Print, Heal, Repeat: 3D Printed Casts with Diana Hall

The Prosthetics and Orthotics Podcast

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Diana Hall shares her journey from chemical engineer to founder of ActivArmor, a company revolutionizing fracture care through 3D printed waterproof and breathable casts that allow patients to maintain normal hygiene and activities while healing.
• Started after seeing children with wet, dirty casts who couldn't practice basic hygiene
• Worked directly with FDA to develop test protocols for 3D printed medical wearables
• Created a turnkey point-of-care fabrication system that clinics can operate with minimal training
• Uses iPhone scanning technology for easy, accessible shape capture in under a minute
• Allows custom design while maintaining standardized mechanical properties
• Enables targeted immobilization that restricts only necessary joints
• Popular with pro athletes, pediatric patients, and workers who need hand washing
• 93% of patients choose Active Armor over traditional casts when given the option
• Now used internationally by top orthopedic surgeons in 15 countries
If you're considering innovating in the medical device space, surround yourself with experienced advisors who understand the regulatory environment—it's challenging but rewarding when you can improve patients' quality of life.

Special thanks to Advanced 3D for sponsoring this episode.
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1. Podcast Introduction and Guest Welcome (00:00:00)

2. Diana's Journey Into Medical 3D Printing (00:02:48)

3. How Active Armor Works and FDA Process (00:09:12)

4. Point-of-Care Manufacturing System (00:16:07)

5. Benefits and Applications of 3D Casts (00:22:56)

6. Patient Scanning and Design Process (00:26:58)

7. Challenges of Healthcare Innovation (00:31:58)

8. Funny Stories and Unique Use Cases (00:36:57)