What was recalled
In the summer of 2021, specifically on July 21st, a significant safety alert was issued by the U.S. Consumer Product Safety Commission (CPSC) involving products from American Outdoor Brands. This recall centers on a specific accessory for shooting sports enthusiasts: the Caldwell® rechargeable lithium-battery pack. It is important to understand that this is not a recall of the earmuffs themselves, but rather the power source designed to operate them. The battery pack was originally included with black E-Max® Pro BT Earmuffs, which are electronic hearing protection devices used to shield ears from loud noises while shooting firearms. These earmuffs allow users to hear conversation clearly while blocking out harmful decibel levels, making them a popular choice for range safety.
To determine if you possess the specific item involved in this recall, you need to look closely at the battery pack housed within one of the earmuff cups. The recalled unit is identified by SKU number 1108859. Visually, this battery pack has a distinct gray exterior and bears the "Caldwell" name printed on its surface. In terms of physical dimensions, it measures approximately 1.25 inches by 1.5 inches. Technically, it is a 3.7-volt lithium-ion battery designed to be recharged via USB. While the E-Max® Pro BT Earmuffs (SKU No. 1099596) are capable of operating on three AAA alkaline batteries as well, this recall applies strictly to the model that came equipped with or utilizes the specific rechargeable lithium-battery pack mentioned above.
Understanding where and how these items were sold helps contextualize the scope of the recall. These products were marketed toward consumers who engage in shooting sports, providing a blend of hearing protection and electronic amplification for situational awareness. The inclusion of the rechargeable lithium battery was intended to offer convenience for frequent users who did not wish to constantly replace disposable alkaline cells. However, it is crucial to note that the official recall notice does not specify the exact number of units sold or distributed globally. Furthermore, while the CPSC investigation highlighted the potential for overheating due to internal soldering issues within the battery housing, there were no reported incidents of fire or burn injuries associated with this specific batch at the time of the announcement. If you own black E-Max® Pro BT Earmuffs that came with a gray Caldwell rechargeable lithium battery pack (SKU 1108859), it is essential to treat this as a serious safety concern regardless of whether any accidents have been publicly reported.
The hazard, explained
To understand why this recall is necessary, it helps to look at what is happening inside the Caldwell E-Max® Pro BT Earmuffs, specifically within the rechargeable lithium-battery pack housed in one of the ear cups. The core issue lies in the soldering connections that secure the internal wiring to the battery’s terminals. Over time, or potentially due to a manufacturing variance, these solder joints can become compromised or detach. In electronics, solder acts as the conductive bridge that allows electricity to flow safely from the battery cells to the device’s circuitry. When that connection fails or becomes loose, it creates an unstable electrical path.
When wiring detaches or makes intermittent contact in this manner, it often results in a phenomenon known as arcing or excessive resistance. Instead of electricity flowing smoothly through the intended circuit to power the earmuffs’ Bluetooth and hearing protection features, the energy is concentrated at the point of failure. This concentration generates significant heat rapidly. Because this occurs inside the small, enclosed housing of the lithium-battery pack, the heat has nowhere to dissipate effectively. Lithium-ion batteries are sensitive to temperature; when they overheat due to internal electrical faults rather than external conditions, their chemical stability can be compromised.
The result of this thermal buildup is a dual threat: fire and burn hazards. First, the extreme local heating can ignite nearby materials within the earmuff casing or the battery pack itself, leading to a fire. While reports indicate no incidents have been reported to date with this specific batch, the potential for ignition is real when lithium cells are subjected to uncontrolled thermal stress. Second, even if a full-blown fire does not occur, the external surface of the battery pack can become hot enough to cause painful skin burns upon contact. Since these earmuffs are worn directly against the head and ears for extended periods while shooting, a user could sustain serious thermal injuries simply by wearing the defective unit.
It is important to distinguish this from normal battery behavior. Standard lithium batteries do not get dangerously hot during regular use if functioning correctly. This hazard is specific to the physical failure of the soldering within the pack housing (SKU No. 1108859). The mechanism is purely electrical and mechanical: a broken or weak connection creates heat, and that heat poses the risk. By removing the battery pack immediately, you eliminate the source of this potential energy release, ensuring your safety while you wait for instructions on disposal and replacement with safer alkaline alternatives.
