ActivArmor

What ActivArmor does

ActivArmor is a US-based medical device company that designs, manufactures, and distributes custom 3D printed waterproof orthopedic casts and splints. The company uses 3D scanning and additive manufacturing to produce immobilization devices precision-fitted to within approximately 1mm of patient anatomy, fabricated from FDA-listed, ISO-10993 certified ABS plastic. Devices are available in locked-on (cast) or removable (splint) configurations and can convert between modes as patients progress through healing, with an Insta-Armor variant offered for quicker provider turnaround.

The company operates a B2B2C distribution model: ActivArmor sells devices and 3D printing hardware/software to licensed healthcare providers—including orthopedic surgeons, sports medicine physicians, hand surgeons, and orthopedic clinics—who then scan, print, and fit devices on-site for their patients. Pricing is comparable to traditional thermoplastic custom splints, and the devices are covered by most insurance plans. Revenue streams include one-time device sales and provider-side hardware/software sales. The company was founded in 2014 by Diana Hall in Pueblo, Colorado, and now operates from Port St. Lucie, Florida with manufacturing in Pueblo.

ActivArmor's provider network spans major US health systems and specialty practices including Mayo Clinic, St. Luke's Hospital, Children's Hospital Colorado, Jacksonville Orthopedic Institute, and Central Indiana Orthopedics. The company is privately held, has raised approximately $2.45M across multiple small funding rounds between 2018 and 2024, and in June 2025 announced its first international expansion into Singapore via a strategic partnership with Addictive3D Asia.

Name

ActivArmor

Legal name

ActivArmor LLC

Website

https://activarmor.com

Company type

Private

Founded year

2014

Operating status

Operating

Headcount range

1–10 employees

Short description

ActivArmor is a US medical device company producing custom 3D printed waterproof orthopedic casts and splints from ABS plastic, sold through licensed healthcare providers and covered by most insurance plans, with international expansion beginning in Singapore.

Ownership category

akta.pro rank

Product category

Custom 3D Printed Orthopedic Immobilization Devices

NAICS

Surgical Appliance and Supplies Manufacturing (339113)

SIC

Orthopedic, Prosthetic & Surgical Appliances & Supplies (3842)

akta.pro primary industry

Medical & Dental 3D Printing Services (patient-specific devices, dental labs) (IMAAADAG)

Keywords

• 3D printed orthopedic casts
• Waterproof medical splints
• Custom immobilization devices
• Orthopedic 3D printing
• Biocompatible casts

Headquarters

HQ city

Port Saint Lucie

HQ country

United States

HQ region

North America

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Operations, Technology or R&D, Marketing or Sales, Personnel

Revenue model

1. Custom 3D Printed Orthopedic Devices: ActivArmor generates revenue from the sale of custom 3D printed waterproof casts and splints. The devices are priced similarly to traditional thermoplastic custom splints and are typically covered by most health insurance plans, making them accessible to patients through their existing healthcare coverage.
2. Provider Equipment and Software: Providers need to have 3D printing equipment and software to create the custom devices. The company provides the scanning hardware, software, and ongoing support for clinics to produce ActivArmor devices.

Pricing tiers

Go-to-market motion1 record

Distribution channels1 record

Marketing channels7 records

Core offering

ActivArmor designs, manufactures, and distributes custom 3D printed waterproof orthopedic casts and splints fabricated from ISO-10993 certified ABS plastic and precision-fitted to each patient's anatomy. Providers receive proprietary scanning/design software and training to produce the devices on 3D printers in their clinics, and the casts can be configured as locked-on or removable configurations depending on the prescribing physician's orders. The devices are FDA-listed as Class 1 splints and are typically covered by health insurance at a price comparable to traditional thermoplastic custom splints.

Product overview

ActivArmor is a custom 3D printed waterproof cast and splint system. The core product consists of custom-fit immobilization devices manufactured using 3D scanning and printing technology. Products are made from 100% ABS plastic and are available in both locked-on (cast) and removable (splint) configurations. The product portfolio includes wrist, hand, finger, elbow, ankle, and foot orthoses. Insta-Armor provides a quick-turnaround option for providers requiring faster fabrication. All devices are FDA-listed Class 1 splints and ISO-10993 certified for biocompatibility.

Differentiator

Problem solved

Functional benefit

Products and services

• ActivArmor Custom 3D Printed Waterproof Casts and Splints Custom-fit, 3D-printed waterproof immobilization devices made from 100% ABS plastic and fitted to within 1mm of patient anatomy, available in locked-on (cast) or removable (splint) configurations. Prescribed and fabricated on-site by healthcare providers for orthopedic injury, post-surgical, and chronic immobilization patients.
• Insta-Armor Quick-fit 3D printed cast and splint option offered to providers for faster patient turnaround, using the same custom-fit ABS plastic system as the standard ActivArmor line.

Quantifiable outcome

• 45-50% reduction in opioid usage reported by Mayo Clinic patient
• +3 more outcomes

Named customers9 records

Segments3 records

Ideal customer profiles2 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature4 records

Partnerships

15 partnerships are on record, tiered core and minor.

