The 3M Combat Arms Earplug lawsuits rank among the largest and most significant mass tort litigations in U.S. history. Thousands of current and former U.S. military service members filed claims alleging that 3M designed, manufactured, and sold dual-ended Combat Arms Earplugs that failed to provide reliable hearing protection. Plaintiffs claim the earplugs could loosen after insertion, reducing their effectiveness and exposing users to dangerous noise without their awareness. Plaintiffs contend that this exposure caused permanent hearing loss, tinnitus, and other lasting auditory damage.
The litigation unfolded over several years, featuring expansive discovery, multiple bellwether trials, and a wide range of procedural rulings issued by the federal court. At its height, the MDL included over 300,000 individual claims, underscoring the unprecedented scale and complexity of the proceedings.
As of 2025, the 3M earplug litigation is in its final settlement phase, with most eligible claimants already compensated through structured settlement programs. This article reviews the latest settlement progress, current MDL case status, and recent court developments.
Background of the 3M Earplug Litigation
The 3M earplug lawsuits targeted 3M and its wholly owned subsidiary Aearo Technologies, which designed and manufactured the Combat Arms Dual-Ended Earplugs. The U.S. military supplied these earplugs to service members, who used them extensively during training exercises and combat deployments.
Plaintiffs allege that the earplugs suffered from a design defect that prevented them from consistently maintaining a proper seal in the ear canal. As a result, the earplugs could loosen during normal use without the wearer’s knowledge, diminishing their noise-blocking capabilities and exposing service members to dangerous sound levels associated with military operations.
Plaintiffs also allege that the earplugs did not meet military hearing-protection requirements and that users were not properly warned about the risk of loosening or diminished noise reduction. They claim this failure contributed to preventable hearing loss, tinnitus, and other long-term auditory injuries.
To address the unprecedented number of filings, the cases were consolidated into a federal multidistrict litigation (MDL) for coordinated pretrial management. At its height, the MDL included over 300,000 individual claims, underscoring its status as the largest mass tort litigation ever centralized in the U.S. federal courts and among the most complex product liability cases on record.
Overview of the $6 Billion Global Settlement
During 2023 and 2024, 3M announced a proposed $6 billion global settlement aimed at resolving the vast majority of claims arising from the Combat Arms Earplug litigation. The settlement was intended to conclude years of complex, resource-intensive proceedings involving hundreds of thousands of current and former U.S. military service members.
The settlement required participation from at least 98% of eligible claimants to take effect. Once claimants met that threshold, the agreement became effective, enabling the rollout of multiple compensation programs and underscoring both the unprecedented size of the litigation and the impracticality of continuing individual trials.
The primary objective of the settlement was to avoid prolonged trials and appeals while providing structured compensation to eligible claimants through an organized claims process. Under the agreement, claimants may pursue compensation through multiple settlement options, including expedited payment programs and more detailed, point-based evaluations, depending on the nature and severity of their alleged injuries.
Importantly, the settlement was reached without any admission of liability or wrongdoing by 3M. As is typical in large-scale mass tort resolutions, the company agreed to fund the settlement to resolve the claims and limit further litigation exposure, while continuing to deny the allegations asserted by plaintiffs.
Overall, the $6 billion settlement stands as one of the largest product liability resolutions involving military-issued equipment and represents a significant milestone in the gradual winding down of the 3M Combat Arms Earplug litigation.
Settlement Programs Explained
Claimants ke liye multiple compensation options introduce kiye gaye:
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Expedited Pay Program (EPP) – Fast-track, fixed payouts
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Deferred / Detailed Pay Program (DPP) – Point-based evaluation system
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Extraordinary Injury Fund (EIF) – Severe hearing injury claims
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Wave Settlements – Early bellwether verdict resolutions
Settlement Payments Progress (2025 Update)
By mid-2025, the distribution of settlement funds in the 3M Combat Arms Earplug litigation had advanced substantially, representing a significant step toward resolving one of the largest mass tort cases in U.S. history. Available settlement data indicates that more than $2.7 billion in settlement funds had already been disbursed to eligible claimants across multiple compensation programs.