Who is most at risk
The primary group affected by this recall consists of individuals who have purchased the Caldwell® E-Max® Pro BT Earmuffs, specifically those units that came bundled with the problematic rechargeable lithium-battery pack (SKU No. 1108859). These earmuffs are designed to provide hearing protection while shooting firearms, meaning they are typically used by recreational shooters, hunters, and professional marksmen. If you own this specific model and relied on the included rechargeable battery rather than the alternative three AAA alkaline batteries, your device is part of this safety notice. The risk is not inherent to all Caldwell products, but is isolated to this particular configuration where the lithium-ion power source is integrated into one of the ear cups.
While the CPSC reports no incidents of fire or burns have been reported to date, the potential for harm exists due to the nature of the defect. The hazard stems from internal soldering within the battery pack housing, which can allow wiring to detach and cause the unit to overheat. For the average adult user, the most immediate danger is a burn injury. Lithium-ion batteries, when they malfunction or overheat, can become extremely hot very quickly. If the earmuffs are in use on your head during shooting, an overheating battery pack located inside the ear cup poses a direct thermal risk to the skin and ears. This could result in painful burns, blistering, or tissue damage, particularly if the user is wearing the device for extended periods without noticing the temperature rise.
We must also consider who might be most vulnerable in a scenario where a fire were to ignite. While no fires have been reported yet, lithium battery fires can escalate rapidly and produce toxic fumes. Individuals with respiratory conditions, such as asthma or COPD, could be at heightened risk if a battery were to vent smoke or catch fire in an enclosed space, such as a vehicle or a small shooting range stall. Additionally, while the product is marketed toward adult shooters, there is always a possibility that these devices are used in shared environments or by younger individuals who may not recognize the warning signs of overheating, such as unusual heat or swelling of the battery casing. Children and the elderly may also have thinner skin, making them more susceptible to burn injuries from contact with hot surfaces.
Furthermore, the risk extends beyond physical injury to property damage. If a user fails to remove the recalled battery pack and continues to charge it or use it until it fails catastrophically, there is a theoretical risk of igniting nearby flammable materials, such as clothing, hearing protection cases, or other gear stored in close proximity. Therefore, anyone who owns this specific SKU combination should treat this recall with urgency, not just for their personal safety but to prevent potential secondary hazards in their home or storage areas.
How to tell if you have the recalled item
Before taking any action, it is essential to confirm whether your specific pair of hearing protection falls under this recall. Because American Outdoor Brands manufactures various shooting accessories, identifying the exact model and its components can sometimes be tricky. The recall targets a very specific configuration: the E-Max® Pro BT Earmuffs (SKU No. 1099596) that were sold with a particular rechargeable lithium-battery pack attached. If you own E-Max earmuffs but they use standard disposable batteries or a different charging system, they are likely not part of this specific safety notice. However, if your earmuffs came with the included rechargeable unit, please read on carefully.
The most critical step is to locate the product packaging or the original sales receipt, as these documents contain the definitive proof of purchase. Look for the Stock Keeping Unit (SKU) numbers printed clearly on the box or label. The recalled earmuffs will be identified by SKU No. 1099596. It is also helpful to note that these are black E-Max® Pro BT models designed primarily for hearing protection while shooting firearms. If you purchased the batteries separately or have a different model number, this recall does not apply to your item.
If you no longer have the box, you must inspect the physical product itself, specifically focusing on the battery pack housed within one of the earmuffs. This is where the hazard originates, so precise identification here is vital. The recalled lithium-battery pack has several distinct visual characteristics that set it apart from other options. First, check the exterior color; the specific housing in question is gray. Second, look for the branding: the name "Caldwell" must be printed on the exterior of the battery pack. Third, verify the technical specifications if visible or known: the unit is a 3.7 V battery with physical dimensions of approximately 1.25 inches by 1.5 inches. If your battery pack matches these gray, branded, and dimensional criteria, it is the recalled component.
It is important to understand that the recall applies to the rechargeable lithium-battery pack (SKU No. 1108859) itself when included with the earmuffs. Even if you have since switched your earmuffs to use three AAA alkaline batteries for daily use, the presence of the original gray Caldwell lithium pack means you still possess a recalled item that needs to be addressed. Do not assume that because you are using alkaline batteries now, you are safe from the risk; the defective lithium unit may still be stored nearby or attached to the device. Please remove this specific gray battery pack immediately and follow the disposal instructions provided by the manufacturer.
