PATIENT INFORMATION
Your ActivArmor
Questions Answered
Discover how custom 3D-printed casts offer a modern, waterproof, and comfortable alternative to traditional plaster. Designed for precision healing, superior hygiene, and maintaining your active lifestyle.
Expert clinical assessment · Precise 3D scanning
CASTING & ORTHOSIS SPECIFIC
Custom 3D-printed casting- including Limb scanning and orthosis design and fitment
Functional splinting
Cast replacement and refitting
Paediatric casting-Clubfoot / talipes equinovarus (serial casting — Ponseti method)
CINICAL/ CONDITION BASED
Fracture management
Post-surgical immobilisation
Ligament and tendon injury support
Stress fracture management
Wrist and hand injury rehabilitation
Foot and ankle immobilisation
Paediatric orthopaedic casting
Chronic pain management
Sports injury rehabilitation
Post-operative recovery
Everything You Need to Know
General
What is an ActivArmor cast?
ActivArmor is a custom 3D-printed orthosis fabricated directly from a 3D scan of your limb. Unlike plaster or fibreglass, it is individually designed to fit your anatomy precisely, providing immobilisation, support, or protection tailored to your injury and clinical needs.
What conditions is it used for?
ActivArmor casts are used for fractures, post-surgical immobilisation, ligament and tendon injuries, stress fractures, and paediatric orthopaedic conditions. They are suitable for wrist, hand, forearm, foot, and ankle injuries. Your physiotherapist will advise whether an ActivArmor cast is appropriate for your specific condition.
How is the cast made?
Your limb is scanned using a 3D scanner to capture its exact dimensions and contours. The scan data is used to design a custom-fitted cast, which is then printed from medical-grade ABS thermoplastic. The cast is typically ready for fitting within 72-96 hours of scanning.
Clinical
Is it as effective as plaster or fibreglass?
Yes. Research has shown that 3D-printed casts are biomechanically equivalent or superior to traditional casting materials in controlled immobilisation. The anatomical fit also reduces internal movement of the limb within the cast, which can improve healing outcomes and patient comfort.
Can it be used immediately after injury?
In most cases, an initial temporary splint may be applied to manage acute swelling. Once swelling has stabilised - typically within 24-72 hours - the 3D scan and fitting can proceed. Your physiotherapist will advise on the appropriate timing for your injury.
Is it suitable for children?
ActivArmor is particularly well-suited to paediatric patients. The lightweight design, absence of a saw at removal, and waterproof properties make it a clinically and practically superior option for children compared to traditional casting.
Clinical Advice: Your physiotherapist will advise on the appropriate timing for your specific injury and whether your cast is prescribed as removable or fixed-wear.
Practical
Can I shower and swim with it on?
Yes. ActivArmor casts are fully waterproof. You can shower, bathe, and swim normally throughout your recovery without any protective covering or cast modification required.
Can the cast be removed at home?
ActivArmor casts are secured with adjustable shock cord ties and can be removed without tools. Whether home removal is permitted depends on your clinical prescription - some injuries require continuous immobilisation. Your physiotherapist will advise whether your cast is prescribed as removable or fixed-wear.
How do I keep it clean?
The open-lattice design allows you to clean both the cast and the underlying skin. The cast itself can be wiped down with mild soap and water. Avoid harsh chemical cleaners or solvents. If the cast is removable, the skin beneath can be washed and dried normally.
What if my swelling changes?
Unlike plaster or fibreglass, the ActivArmor cast can be adjusted or refitted if significant changes in limb volume occur. If the cast feels too tight or loose, contact your physiotherapist promptly. In cases of significant swelling reduction, a replacement cast can be fabricated from a new scan.
Take the Next Step
Ready for a Better Recovery?
Your custom 3D-printed cast is typically ready for fitting within 72-96 hours of scanning, ensuring you get the precise, waterproof support you need without unnecessary delay.
Consultations available with our expert physiotherapists
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