PRovider Frequently Asked Questions

ActivArmor is the only water resistant cast made from 3D printing technology on the market, so we understand you may have some questions.

Become a provider

Use Cases

ActivArmor is used for most injuries that involve immobilizing the wrist, elbow, hand, fingers, or ankle. View an inclusive list of ActivArmor immobilization device use cases →
There are many reasons why ActivArmor is far and away superior to off-the-shelf splints in terms of comfort, ease of use, cost, and compliance. Learn why you should use ActivArmor →
Yes, you can! In the latest research studies, ActivArmor’s new AFO walking boot has better off-loading test results compared to that of the total contact cast for patients with Charcot Foot. This gives those patients with diabetes or wound issues a hygienic option for redistributing weight and reducing the pressure away from wounds.
ActivArmor’s waterproof, breathable, hygienic casts allow kids with injuries or conditions requiring immobilization to continue their daily activities while healing. In fact, ActivArmor founder, Diana Hall, developed the product in 2014 while running a mentoring program for children in poverty. Since then, ActivArmor has helped hundreds of pediatric patients! Learn more from Children’s Hospital Colorado.
ActivArmor provides many benefits to geriatric patients requiring orthopedic support, including those with thinning skin, diabetes and mobility challenges. Learn about ActivArmor for Geriatric patients →
ActivArmor costs the same amount as traditional thermoplastic custom splints and is covered by most insurance, depending on your plan. Learn more on our blog →
ActivArmor provides many benefits to patients requiring long-term immobilization and support for chronic conditions like Carpal Tunnel Syndrome. Learn about ActivArmor for Carpal Tunnel Syndrome →
Yes, you can! ActivArmor devices are being used by physicians as a cast during the acute injury phase, and then transitioning into a removable splint for ongoing support and protection, saving both the patient and the clinic, time and money!
Athletes, from kids to pros, love the freedom and comfort of healing in an ActivArmor device. Its breathable, waterproof, hygienic design, allows for training and staying active, while they heal. Learn how athletes use ActivArmor →
Yes, it does. ActivArmor devices are custom designed, and therefore adaptable for use with the latest in high-tech healing options like bone and muscle stimulators, ultrasound, NMES, and TENS units, and biomonitors. Learn about ActivArmor technology →
ActivArmor is made from 100% ABS (Acrylonitrile butadiene styrene) – a stable, hard, and durable plastic used in toys, food packaging, and surgical tools, to name a few. It is biocompatible, washable, cold sterilizable, reusable, as well as recyclable. It is temperature resistant and will not deform in heat, so patients can ice-bath or hot tub in ActivArmor without worry. Learn more about ActivArmor materials →
With the locked-on option, strong, locking nylon zip ties are embedded into the seams of the device and must be cut off in order to remove it. This ensures pediatric compliance and keeps the immobilization devices stabilized and protective for the patient, unlike the flexible closures on removable splints. Kids can’t get them soggy and pick them apart or chew them off. And the custom fit means that little wigglers and escape artists are more secure in ActivArmor – and better immobilization results in better healing! Learn about ActivArmor’s lock feature →
Yes, we do! Read our ActivArmor provider testimonials →

Yes, it will! ActivArmor replaces traditional casting and splinting efforts in the clinic – increasing patient throughput and billing opportunities. ActivArmor replaces labor and cost-intensive casting and splinting with a 30-second scan, so you can spend more time doing what you do best: providing top-notch care for your patients. Learn about becoming an ActivArmor provider →
ActivArmor is made from 100% ABS (Acrylonitrile butadiene styrene) – a stable, hard, and durable plastic used in toys, food packaging, and surgical tools, to name a few. It is biocompatible, washable, cold sterilizable, reusable, as well as recyclable. It is temperature resistant and will not deform in heat, so patients can wear their water resistant cast in an ice-bath or hot tub in ActivArmor without worry. Learn more about ActivArmor materials →
Yes, it does. ActivArmor’s custom design gives physicians the ability to expose and/or protect skin lacerations/ulcers, incisions and post-surgical hardware. Specified areas, custom to each patient, can be identified for exposure or offset protection, for truly personalized medicine. Learn more about post-surgery and wound care with ActiArmor →
Yes, we can put your clinic or team logo on your ActivArmor casts. ActivArmor casts draw attention and market THEMSELVES! This is a huge marketing advantage for you! If you are a providing clinic, let your patients advertise for you as a provider of the latest in next-gen immobilization technology with a custom logo splayed across their cast. Learn about custom ActivArmor casts →
Dustin Jones, a licensed orthotic fitter and fracture casting technician with Northeast Orthopedics, has seen how the clinic benefits from using ActivArmor over traditional casts: “It saves us clinic staff time and improves our patient throughput.” Dustin has also seen how ActivArmor benefits the patients “Patients’ skin condition is much better while they are healing. We get fewer complaints, replacements, and adjustments.”
How does ActivArmor compare to other casting options? Learn how ActivArmor is the best cast and splint option →
When people in careers requiring hygienic or sterile conditions (like healthcare and food handling) get injured or have a chronic condition like Carpal Tunnel Syndrome that requires immobilization, they are often required to take time off from their jobs, short-term, or long-term disability. ActivArmor devices are the only fully washable and hygienic casts/splints in the marketplace. ActivArmor is fully covered by Worker’s Comp at most of our providing clinics (call the specific clinic for details). Learn about worker’s comp with ActivArmor →
Traditional casts can trap moisture against the skin – a breeding ground for bacteria. This can be especially dangerous in post-surgical treatment, and injuries with skin lacerations. ActivArmor is a water resistant cast that allows patients and providers to observe and treat their skin throughout the immobilization phase. This ability is key in early detection and avoidance of infection.
You can print on-site in a matter of hours with our point-of-care fabrication system. Learn about ActivArmor turnaround time →
Our point-of-care 3D printing system is now available! We offer a full turnkey package including scan, design and print within a few hours. Contact us to start printing Activarmor casts →
We have made a step-by-step guide and a training video to help.
Yes, it is! ActivArmor devices are custom-fit, but also adjustable, and can accommodate swelling. ActivArmor can reduce the risk of compartment syndrome, because (unlike traditional casts), swelling is instantly visible and easily accommodated! Learn about the adjustable 3D casts →

