatives.\u003c\/p\u003e\n\n\u003ch3\u003eWhen should I replace the foam tips?\u003c\/h3\u003e\n\u003cp\u003eReplace the foam tips when the foam no longer compresses and re-expands consistently, when the tip surface is visibly contaminated (earwax, debris that cannot be cleaned), or when the tip has been used for the equivalent of 30+ shifts. Replacement tip sets are sold separately — see the BattlePlug replacement tips in the \u003ca href=\"\/collections\/moldex-earplugs\"\u003eMoldex Earplug Collection\u003c\/a\u003e. The stem housing is designed to last indefinitely with tip replacement.\u003c\/p\u003e\n\n\u003ch3\u003eCan I use BattlePlugs for industrial OSHA compliance?\u003c\/h3\u003e\n\u003cp\u003eYes — in the closed position, BattlePlugs satisfy OSHA 29 CFR 1910.95 hearing protection requirements when NRR 24 (effective 8.5 dB(A)) is adequate for the measured noise exposure. Apply the standard 50% derating. For environments requiring higher attenuation, the Moldex SparkPlugs or Pura-Fit with NRR 33 (effective 13 dB(A)) provide better single-protector coverage. BattlePlugs are particularly useful in facilities where workers need to communicate during the shift without removing hearing protection.\u003c\/p\u003e\n\n\u003ch3\u003eCan I use the combo pack to try different sizes?\u003c\/h3\u003e\n\u003cp\u003eThe Moldex BattlePlug Combo Pack (SKU 6598) includes one BattlePlug unit and one pair of Moldex SparkPlugs NRR 33 in a single package — it is not a multi-size sampler. For sizing trials, purchase individual units in each suspected size and test insertion and seal before committing to bulk quantities. Most adults find their correct size on the first or second try by starting with M and adjusting.\u003c\/p\u003e\n\u003c\/section\u003e","brand":"Moldex","offers":[{"title":"Default Title","offer_id":44052816396376,"sku":"6497","price":15.69,"currency_code":"USD","in_stock":true}],"thumbnail_url":"\/\/cdn.shopify.com\/s\/files\/1\/0594\/1900\/0920\/files\/1e2db027cc892a2c4d4664120891934b.jpg?v=1777502963","url":"https:\/\/wcsafety.com\/products\/moldex-battleplugs-6497-dual-mode-reusable-earplugs-small-nrr-24db-closed-nrr-12db-open","provider":"WC Safety","version":"1.0","type":"link"}