How ActivArmor Transformed the Static Industry of Fracture Care: Leveraging the Power of Fusion3 3D Printers

For decades, traditional methods of fracture care have seen little to no innovation, with providers often forced to administer their patients bulky fiberglass casts and fragile slings.?

Ripe for disruption, this static industry caught the attention of Diana Hall , engineer and entrepreneur. Hall took to 3D printing technology to develop a waterproof, custom-designed cast tailored for each patient—giving rise to ActivArmor in 2014.?

Through its partnership with Fusion3 - 3D Printers , ActivArmor works with leading orthopedic surgeons and hospitals across the nation such as Children's Hospital Colorado and St. Luke's. Today, its impact extends globally with contracts in over 15 countries such as Greece, South Africa, and Kuwait.

How ActivArmor Overcame the Limitations of Orthopedic Casts

Although traditional orthopedic casts are an effective means of healing injuries, their weight and rigidity can be major hindrances for patients as they navigate daily activities. Not to mention, their lack of ventilation and susceptibility to water damage can cause skin irritation and hygiene issues during recovery.?

Through the power of 3D printing, ActivArmor is addressing these challenges head-on, and here's how:

Custom-Fit Comfort

After using a 3D scan to assess a patient’s injury, ActivArmor prints a custom cast specially designed for each user. Plus, its unique construction helps alleviate pressure and friction on the affected area to promote a more comfortable healing experience.

Waterproof + Durable

Unlike traditional methods, ActivArmor uses waterproof and medical-grade, ISO-certified ABS plastic so that patients can shower, wash their hands, or even swim without compromising the cast’s functionality. They are particularly beneficial for athletes, who can engage in wider ranges of motion during rehabilitation. As a result, ActivArmor has become a popular choice among Olympians and NFL players alike.?

Medical-Grade + Ultra-Sanitary

Developed according to physician prescriptions, these casts allow for targeted exposure of post-surgical hardware and incisions. Plus, their modular constructions promote optimal air circulation to prevent moisture build-up and make for easier wound monitoring and cleaning. Now, with ActivArmor's new iOS application, providers can easily recommend these custom, 3D-printed casts to their patients—where they are designed, printed, and assembled in a matter of hours.?

Diverse Applications

ActivArmor casts are covered by insurance and benefit a diverse range of patients including active kids, individuals with cast claustrophobia, patients managing diabetes, those with sensory needs, and individuals in professions that require cleanliness or involve extensive physical labor, such as active military personnel, construction workers, mechanics, and professionals in healthcare or food handling.

How Fusion3 is Supporting Medical Manufacturers with 3D Printers

At Fusion3, we understand the critical need for customization in today’s medical landscape. To best meet the needs and demanding specifications of our nation’s healthcare professionals, we offer industry-leading 3D printers that work with you and for you to get the job done. When you print with Fusion3, you gain access to:?

The Widest Range of Printable Materials

Recognizing the growing demand for customizable casts, we continuously work toward expanding our material library to better support leading manufacturers like ActivArmor. Currently, all of our 3D printers are compatible with more than 140 engineering-grade materials to allow for greater flexibility when printing.?

Best-in-Class Support

Committed to continuous improvement for our users, we offer live support calls with our team of dedicated engineers and developers. Manufacturers like ActivArmor can troubleshoot G-code issues via one-on-one consultations—streamlining their production processes as the company expands globally.?

Remote Network Operation + User-Friendly Interface?

Our 3D printers allow for real-time control over one’s projects. Users can pause, resume, and adjust settings mid-cycle to allow for even greater flexibility when printing. As ActivArmor continues to introduce its in-house, 3D production process at hospitals and orthopedic clinics, our EDGE 3D printer’s intuitive interface will enable physicians to easily scan patient injuries, design custom casts, and print them on-site in less than two hours.?

Advanced Software

With hundreds of settings and slicer profiles, Fusion3 3D printers are highly customizable to each project. As ActivArmor tailors its offerings to meet the specific needs of physicians, providers, and patients, this adaptability has become increasingly essential to its mission.