What to do — step by step
If you own the Caldwell E-Max Pro BT Earmuffs equipped with the specific rechargeable lithium-battery pack described in this recall, your immediate priority is to eliminate the risk of fire or burns. The remedy provided by American Outdoor Brands is straightforward but requires prompt action. Please follow these steps carefully to ensure your safety and resolve the issue. First and foremost, you must immediately stop using the recalled component. Do not attempt to charge the battery, do not use the earmuffs with this specific pack, and do not try to fix the wiring or soldering yourself. The hazard stems from internal wiring that can detach due to faulty soldering within the battery housing. Attempting to open the unit or tamper with it could trigger the very overheating event you are trying to avoid. Simply taking the battery out is the safest first move, but do not discard it in your regular household trash yet. Second, carefully remove the recalled lithium-battery pack from one of the earmuffs. This specific pack is housed inside one of the ear cups and has a gray exterior with "Caldwell" printed on the outside. It measures 1.25 inches by 1.5 inches and operates at 3.7 V. If you have swapped it out for the alternative power source mentioned in the product description, you may continue to use your earmuffs safely, provided they are running on three standard AAA alkaline batteries instead of the recalled lithium pack. Third, contact American Outdoor Brands to get instructions on how to dispose of the hazardous battery pack and to receive your free replacement. You should reach out via one of the following methods: * Call their toll-free number at 877-416-5167. They are available Monday through Thursday from 8 a.m. to 5 p.m. CT, and on Fridays from 8 a.m. to 2 p.m. CT. * Email them directly at support@caldwellshooting.com. * Visit their dedicated recall page at www.caldwellshooting.com/recall or go to www.caldwellshooting.com and click the "Recall" link under "Customer Service" at the bottom of the page. When you contact them, they will provide disposal instructions that comply with local laws for lithium batteries. Importantly, American Outdoor Brands is offering free replacement alkaline batteries, including shipping costs, to affected consumers. This means you do not need to pay for new batteries or return the faulty pack if they instruct you otherwise; simply follow their specific guidance. By taking these steps, you turn a potential safety hazard into a simple customer service interaction, ensuring your hearing protection remains reliable and safe for future use at the range.Your refund, repair, or replacement options
If you have determined that your Caldwell E-Max® Pro BT Earmuffs are part of this recall, the good news is that American Outdoor Brands has established a clear and accessible remedy to ensure your safety without placing a financial burden on you. It is important to understand upfront that there is no traditional "refund" or monetary reimbursement involved in this specific process. Instead, the company is offering a free replacement solution focused entirely on resolving the hazardous component. The core of their offer is a set of free alkaline batteries, which are included with shipping costs covered by the manufacturer. This approach is designed to be straightforward: you remove the dangerous part, and they provide a safe, reliable alternative so you can continue using your hearing protection gear without worry.
The first step in securing your remedy is immediate action regarding the recalled lithium-battery pack. You must carefully remove the gray lithium-battery pack from one of the earmuffs. This unit measures 1.25 inches by 1.5 inches and bears the "Caldwell" name on its exterior. Because the hazard involves potential overheating due to detached wiring, do not attempt to recharge or use this specific battery pack again. Once removed, you should contact American Outdoor Brands for specific disposal instructions that comply with your local laws regarding lithium batteries. This step is crucial not only for your safety but also for proper environmental handling of potentially unstable power sources. The company emphasizes that they will guide you on how to dispose of the recalled pack correctly, so do not simply throw it in regular household trash without their guidance.
To initiate the process for receiving your free replacement alkaline batteries, you can reach American Outdoor Brands through several convenient channels. You may call their toll-free number at 877-416-5167. For those who prefer written communication or detailed information, you can send an email to support@caldwellshooting.com. Additionally, the company maintains a dedicated section on their website for this recall. You can visit www.caldwellshooting.com/recall or go to the main site and click the "Recall" link located under the "Customer Service" menu at the bottom of the page. These digital resources provide comprehensive details to ensure you have all the necessary context before making contact.
When you reach out, keep in mind their customer service hours to ensure you get timely assistance. Phone support is available from 8 a.m. to 5 p.m. Central Time Monday through Thursday, and from 8 a.m. to 2 p.m. Central Time on Fridays. Email support is likely available outside these hours, but phone lines will be closed during weekends and after hours. By following this process, you are not just getting free batteries; you are effectively converting your dangerous rechargeable device into a safe, non-rechargeable one using standard AAA alkaline cells. This remedy eliminates the fire risk entirely while allowing you to maintain the functionality of your hearing protection for shooting sports.
