January 16, 2026
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January 16, 2026
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ActivArmor partners with Fusion3 to offer better 3D Printed Casts in the US

Key Takeaways
ActivArmor CEO Diana Hall with custom 3D printed casts
Above: ActivArmor CEO Diana Hall with custom 3D printed casts/Source: ActivArmor

ActivArmor, a Biomedical technology company, is expanding its distribution model through a partnership with Fusion3, a US-based 3D printer manufacturer to bring their hygienic, waterproof 3D printed casts fabrication directly into hospitals and clinics across the country.

The collaboration between ActivArmor and Fusion3 began in 2016, and since then, Fusion3’s 3D printers have provided the majority of ActivArmor’s in-house production capability.

ActivArmor’s 3D Printed Casts

ActivArmor custom 3D printed casts
Above: ActivArmor custom 3D printed cast/Source: ActivArmor

The only sanitizable cast on the market, ActivArmor’s 3D printed casts allow patients to wash their hands during the Covid-19 global pandemic. These next-generation casts are completely customised, precisely fitting to each patient using a body scan, designed per the doctor’s prescription, with the ability to expose post-surgical hardware or incisions, and adaptable for use with ultrasound and other advanced technologies.

ActivArmor orthoses are prescribed by doctors and therapists for injuries such as breaks, sprains, Carpal Tunnel Syndrome, and Charcot Foot on their website and in top orthopaedic clinics across the country. St. Luke’s Medical Center, Colorado Institute of Sports Medicine, Orthopedic and Sports Medicine Center, Alpine Orthopedics, iOrtho, Central Indiana Orthopedics, Children’s Hospital Colorado, and Jacksonville Orthopedic Institute are just a few of these clinics.

ActivArmor’s new phase of growth aims to decentralise production and provide hospitals and orthopaedic clinics with a complete in-house, on-demand 3D fabrication capability. A new integrated package of hardware and software, including Fusion3’s EDGE 3D printer, allows a physician to scan a patient’s injury, custom-design the cast, and print it on-site in hours for immediate application to the patient.

“Fusion3 is our supplier of choice for this game-changing project. Fracture-care patients need casts that are protective, strong, safe, and fast! We chose Fusion3 as our partner because ease-of-use, consistency, speed, and reliability are essential to the adoption of a new technology in the traditional casting space.”

– Diana Hall, CEO of ActivArmor

Chip Royce, CEO of Fusion3, remarks, “Fusion3 is excited to support ActivArmor in this next phase of their expansion. The ActivArmor 3D printed casts and splits are fantastic, semi-custom products that leverage the unique capabilities of our 3D printers: the ability to deliver a large, strong part quickly using engineering-grade materials, day in and day out, as part of a mission-critical application. We believe both medical providers and patients will find the ActivArmor in-house production solution to be a game-changer.”

About ActivArmor: ActivArmor was established in 2014 by Diana Hall, a Colorado School of Mines graduate in Chemical Engineering, while she was running a mentoring program for children in poverty.

About Fusion3: Fusion3 designs, manufactures, and supports their affordable, high-performance 3D printers from their facility in Greensboro, North Carolina, USA.


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Manufactur3D Team
Manufactur3D Team reports on the latest news, insights and analysis from the Indian and the Global 3D Printing Industry. They share updates from Industry leading companies to Startups and covers their latest developments.
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