• Addictive3D AsiacoreStrategic or Co-development Partner · 13 June 2025Strategic partnership to bring ActivArmor waterproof casts and splints to Singapore. Addictive3D Asia is described as a 3D printing pioneer in Singapore, expanding ActivArmor's international footprint.
• Jacksonville Orthopedic Institute (JOI)coreImplementation/ SI/ Consulting PartnerOne of the first clinics to offer ActivArmor, including being first to fit a full-leg 3D printed cast. JOI has been an early adopter and provider partner.
• Central Indiana OrthopedicscoreImplementation/ SI/ Consulting PartnerMajor orthopedic practice where providers prescribe ActivArmor for 70% of casting and splinting needs. Dr. Jared Jones is a featured provider.
• Children's Hospital ColoradocoreImplementation/ SI/ Consulting PartnerPediatric hospital offering ActivArmor as an alternative to traditional casts for children who can continue being active while healing.
• St. Luke's HospitalcoreImplementation/ SI/ Consulting PartnerSt. Luke's conducted independent research study at ASSH on the efficacy of custom 3D printed waterproof casts, validating the technology.
• Mayo CliniccoreImplementation/ SI/ Consulting PartnerMayo Clinic in Rochester, MN has patients using ActivArmor, with one patient reporting significant reduction in opioid usage.
• Regional Orthopedics (Staten Island)minorImplementation/ SI/ Consulting PartnerDr. Gregory Montalbano of Regional Orthopedics interviews and discusses benefits of ActivArmor over traditional casts.
• Lovell Hand and Orthopedic CenterminorImplementation/ SI/ Consulting PartnerDr. Randy Lovell III, hand surgeon and athlete, partners with ActivArmor describing the vision of merging innovation, technology, and orthopedic principles.
• Alpine OrthopedicsminorImplementation/ SI/ Consulting PartnerGunnison, Colorado clinic where Jason Browder PA has been prescribing ActivArmor for 8-10 months with great patient outcomes.
• Bowen Hefley OrthopedicsminorImplementation/ SI/ Consulting PartnerDr. Jesse Abeler, board-certified orthopedic surgeon specializing in hand and upper extremity surgery, provides ActivArmor to patients.
• Motion is Medicine Sports MedicineminorImplementation/ SI/ Consulting PartnerDr. Daniel Clearfield's practice serving athletes at all levels including NCAA, Olympian, NFL, NHL athletes who benefit from ActivArmor.
• Precision Orthopedics & Sports MedicineminorImplementation/ SI/ Consulting PartnerPartner clinic offering ActivArmor waterproof casts and splints to patients in their region.
• University of South CarolinaminorImplementation/ SI/ Consulting PartnerUniversity health services offering ActivArmor as an option for student athletes and campus community.
• UofL HealthminorImplementation/ SI/ Consulting PartnerUniversity of Louisville health system partner offering ActivArmor to patients.
• Fitzmaurice Hand InstituteminorImplementation/ SI/ Consulting PartnerScottsdale, AZ hand specialist clinic that has fitted patients including children with ActivArmor devices.

Scale indicators4 records

Recent moves7 records

Expansion highlights5 records

Direct peers

• Breg: Breg manufactures orthopedic bracing, cold therapy, and casting/splinting products for orthopedic practices, competing directly with ActivArmor in the immobilization and bracing category. Both sell through orthopedic and sports medicine provider channels.

Broad incumbents

• Ossur: Ossur is a global leader in non-invasive orthopedics including braces, supports, and splints for injury recovery and rehabilitation. It is a broader incumbent serving similar patient populations with a wider portfolio of orthopedic immobilization products.
• DJO (Enovis): DJO/Enovis is a major orthopedic device company offering braces, supports, and recovery products including the Exos thermoformable bracing line (co-founded by ActivArmor advisor Dr. Ralph Bovard). Competes in the same orthopedic provider channel with established distribution.
• 3M Health Care (Casting & Splinting): 3M is the dominant incumbent in traditional fiberglass and plaster casting tapes used by orthopedic providers. Represents the conventional standard ActivArmor is disrupting with 3D printed waterproof alternatives.
• Bsn medical (Essity): BSN medical (now part of Essity) produces traditional casting products, bandages, and compression therapy used by orthopedic and emergency clinicians. Represents established competition in casting materials and immobilization products.
• Medi USA: Medi manufactures orthopedic braces, supports, and compression products for sports medicine and post-surgical immobilization. Operates in the same orthopedic bracing category with broader product lines.
• Stryker: Stryker is a major orthopedic medical device company with broad portfolio including trauma, sports medicine, and surgical solutions. A potential acquirer or competitor in 3D printed orthopedic applications given resources and established hospital distribution.

Emerging players

• Materialise: Materialise specializes in 3D printing solutions for medical applications including patient-specific surgical guides and implants. Comparable through its additive manufacturing approach to patient-specific medical devices, though focused more on surgical planning than immobilization.

Others

• Stratasys (Healthcare): Stratasys provides 3D printing systems and materials used in medical device production including patient-specific anatomical models and orthotics. Acts as an enabling technology provider rather than direct competitor, supplying the type of printers ActivArmor providers use.
• 3D Systems (Healthcare): 3D Systems produces 3D printing technology for medical applications including surgical planning models, dental, and patient-specific devices. Functions as an adjacent 3D printing technology provider that could enable or compete with ActivArmor depending on strategic direction.

Market position

Strengths4 records

Weaknesses4 records

Competitive moat4 records

Key risks5 records

Key highlights7 records

Customer concentration

• Xx.com/ActivArmor
• LinkedInlinkedin.com/company/activarmor

Compliance2 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles6 records

Funding overview

Funding rounds5 records

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about ActivArmor