About ActivArmor™

the global leader in 3D printed waterproof cast Alternatives

We leverage revolutionary 3D printing technology to create ActivArmor cast and splints that support patients' active lifestyles.

Backed by Orthopedic, Pediatric, Olympic,

and Sports Medicine Experts.

Dr. Keith Michael Nord, MD

Chief Medical Officer and Physician Advisor for ActivArmor.

Dr Nord brings deep clinical expertise in orthopedic surgery, hand surgery, and upper extremity care. He is a board-certified orthopedic surgeon and board-certified hand surgeon with fellowship training in Hand & Upper Extremity Surgery from OrthoCarolina in Charlotte, North Carolina. Dr. Nord completed his orthopedic surgery residency at the University of Arkansas for Medical Sciences and earned his medical degree from the University of Tennessee Health Science Center in Memphis. His specialized experience in orthopedic and hand care helps inform ActivArmor’s clinical direction and its mission to improve modern immobilization care.
Dr. Ralph Bovard

Physician Advisor for ActivArmor and is the Co-Founder of Exos, Inc.
Dr. Ralph Bovard serves as a board-certified occupational and preventive medicine physician with more than 30 years of clinical experience, Dr. Bovard brings deep expertise in sports medicine, occupational health, patient recovery, and real-world healthcare innovation. His work as a physician, founder, medical advisor, and consultant gives him valuable perspective on how new medical technologies move from concept to practical use. His clinical and advisory background helps inform ActivArmor’s mission to advance modern immobilization care for patients, providers, and active individuals.
Dr. Gloria Beim

Physician Advisor for ActivArmor and and US Olympic Team Physician.

Dr Beim is an award-winning sports medicine specialist, orthopedic surgeon, and US Olympic Team Physician. She has held major medical leadership roles across the Olympic and Paralympic movement, including serving as Head Team Physician for Team USA at the 2024 Paris Olympic Games, Chief Medical Officer for Team USA at the 2014 Sochi Winter Olympic Games, and Head Team Physician for Team USA in Livigno at the Milano Cortina 2026 Olympic Winter Games. Since 2001, Dr. Beim has contributed to medical teams and leadership roles at multiple Olympic and Paralympic Games, bringing deep experience in sports medicine, orthopedic care, athlete recovery, and high-performance medical support. Her clinical leadership helps inform ActivArmor’s mission to advance modern immobilization care for active patients, providers, and performance-focused care settings.
Listen to Dr. Beim speak on the latest in high-tech immobilization options at the BSATSMC conference.
Dr. Peter F. Armstrong

Retired CMO, Shriners Hospitals and OrthoPediatrics.

Dr. Peter F. Armstrong, MD, FRCSC, FAOA, FACS, FAAP, is an internationally recognized pediatric orthopaedic surgeon and healthcare leader with more than five decades of clinical, academic, and executive experience. He has served on the orthopaedic staff at The Hospital for Sick Children in Toronto, as Chief of Staff at Shriners Hospitals for Children Intermountain, Professor of Orthopaedic Surgery at the University of Utah, and Chief Medical Officer for the 22 Shriners Hospitals for Children. A former Chief Medical Officer for OrthoPediatrics and founder of the Armstrong Children’s Orthopaedic Alliance, Dr. Armstrong brings deep expertise in pediatric orthopaedic education, safety, value, and innovation to ActivArmor’s Advisory Board.
Dr. Amanda Harding

Physician Advisor for ActivArmor and Board-Certified Pediatrician.

Dr. Amanda Harding serves as Physician Advisor for ActivArmor and is a board-certified pediatrician dedicated to supporting the health and care of children and families. Her pediatric expertise brings a valuable perspective to ActivArmor’s mission, particularly in helping address the comfort, safety, and real-world needs of younger patients during recovery. Her work with Zzap health also reflects her interest in practical, patient-centered innovation for children and families. As a physician advisor, Dr. Harding helps inform ActivArmor’s continued work to advance modern immobilization care for patients, providers, and families.
Dr. Kevin Kaplan

Physician Advisor and NFL Team Physician.
Dr. Kevin Kaplan serves as an Advisory Board Member for ActivArmor and is a board-certified orthopedic surgeon and sports medicine specialist with deep experience in elite athlete care. Since 2013, he has served as Head Team Physician for the NFL’s Jacksonville Jaguars, becoming the youngest head team physician in NFL history when he assumed the role. He also served as an assistant team physician for the Los Angeles Lakers, Los Angeles Dodgers, Los Angeles Kings, and Anaheim Ducks during his fellowship at the Kerlan-Jobe Orthopaedic Clinic. His sports medicine expertise helps guide ActivArmor’s work to improve modern immobilization care for active patients, athletes, and providers.
Listen to Dr.Kaplan speak on ActivArmor in his practice.
Dr. Michael Redler