What can happen if you ignore it
It is natural to want to finish a job or enjoy a hobby without interruption, but ignoring this recall carries risks that extend far beyond the inconvenience of buying new batteries. The core issue with these specific Caldwell E-Max® Pro BT Earmuffs lies in the internal construction of the rechargeable lithium-battery pack (SKU No. 1108859). The recall notice highlights a critical manufacturing flaw: the soldering within the battery housing is prone to failure. This is not merely a matter of the battery losing its charge prematurely; it is a structural integrity issue that can lead to immediate physical danger.
If you continue to use the earmuffs with the recalled lithium pack installed, you are essentially keeping a potential fire source inside a device worn directly against your head. The solder joints that hold the wiring in place can detach due to normal vibration, heat cycles, or even minor physical stress during handling. When these connections fail, they do not simply stop working; they often create an electrical short circuit. A short circuit within a lithium-ion battery generates intense, rapid heat because the energy has no controlled path to follow. This overheating is the primary mechanism behind the burn hazard mentioned in the official recall.
The consequences of this failure mode can be severe and sudden. Lithium batteries that overheat due to internal shorts are at risk of thermal runaway, a condition where the heat generated causes further chemical reactions that produce even more heat. In the worst-case scenario, this can lead to the battery casing rupturing, releasing hot gases, or in extreme cases, igniting nearby materials. Because these earmuffs are designed to be worn for extended periods while shooting, your head and ears are in close proximity to the failure point. A burn injury in this area is particularly dangerous and difficult to treat, potentially causing permanent damage to sensitive tissue.
Furthermore, there is a secondary risk of fire in your home or vehicle. If the battery continues to overheat while stored in a pocket, on a shelf, or inside a case after you have finished using it, it can ignite surrounding items. While the Consumer Product Safety Commission (CPSC) reports no incidents for this specific batch as of the recall date, the absence of reported injuries does not mean the risk is zero. It means that so far, luck has intervened. Relying on luck when dealing with electrical components near your body is a dangerous gamble. The heat generated by a failing solder joint can also damage the plastic housing of the earmuffs themselves, causing them to melt or deform, which renders the hearing protection useless exactly when you need it most.
Ignoring the recall also means you are forgoing a free remedy. By continuing to use the defective lithium pack, you are not saving money in the long run; you are risking costly medical attention or property damage to avoid a few minutes of effort. The manufacturer has provided a clear, free path to safety: swapping the dangerous lithium pack for standard alkaline batteries. Choosing to disregard this offer leaves you exposed to a known, preventable hazard that could result in serious injury or fire, turning a simple shooting accessory into a genuine threat to your well-being.
Staying safe: broader tips
While this specific recall addresses a manufacturing defect in the Caldwell E-Max Pro BT earmuffs, it serves as a timely reminder that lithium-ion batteries are powerful but sensitive components that require respect and proper care. These batteries power everything from our smartphones to power tools and hearing protection devices, and understanding how to handle them can prevent fire hazards in your home generally. The core issue here was internal wiring detachment due to soldering flaws, but even with high-quality products, batteries can degrade or fail if mistreated. To stay safe, always use only the charger and battery type specified by the manufacturer. Using mismatched chargers is a leading cause of lithium-ion battery failures because it can force too much current into the cell, causing it to overheat uncontrollably.
Proper storage and disposal are equally critical for long-term safety. Never store spare lithium batteries in your pocket or purse where loose keys or coins can bridge the contacts and create a short circuit. Instead, keep them in their original packaging or in individual plastic cases until you are ready to use them. When it comes time to dispose of old or damaged batteries, do not throw them in the regular trash. Lithium batteries can ignite in garbage trucks and landfills if crushed. Look for local hazardous waste collection sites or electronics recycling programs that accept lithium-ion cells, ensuring they are handled by professionals who can neutralize any remaining charge safely.
Beyond battery safety, proactive maintenance of your electronic devices is the best defense against unexpected failures. Regularly inspect the charging ports and cables on all your devices for signs of wear, fraying, or damage. If a cable feels hot to the touch while charging, unplug it immediately; this indicates excessive resistance or a fault in the power delivery system. Additionally, keep your electronic gear away from direct sunlight and extreme temperatures, as heat is the enemy of battery integrity. For those who enjoy shooting sports or other hobbies involving electronic equipment, consider establishing a routine check-up for all gear at the start of each season.
Finally, make checking for recalls a regular habit rather than a reactive one. Many consumers only learn about recalls after hearing about an incident in the news, but acting early prevents risk entirely. You can sign up for email alerts from the U.S. Consumer Product Safety Commission (CPSC) to receive notifications about new recalls relevant to your household. By staying informed and treating all electronic components with caution, you ensure that your gear remains a tool for enjoyment rather than a source of danger.