ActivArmor™ Product and Process

There are so many reasons that ActivArmor’s waterproof, hygienic, fully custom, and breathable orthoses are superior to the existing casting and splinting technologies. Take a look at the answers to our frequently asked questions below to dive deep into the ActivArmor product and process. If you have additional questions, or would like to become an ActivArmor Provider, please use the Contact Form at the bottom, to reach out.

ActivArmor’s Customized Design and Fabrication System

The proprietary ActivArmor™ process includes a scan (precise to 0.5 mm), creating a 3D model of the patient’s limb, and designs a completely individualized and fitted splint based on the physician’s specific positioning and instructions for each patient’s unique needs. The ActivArmor™ device is then custom fabricated for the patient from recyclable ABS plastic.
ActivArmor™ uses (3D) 3-dimensional mapping of the injured limb to create the exact fit for the client unlike other methods of immobilization (low temperature thermoplastic or progressive layers of tape molded directly upon the client).
ActivArmor™ is a support device custom fit to each patient’s unique body, mapped to the contours of the limb or injuries requiring stabilization and support.
Unlike traditional cast and immobilization methods ActivArmor™ is custom fabricated using a high temperature thermosetting plastic yielding the strong and unique ActivArmor™ immobilization device.

What’s Unique About ActivArmor™?

The exact fit allows the tissues to remain in the desired position for optimal rest and healing.

Custom design allows doctors the freedom to immobilize or free-up specific areas which is not possible with prefabricated devices.
Observation of skin condition is performed easily.
Allows the client to bathe and also swim without concern for the ActivArmor™ device losing its ability to provide support.
The ActivArmor™ device can be made to be either easily removable or be semi-permanent as prescribed.
Reduces the need for maintaining product inventory and/or the storage of prefabricated devices.
Adjustments for swelling or atrophy are easy to make.

Common Uses for ActivArmor™?

Hand Based Thumb Spica

Common Diagnoses*:

  • Thumb Fractures/Dislocations
  • Hand Metacarpal Fractures
  • Thumb MP Collateral Ligament injuries (e.g. skier’s thumb)
  • Basal Joint Arthritis/Instability (TMC joint)
  • Peripheral Nerve Injuries (anti-deformity)

Wrist Cock-up

Common Diagnoses*:

  • Wrist Fracture (distal radius/ulna)
  • Wrist Sprain
  • Mid Carpal Instability
  • Scapho-lunate Instability
  • SLAC Wrist
  • DRUJ Injury/Instability
  • TFCC Injury/Repair
  • Wrist Tendonitis
  • Carpal Tunnel Syndrome
  • Median or Ulnar Nerve Repairs
  • Radian Nerve Palsy/Injury

Thumb Spica/Ulnar Gutter/MP Blocking

Common Diagnoses*:

  • Scaphoid Fractures Wrist/Thumb Tendonitis (e.g. Dequervain’s tenosynovitis)
  • Collateral Ligament Injuries
  • Osteo & Rheumatoid Arthritis
  • Peripheral Nerve Injuries

Posterior tibial tendon dysfunction (PTTD)

Common Diagnoses*:

  • Foot Drop
  • Foot/Ankle Fractures
  • Lower Leg Surgeries
  • Ankle DJD Degenerative Joint Disease
  • Charcot Foot/Ankle
  • Ankle Sprains

Additional Information

ActivArmor for Diabetic/Charcot Foot

How much does ActivArmor Cost?

How to scan with the iPhone App

How To Do Fittings and Adjustments

But what about that turnaround time??

ActivArmor is Adjustable for Swelling

Casting Option Comparison

ActivArmor Improves Clinical Staff Efficiency and Patient Throughput

Observation of Skin While Immobilized Can Catch Infections Earlier

“We get fewer complaints, replacements and adjustments”

3D Printing In Your Clinic

ActivArmor Saves Patients AND Clinics Time and Money

ActivArmor and Edema (Swelling)

ActivArmor: customized protection and exposure of wounds, incisions and post-surgical hardware for observation and treatment

Prescriber Testimonial – We use ActivArmor for 70% of our casting and splinting

ActivArmor – Safe and Skin Friendly

ActivArmor – A Strong Competitive Advantage for Providing Clinics

ActivArmor Improves Clinical Staff Efficiency and Patient Throughput

ActivArmor Clinical Flow Process

ActivArmor Casting/Splinting Use Cases

ActivArmor Transitions from Cast to Splint Through Healing Phases

Pediatric Compliance: Will my child be able to take it off?

ActivArmor Supports Improved Patient Compliance

ActivArmor and Carpal Tunnel Syndrome

ActivArmor – A Welcome Alternative For Pediatrics

Some Patients Choosing Surgery over a Cast

ActivArmor Benefits Geriatric Patients

ActivArmor Gets Worker’s Comp Patients Back to Work!