The largest share of settlement payments has been distributed to participants in the Expedited Pay Program (EPP). As of 2025, more than 230,000 EPP claimants had received their settlement awards, reflecting the program’s streamlined structure and accelerated review process. Because EPP claims required less documentation and provided fixed payout amounts, they generally moved through the settlement system more efficiently than claims in other compensation categories.
Payments under the Wave Settlements and the Extraordinary Injury Fund (EIF) have also continued throughout 2025. Wave claimants, whose cases were tied to earlier bellwether trials and verdicts, were among the first to receive compensation. Payments under the Extraordinary Injury Fund (EIF) have progressed at a slower pace due to the program’s heightened medical review requirements and stricter eligibility standards, which necessitate individualized evaluations for severe injury claims.
Overall, the majority of claimants elected the Expedited Pay Program (EPP), largely due to its faster payment timeline and reduced administrative burden. Although other programs offered the potential for higher compensation, many claimants prioritized certainty and speed, contributing to the substantial volume of EPP payouts completed by mid-2025.
As settlement administration continues, additional payments are expected for remaining Deferred / Detailed Pay Program (DPP) and Extraordinary Injury Fund (EIF) claims, further reducing the number of unresolved cases and bringing the litigation closer to its final resolution.
Point Dollar Value for DPP Claimants
In 2025, an important milestone was reached for claimants participating in the Deferred / Detailed Pay Program (DPP) with the announcement of the Point Dollar Value. This calculation plays a central role in determining how much compensation DPP claimants ultimately receive under the settlement framework.
Under the DPP system, evaluators assign each claimant a specific number of points after conducting a detailed, individualized review of the claim. They determine point values by weighing multiple factors, including the severity of the alleged hearing injury, the length and nature of military service, documented noise exposure, and the strength of supporting medical and service records. Claims involving more severe injuries or stronger supporting documentation generally receive higher point totals.
Once all eligible DPP claims are scored, the settlement funds allocated to the DPP are divided by the total number of points awarded across participating claimants. This calculation establishes the per-point dollar value, which determines how much each individual point is worth at that stage of the settlement process.
A claimant’s final payout is then calculated by multiplying their assigned point total by the established per-point dollar value. As a result, DPP compensation amounts can vary significantly from claimant to claimant, depending on both their individual point score and the final dollar value assigned to each point.
Because the Point Dollar Value depends on both the number of participating claimants and the funds available at a given time, administrators may calculate it in phases rather than as a single fixed amount. This phased approach reflects the complexity of managing large-scale settlements and allows administrators to adjust payment amounts as claims continue through review and resolution.
Overall, the Point Dollar Value system delivers a more individualized compensation framework for DPP claimants by rewarding claims supported by stronger documentation and more severe injuries while maintaining consistency and transparency throughout the settlement process.
Current MDL Case Count Status
As of 2025, the number of pending cases in the 3M Combat Arms Earplug multidistrict litigation (MDL) has declined dramatically, indicating that the litigation is approaching its final stages. At its peak, the MDL encompassed more than 300,000 individual cases, making it the largest mass tort proceeding ever consolidated in the U.S. federal court system. That number has now been reduced to only a few thousand remaining cases.
This substantial reduction is largely the result of the global settlement’s ongoing administration. As settlement payments have been processed, cases have been formally dismissed from the MDL docket. In addition, the court and settlement administrators conducted extensive case cleanup efforts, which included the dismissal of duplicate filings, incomplete claims, and cases that failed to meet settlement eligibility or documentation requirements.
The steady decline in pending cases also reflects the resolution of claims through multiple settlement programs, including expedited payments, wave settlements, and point-based evaluations. As more claims are finalized and paid, the MDL continues to shrink month by month.
Overall, the MDL has entered its winding-down phase, with only residual administrative matters and a limited number of unresolved claims remaining. While final payments continue and the court resolves remaining issues, the declining case count shows that the litigation is nearing its conclusion after years of large-scale federal court proceedings.
Insurance Disputes and Court Orders
Despite the implementation of the global settlement, legal disputes have continued between 3M and several of its insurance carriers over coverage obligations and defense costs related to the Combat Arms Earplug litigation. These disputes primarily focus on whether insurers must reimburse 3M or its subsidiary for hundreds of millions of dollars in legal defense and settlement-related expenses.
