3D-Printed Casts

ActivArmor 3D Printed Casts Now in Pittsburgh, PA

Ask anyone who has suffered a broken bone, sprain, or joint injury about their recovery, and you will likely hear the same grievances: weeks of itchy skin, foul odors, awkward plastic bags taped over arms in the shower, and a complete disruption of daily life. For nearly a century, traditional plaster and bulky fiberglass casting have remained largely unchanged. While effective at immobilizing bones, they leave patients dealing with significant inconvenience, hygiene challenges, and temporary disability.

At Modern Edge Sports and Orthopedic Medicine, we believe orthopedic care should adapt to your life—not force you to put your life on hold. That is why we are thrilled to bring a ground-breaking innovation to Western Pennsylvania: ActivArmor™ custom 3D printed casts and splints.

We are proud to share that Modern Edge Sports and Orthopedic Medicine is the first provider in the Pittsburgh region offering this technology. Even better, we house an advanced, on-site 3D printer directly inside our clinic. This allows us to scan, design, and custom-fabricate your modern medical device right here in our office, giving local patients the true modern edge in fracture management and sports medicine.

The Evolution of Healing: Why Choose ActivArmor?

ActivArmor replaces outdated plaster and fiberglass with custom-mapped, high-strength ABS plastic. Designed with a lattice-like structure, these devices offer structural integrity alongside unprecedented freedom during recovery.

1. 100% Waterproof and Washable Summers along Pittsburgh's rivers or simple daily showers no longer require complex waterproofing hacks. For appropriate injuries and when cleared by your treating provider, ActivArmor’s waterproof design can allow patients to shower, swim, and stay active while protected. You can wash your hands with soap and water—a critical benefit for hand and wrist injuries—and dry off naturally without trapping moisture against your skin.

2. Precision 3D Digital Customization Every body is unique, and standard casting materials often create pressure points, rubbing, or bulk. At Modern Edge Sports and Orthopedic Medicine, we use a specialized 3D iPhone scanner to capture a high-definition digital map of your limb. This data is fed directly to our in-clinic 3D printer, creating a device tailored to your anatomical contours to support stability, fit, and comfortable weight distribution.

3. Breathable, Hygienic Skin Health Traditional casts can create hygiene challenges, including trapped moisture, itching, odor, and skin irritation. ActivArmor’s open-grid design allows constant airflow, keeping your skin dry and healthy throughout the healing timeline.

4. Adaptable & Therapy-Ready Recovery is a dynamic process. ActivArmor devices can be customized based on your doctor’s specific protocol. They can be permanently locked in place like a traditional cast during the acute healing phase, or fabricated as a removable splint to accommodate physical therapy, range-of-motion exercises, and early functional rehabilitation.

Clinical Safety & Evidence-Grounded Care

We didn't bring ActivArmor to Pittsburgh simply because it looks futuristic—it is an FDA-listed Class 1 splint option with clinical use and supporting research in appropriate immobilization cases.

  • Regulatory Approvals: ActivArmor is listed with the U.S. Food and Drug Administration as a Class 1 splint.
  • Biocompatibility: ActivArmor has been biocompatibility tested (ISO 10993-5 certified), supporting skin-contact use as directed by a treating provider.
  • Clinical Efficacy: Research presented at ASSH has reported that custom 3D-printed immobilizers may provide comparable immobilization performance to traditional options in appropriate cases, while also supporting patient-centered benefits such as comfort, hygiene, and daily usability.

Trusted Sports Medicine Credibility

ActivArmor is also used in sports medicine settings, and its advisory board includes physicians with experience caring for high-level athletes. For local patients, the key benefit is access to a custom, waterproof, breathable immobilization option when appropriate for their injury and treatment plan.

What Conditions Can ActivArmor Treat?

Custom 3D-printed immobilization is versatile and can be applied to a wide range of upper and lower extremity conditions, including:

  • Upper extremity fractures (distal radius, scaphoid, wrist, and forearm breaks)
  • Severe sprains, ligament tears, and joint instability
  • Carpal tunnel syndrome and repetitive strain injuries
  • Post-operative immobilization and tendon repairs
  • Lower extremity fractures and ankle injuries (depending on weight-bearing status)

Experience the Modern Edge in Pittsburgh

If you or a family member suffer a fracture or joint injury, you don't have to settle for the discomfort of 20th-century plaster. Experience a cleaner, more comfortable, and more practical recovery option right here in Western Pennsylvania.

Contact Modern Edge Sports and Orthopedic Medicine today to schedule an evaluation with our orthopedic specialists and see if custom 3D-printed casting is right for your injury.