ActivArmor™ Product and Process

There are so many reasons that ActivArmor’s watersafe, 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 ActivArmorTM 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 100% recyclable ABS plastic.

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.

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).

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.

  • Allows the client to bathe and also swim without concern for the ActivArmor™ device losing its ability to provide support.

  • Reduces the need for maintaining product inventory and/or the storage of prefabricated devices.

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
  • 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

ActivArmor™ Technical Blog


Dr. Kevin Kaplan shows you how to fit your ActivArmor facemask


ActivArmor has a solution for moisture inside your facemask! Here’s how to address it.


With the N95 mask shortage, ActivArmor has stepped to the plate with a lightweight, transparent, fitted facemask. Here’s how they compare.

*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.
WARNING: ActivArmor is not suggested for use when there is acute edema or
may be present in the future. For athletes, the sport coating is recommended for activities
that incur high force impact or torque on the device.  Use according to doctor’s orders.

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