Physician Advisor and Orthopedic Sports Medicine Specialist.
A board-certified orthopedic surgeon with over 40 years of experience specializing in sports medicine and upper extremity surgery, has significantly contributed to the field through his role as a founding partner of The Orthopaedic and Sports Medicine Center, which merged with Connecticut Orthopaedics in 2018. His extensive expertise, including designing surgical instruments and lecturing globally, enhances his impactful advisory board contribution at ActivArmor, particularly in advancing orthopedic care and education.

ABOUT OUR Leadership TEAM

Diana Hall wearing a pink ActivArmor cast

A Colorado School of Mines graduate in Chemical Engineering, Diana Hall founded ActivArmor in 2014 while running a mentoring program for children living in poverty.
After working in Fortune 500 companies across the country and finishing her master’s degree in Business from Colorado State University in Fort Collins, Diana moved back to her hometown of Pueblo, CO, to advocate for children on Pueblo’s east side.
Through the mentoring program, Diana worked with children involved in domestic violence situations and living in substandard conditions. The children who wore casts would get them filthy after just weeks of wear from simply playing on the playground or going to school.
“The children with casts for 5 weeks could not even wash their hands to have a snack! One girl had bed bugs in her cast. Another little boy was being raised by his disabled grandparents and was not able to keep his cast dry when showering by himself. He got his cast wet and did not want to get in trouble and had no transportation to get it replaced, so he did not tell and ended up with permanent scarring on his arm from the skin breakdown. That’s when I knew I had to come up with a better solution.”
Adam Halen has extensive experience as the founder and CEO of Halen Digital Marketing. With over a decade in digital marketing, he specializes in innovative social media strategies and content production.
Adam's expertise has been instrumental in enhancing ActivArmor's online presence and effectively communicating its mission to a broader audience. His strategic insights have positioned ActivArmor as a leader in 3D-printed waterproof cast alternatives.
Beyond his marketing role, Adam is a sought-after speaker and consultant, regularly sharing his knowledge at industry conferences and events.

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About Our Solution

Diana’s mission was to create a better alternative to casting and splinting by leveraging additive manufacturing.

The goal: Create breathable casts and splints using hygienic materials and a custom-fit design that allows for improved healing, treatment options and the freedom of maintaining an active lifestyle.

The challenge: After researching the current cast options, Diana found that there were many reasons why this technology and product was not available to American consumers.

The solution: ActivArmor’s team of global leaders, engineers, top orthopedic surgeons and sports medicine doctors, regulatory compliance experts, athletes and patients addressed these challenges over 3 years of field tests and hundreds of commercial sales. ActivArmor is now available in clinics across the globe, being worn by professional athletes and patients worldwide.

Problem: Design and fabrication of custom splints by hand takes both time and labor.
Solution: Leverage revolutionary 3D technology to produce custom ActivArmor cast and splints
Problem: Casts need to be strong enough to heal patient limbs but made with lightweight materials.
Solution: Find the ideal balance of thickness and coverage area (for protection of a broken limb) and lightweight breath-ability (for comfort and freedom for the patient).
Problem: Casts need to be durable enough to be used in sports, while still low-profile enough to allow for maximized mobility and freedom of movement.
Solution: Source 100% ABS (Acrylonitrile butadiene styrene) – a stable, hard, and durable plastic used in toys, food packaging, and surgical tools.
Problem: Casts need to pass regulations and can’t trap moisture or bacteria against the skin.
Solution: Ensure 3D printed materials and finished products are biocompatible and non-porous.

Problem: Casts need to be custom because every patient’s limbs and injuries are unique.
Solution: Implement the right equipment with the right process and quality controls to ensure a precise fit to the limb for accurate immobilization of parts as small as fingers for comfort and ideal healing outcomes.
Problem: Casts need to be easily adapted by clinics.
Solution: Implement software that makes it easy for physicians to use.
Problem: Casts need to be locked-on like a cast, but also removable like a splint.
Solution: Design cast with strong, locking nylon zip ties with adaptable bungee closure kit, to be applicable for both acute injuries and chronic conditions.
Problem: Casts need to be accessible to everyone.
Solution: Make casts available in the same price range as traditional splints, and covered by insurance by developing the latest technology in precision scanning hardware and software affordable, including the labor of CAD design unique to each patient, fabrication and hand-finishing of each device in an FDA-registered manufacturing facility.