ActivArmor for Athletes

ActivArmor – The Solution for Cast Claustrophobia

How Does ActivArmor Compare to Off-the-Shelf Splints?

Athletes Love ActivArmor!

ActivArmor In Action

Casting and Splinting for Patients with Diabetes

ActivArmor: Designed for use with Advanced Healing Technologies

Casting: Leaving Physicians in the Dark

ActivArmor – A digital solution in an analog market

Custom Care through 3D Printing

ActivArmor for Diabetic/Charcot Foot

ActivArmor for Diabetic/Charcot Foot

How much does ActivArmor Cost?

How much does ActivArmor Cost?

How to scan with the iPhone App

How to scan with the iPhone App

How To Do Fittings and Adjustments

How To Do Fittings and Adjustments

But what about that turnaround time??

But what about that turnaround time??

ActivArmor is Adjustable for Swelling

ActivArmor is Adjustable for Swelling

Casting Option Comparison

Casting Option Comparison

ActivArmor Improves Clinical Staff Efficiency and Patient Throughput

ActivArmor Improves Clinical Staff Efficiency and Patient Throughput

Observation of Skin While Immobilized Can Catch Infections Earlier

Observation of Skin While Immobilized Can Catch Infections Earlier

“We get fewer complaints, replacements and adjustments”

“We get fewer complaints, replacements and adjustments”

3D Printing In Your Clinic

3D Printing In Your Clinic

ActivArmor Saves Patients AND Clinics Time and Money

ActivArmor Saves Patients AND Clinics Time and Money

ActivArmor and Edema (Swelling)

ActivArmor and Edema (Swelling)

ActivArmor: customized protection and exposure of wounds, incisions and post-surgical hardware for observation and treatment

ActivArmor: customized protection and exposure of wounds, incisions and post-surgical hardware for observation and treatment

Prescriber Testimonial – We use ActivArmor for 70% of our casting and splinting

Prescriber Testimonial – We use ActivArmor for 70% of our casting and splinting

ActivArmor – Safe and Skin Friendly

ActivArmor – Safe and Skin Friendly

ActivArmor – A Strong Competitive Advantage for Providing Clinics

ActivArmor – A Strong Competitive Advantage for Providing Clinics

ActivArmor Improves Clinical Staff Efficiency and Patient Throughput

ActivArmor Improves Clinical Staff Efficiency and Patient Throughput

ActivArmor Clinical Flow Process

ActivArmor Clinical Flow Process

ActivArmor Casting/Splinting Use Cases

ActivArmor Casting/Splinting Use Cases

ActivArmor Transitions from Cast to Splint Through Healing Phases

ActivArmor Transitions from Cast to Splint Through Healing Phases

Pediatric Compliance: Will my child be able to take it off?

Pediatric Compliance: Will my child be able to take it off?

ActivArmor Supports Improved Patient Compliance

ActivArmor Supports Improved Patient Compliance

ActivArmor and Carpal Tunnel Syndrome

ActivArmor and Carpal Tunnel Syndrome

ActivArmor – A Welcome Alternative For Pediatrics

ActivArmor – A Welcome Alternative For Pediatrics

Some Patients Choosing Surgery over a Cast

Some Patients Choosing Surgery over a Cast

ActivArmor Benefits Geriatric Patients

ActivArmor Benefits Geriatric Patients

ActivArmor Gets Worker’s Comp Patients Back to Work!

ActivArmor Gets Worker’s Comp Patients Back to Work!

ActivArmor for Athletes

ActivArmor for Athletes

ActivArmor – The Solution for Cast Claustrophobia

ActivArmor – The Solution for Cast Claustrophobia

How Does ActivArmor Compare to Off-the-Shelf Splints?

How Does ActivArmor Compare to Off-the-Shelf Splints?

Athletes Love ActivArmor!

Athletes Love ActivArmor!

ActivArmor In Action

ActivArmor In Action

Casting and Splinting for Patients with Diabetes

Casting and Splinting for Patients with Diabetes

ActivArmor: Designed for use with Advanced Healing Technologies

ActivArmor: Designed for use with Advanced Healing Technologies

Casting: Leaving Physicians in the Dark

Casting: Leaving Physicians in the Dark

ActivArmor – A digital solution in an analog market

ActivArmor – A digital solution in an analog market

Custom Care through 3D Printing

Custom Care through 3D Printing

*Use Indications
ActivArmor™ devices are labeled for external, non-sterile use to provide support, stability, and immobilization for extremities. ActivArmor™ has not been formally tested for acute injuries and is not intended to provide bone-level strength to the extremity. The physician or non-physician provider (NPP) – therapist, NP, PA-C etc. should determine the appropriate use, time, duration and intensities, for the medical condition.
The ActivArmor™ devices are to be used at the sole risk of the consumer, and are not labeled for use with injuries requiring physician oversight or for acute injuries. ActivArmor™ is not responsible for injury or adverse healing outcomes from device use or misuse.