Benefits & Process

Technical FaQs

3D scanning can take some practice. Ensure you’re scanning properly by watching our ActivArmor Scanning Tutorial.
Read our ActivArmor Scanning Guide for instructions on how to log into and use our 3D scanning app.
For a more detailed explanation, watch full our ActivArmor Scanning Tutorial.
If you still need assistance, contact ActivArmor.
You may need to update your iPhone software. If you are not on the latest iOS version, your scan may not upload.
Please also check your WiFi or signal connection if the issue persists.
Ensure full coverage of the area that will be covered by the cast, including the thumb webbing area. Make sure the scan is smooth, and that there are no gaps or ridges.
Watch our ActivArmor Scanning Tutorial for further guidance.

Scanning support

ActivArmor cast are designed to put on and take off easily. Please refer to our ActivArmor Fitting Guide or watch our fitting tutorial.
Learn how to apply bungees to your ActivArmor cast splint on our ActivArmor Fitting Guide. If you’re trying to convert your ActivArmor cast into a removable splint, watch our tutorial.
Learn how to apply adjust ActivArmor using our ActivArmor Fitting Guide. If you’re trying to convert your ActivArmor cast into a removable splint, watch our tutorial.
Fittings and adjustments are expected with acute injuries, as changes in edema and atrophy are common. Adjustments are easy to perform. Please refer to our ActivArmor Fitting Guide or watch our fitting tutorial.
If you feel that the design was not correct, please check the following:
1. Was the patient positioned correctly for their functional position during the scan? If not, this could result in constant pressure when wearing the final device. Test the fit of the device in the same position the patient was scanned. Rescan the patient in the correct position.
2. Has the patient had body shape changes since the scan was performed? Remeasure the patient at the time of fitting and see if you get the same measurements. If not, there was a change in body shape. When you measure, make sure the tape measure is pulled to the tightness you want the cast to be, considering skin compression.
3. Is the skin being compressed? Make sure there is no skin compression by the device on one side leaving a gap on the other side.
ActivArmor is waterproof and is made with materials that reduce bacterial loads Here are ways you can prevent skin irritation.
1. Keep the skin clean underneath. ActivArmor casts are inert, non-reactive plastic. Most skin irritation occurs by substances trapped underneath the device.
2. Keep the skin dry underneath. If moisture is trapped underneath, blow inside with a hairdryer to ensure the skin stays dry. You may also add spacers to give a little extra room to allow for airflow.

Fitting support

If you see bubbles or holes in your 3D printed cast, this issue is likely due to filament that has been moisture or humidity compromised.
Sometimes in shipping, the sealed bag can get punctured and moisture can get in. Make sure as soon as you receive the filament, you put it in a ziplock bag with desiccant. You can ship Filament Storage Sealed Bags with Desiccant with your ActivArmor order.
A hook might break off when removing supports on the hook. If this happens there are 3 options.
Option 1: If you printed a locked on cast that secures with zip ties, don’t worry. The hook on a locked on cast is not needed.
Option 2: If you printed a removable cast (that uses bungee) the cast will need to be reprinted. Please take your time removing the supports on the new printed cast.
Option 3: If you printed a cast that is a locked on cast converting to a removable, reprint the cast now or before the transition date.
1. Make sure the bed is clean and there is no glue, skin oils, or debris.
2. Make sure the bed is cool. Do not put glue on a warm bed.
3. Put 3 layers of glue everywhere the print will cover on the bed. Layer purple glue in the x-axis without gaps, then the y-axis without gaps, then the x-axis again. Using too much or too little glue can be an issue.
4. Watch the first layer print and make sure it is pressed into the bed (not rounded on the top, but not blocking the extrusion.) If the layer is too thin or not thick enough, manually adjust the first layer height on the user interface screen until the proper compression is seen.
Watch our 3D printing tutorial to see if you’re printing correctly.
Your print file will be in a Google Drive folder sent by ActivArmor with a title of your clinic name. There may be a URL and QR code sticker on the front of your printer with the link. If not, contact ActivArmor and our team will send you the file.
The files are listed in chronological order (newest on top). Double-click to open the file and click the download button.
Make sure your patient is using the cast according to product labeling instructions. Then, reprint the cast for them at no cost.
ActivArmor casts need to be filed and sanded after printing to achieve a smooth and shiny finish. You can also wipe the cast with an acetone wipe to remove any debris from sanding and for extra shine. Watch our ActivArmor Fabrication Tutorial for more information.
Troubleshoot your Fusion3 printer by using this error message guide.
Maintenance schedules are on a timer and don’t necessarily need to be done when the message comes up. Feel free to turn the alerts off.
Refer to the maintenance guides to ensure your Fusion3 continues functioning properly.
There are several reasons why a USB thumb drive won’t read:
1. Make sure the gcode file completed uploading onto the storage device from the computer.
2. Make sure you are properly ejecting the storage device from the computer.
3. Make sure the USB thumb drive is all the way inserted into the printer.
4. Turn the printer off and let sit for 2 minutes and reinsert the storage device. Turn back on and check again.
5. If the printer still isn't finding the device try using another storage device.
There might be several reasons why your filament won’t load. Troubleshoot using this Fusion3 EDGE 3D Printer filament feed problems guide.
Follow this procedure guide to level your bed.