An earplug assembly includes a first earplug, a second earplug, and a cord including a first end, a second end, each earplug including a stem and a sound attenuating body. A method for preparing the earplug assembly includes attaching the first and second ends of the cord to the first and second earplugs, respectively, by contacting a hot tip to the proximal end of the stem of the earplug to form an attachment point, removing the hot tip, and contacting or inserting the end of the cord to the attachment point to thermally bond the end of the cord to the stem of the earplug.