In a series of court rulings, judges have closely examined the scope and language of insurance policies issued to Aearo Technologies, the subsidiary responsible for manufacturing the Combat Arms Earplugs. Courts have generally ruled that certain insurance policies issued in Aearo’s name do not automatically extend coverage to 3M for all defense or settlement costs. As a result, insurers have contested their responsibility to contribute to portions of the litigation expenses, leading to ongoing arbitration and coverage litigation.
The courts have also issued multiple procedural and compliance-related orders throughout the settlement administration process. These orders have addressed matters such as claim submission requirements, attorney compliance with case management directives, lien resolution procedures, and the timely distribution of settlement funds. Judges overseeing the MDL have consistently emphasized strict adherence to these orders to promote fairness, transparency, and efficiency as the litigation enters its final stages.
Importantly, these insurance disputes and related court orders do not directly impact claimant settlement payments because the settlement framework, not insurance reimbursement outcomes, funds compensation. Instead, they represent a separate aspect of the litigation’s endgame, focused on allocating financial responsibility among corporate entities and insurers rather than determining compensation for individual claimants.
Overall, while these disputes may continue beyond the bulk of settlement payments, they are largely administrative and financial in nature and do not alter the resolution already achieved for participating claimants.
Are New Individual Lawsuits Still Possible?
As a general rule, the court no longer accepts new claims into the 3M Combat Arms Earplug multidistrict litigation (MDL). After the global settlement took effect and court-imposed deadlines expired, the MDL closed to new filings. As a result, individuals who did not previously file claims or enroll in the settlement program generally cannot join the MDL at this stage.
However, in limited and fact-specific circumstances, individual lawsuits outside the MDL framework may still be possible. Such cases would not fall within the scope of the global settlement and, if viable, would typically proceed as standalone actions rather than as part of the consolidated MDL proceedings.
Potential scenarios in which individuals may still pursue individual claims include:
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Products or circumstances excluded from the settlement, including claims involving earplug models or usage scenarios not covered under the terms of the settlement agreement.
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Post-settlement damages, where a claimant alleges new or newly discovered injuries that occurred or became apparent after the settlement period.
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Strong, well-documented medical evidence, particularly in cases involving severe hearing loss or tinnitus supported by contemporaneous medical records and clear proof of causation.
It is important to note that these situations are exceptional rather than typical, and pursuing an individual lawsuit may involve significant legal and procedural challenges. Factors such as applicable statutes of limitation, prior settlement releases, and evidentiary burdens can play a critical role in determining whether a claim is legally viable.
Because each potential claim depends heavily on its specific facts, individuals considering legal action related to the Combat Arms Earplugs should consult a qualified attorney who can evaluate their circumstances under the settlement terms and applicable law.
Final Thoughts
The 3M Combat Arms Earplug litigation shows how large-scale product liability cases can extend over many years before courts resolve them through structured, court-approved settlements. What began as individual claims filed by military service members evolved into the largest multidistrict litigation in U.S. history, involving extensive discovery, bellwether trials, and a highly complex settlement process.
The global settlement reflects the practical realities of mass tort litigation, providing a structured resolution for the vast majority of claimants while allowing the litigation to move toward its conclusion. Although outcomes varied among participants, the settlement offered a clear path to compensation and closure after years of legal uncertainty.
As the MDL continues to wind down, remaining activity primarily involves final payments and administrative matters rather than new claims or trials. For many affected service members, the focus has now shifted from ongoing litigation to resolution.
At LawsuitDeck.com, we will continue to provide timely, factual, and clearly explained updates on major mass tort and product liability cases, including developments related to the 3M earplug settlement, to help readers stay informed and understand what to expect next.
Disclaimer: This article provides general information, not legal advice. If you have any questions about this, please don’t hesitate to contact us.
Muhammad Suleman Ahmad is a content writer covering lawsuits, legal explainers, and court-related topics for LawsuitDeck.com. His work is structured for clarity and general understanding.
