3D Printed Casts & Splints: Market Validated For A Decade

Ten Years of ActivArmor

Breakthroughs in medical devices don’t happen overnight. It takes years of research, development, testing, and real-world validation to bring truly transformative solutions to patients. For over a decade, ActivArmor has been at the forefront of a revolution in orthopedic care, leading the charge with 3D printed casts and splints that redefine how patients recover from fractures. With global market validation and years of proven outcomes, ActivArmor is setting a new standard in the world of custom, waterproof, and functional cast alternatives.

A revolution in value-based orthopedic care

Traditional plaster and fiberglass casts have long been the only solution for immobilizing fractures and injuries. However, these rigid and uncomfortable options come with numerous drawbacks: they trap heat and moisture, often leading to discomfort, skin irritation, and hygiene challenges. Moreover, they severely limit a patient’s lifestyle, making it difficult to shower, exercise, and engage in day-to-day activities. Today, ActivArmor offers a game-changing cast alternative that addresses all these concerns. Over the last decade, ActivArmor has been delivering 3D printed casts and splints that are breathable, water-resistant, lightweight, and custom-fit. By leveraging 3D printing technology, ActivArmor provides patients with a comfortable, functional, and superior option to traditional casts, without sacrificing the immobilization and protection needed for proper healing.

A decade of 3D printing and customization

ActivArmor's rise over the past decade is rooted in cutting-edge 3D scanning and printing technologies. Unlike traditional one-size-fits-all casts, each ActivArmor device is custom fabricated to the patient’s unique anatomy using a precise 3D scan of the injured area. This ensures a perfect fit that improves comfort and optimizes the healing process by providing targeted support exactly where needed.

Since its founding, ActivArmor has continuously refined its technology, incorporating patient and physician feedback to develop splints and casts that meet the demands of modern recovery. Even just this year, ActivArmor launched a new iPhone scanning app, ActivArmor Scan Pro, to make the fabrication process for providers even easier. This commitment to innovation and improvement has driven the company’s market success, with countless patients and providers trusting ActivArmor to deliver superior healing solutions.

Market-validated success

After ten years in the market, ActivArmor’s products have been widely validated by both patients and healthcare providers alike. The innovative casts and splints are used by some of the most respected orthopedic clinics, hospitals, and sports medicine professionals across the country. This widespread adoption is a testament to the quality, efficacy, and demand for ActivArmor.

ActivArmor patient testimonials are also overwhelmingly positive. People of all ages and activity levels—children, professional athletes, and senior citizens—report better comfort, faster recovery times, and an overall improved healing experience when using ActivArmor. Clinics that have adopted the technology also report higher patient satisfaction, fewer complications related to cast hygiene, and improved compliance with treatment protocols.

Benefits of cast alternatives

What makes ActivArmor’s 3D-printed casts and splints stand out from traditional options? Here are the key benefits that have driven its success over the past decade:

1. Breathability and Comfort

ActivArmor’s open-lattice design allows air to circulate around the injury, keeping the skin dry and comfortable. Patients are no longer plagued by the heat, itchiness, odor, and even claustrophobia that come with traditional casts. The breathable design also helps prevent skin breakdown and irritation, ensuring a healthier recovery experience.

2. Waterproof

Unlike traditional casts that must be kept dry, ActivArmor casts are waterproof. Patients can shower, swim, and continue daily activities without worrying about damaging their cast. This water resistance is a game-changer for athletes, active individuals, and anyone looking to maintain a normal lifestyle while healing.

3. Custom fitted

Using 3D scanning technology, each ActivArmor cast is perfectly tailored to the patient’s unique native anatomy. This custom fit ensures improved comfort for the patient and proper immobilization and support, enhancing the healing process and reducing the risk of complications. 

4. Custom designed

Providers can also customize ActivArmor to be thick or thin, locked-on or removable, with unlimited coverage-area designs that can include hands, wrists, thumb, any combination of fingers, ankles and feet.  Custom offsets to protect but avoid incisions, wounds, wraps or bandages, and custom holes to adapt to fit with the latest in advanced healing technologies like bone and muscle stimulators, ultrasound, NMES and TENS units, and biomonitors.

5. Hygienic/Sanitizable 

Traditional casts are notorious for trapping moisture and harboring bacteria, which can spread viruses and lead to skin infections and other complications. ActivArmor’s open design allows for easy cleaning and regular skin observation, making it easier for patients to maintain proper hygiene throughout their recovery.

6. Aesthetic Appeal

Patients can choose from a variety of colors and designs, allowing them to personalize their cast. For children, this can make the experience of wearing a cast more fun, while adults can enjoy the freedom of customizing their device which matches their style.

ActivArmor’s legacy

As ActivArmor celebrates a decade of pioneering 3D-printed orthopedic solutions, it’s clear that this innovation has become a trusted, market-validated alternative to traditional casting. ActionArmor’s support of patients’ active lifestyles has driven widespread adoption among healthcare providers, and its technology continues to evolve to meet the growing needs of the medical community.

As we look to the future, ActivArmor’s breathable, customizable, and market-validated technology is poised to become the new standard in orthopedic care.