3D-Printed Custom Orthotics
XO Armor is an on-site 3D-printed custom orthotic system. Your staff scans, customizes, prints, and fits a device in a single appointment. At one-fifth the cost of traditional custom DME. No outsourcing. No weeks waiting.
The Challenge
Traditional custom orthotics require sending molds to an outside lab. Patients wait 2 to 6 weeks for a device from an outside lab. XO Armor delivers same day. Every delay risks a missed follow-up or a patient who gives up.
Traditional custom DME fabrication costs five times more than on-site 3D printing. That cost gets passed to patients, payers, or absorbed by the practice. XO Armor eliminates the middleman.
Prefabricated braces are one-size-fits-some. They do not account for the patient's specific anatomy, injury, or activity level. True custom devices deliver better outcomes and higher satisfaction.
The Workflow
Your staff learns the entire scan-to-print workflow in 15 to 20 minutes. No specialized training. No certifications required.
Use a handheld 3D scanner to capture the patient's anatomy. The scan takes less than two minutes and creates a precise digital model of the treatment area.
Guided modeling software lets your staff adjust fit, offsets, thickness, and ventilation patterns. The software walks through each step. No CAD experience needed.
The on-site 3D printer fabricates the custom device. Print time varies by size but the entire scan-to-print process completes same day.
Warm-mold fitting for final adjustments. Add straps and padding. The patient walks out with a custom-fitted device the same visit. Done.
Why XO Armor
On-site fabrication eliminates outsourcing markups. Flat subscription pricing with unlimited materials means your per-device cost drops as volume increases.
No second appointment. No shipping delays. No patient drop-off. Same-day custom devices. Simple splints in under an hour, fully custom braces in under 8 hours. Patient satisfaction goes up. No-show rate goes down.
Your hand therapists, orthotists, and clinical staff reach proficiency in 15 to 20 minutes. The guided software does the heavy lifting.
The 3D printer sits in your clinic. Your existing staff operates it. No new hires. No new room. No disruption to patient flow.
Unlimited materials under a flat monthly subscription. No per-device surcharges. No surprise costs. Predictable economics that scale with your practice.
XO Armor received a $1.5 million Small Business Innovation Research award from the Department of Defense. Validated by the military. Trusted by NFL teams. Ready for your clinic.
Applications
Custom hand splints, wrist braces, and forearm supports. Your hand therapists can fabricate same-visit devices that fit better than anything off the shelf.
Ankle-foot orthoses, foot supports, and lower leg devices. Precise anatomical fit from 3D scanning reduces pressure points and improves compliance.
Protective padding, custom guards, and return-to-play devices. Multi-sport capability. Scan an athlete, print a protective device, and get them back on the field the same day.
Immobilization devices, post-operative splints, and recovery braces. Custom fit from day one of recovery, not weeks later when swelling has changed the anatomy.
Reimbursement
1/5th the cost. Same or better clinical outcomes. Higher patient satisfaction.
For Your Practice
Scan to print same day. The athlete leaves with a custom protective device the same visit.
No outsourcing delays. One-fifth the cost. Multi-sport capability. Scale across teams without scaling costs.
Custom splints today. No weeks waiting for outside fabrication.
Your hand therapists can operate the system after 15 to 20 minutes of training. Reimbursable through CPT and L-codes. Same-visit delivery drives patient satisfaction and eliminates no-show follow-ups.
On-site custom DME at one-fifth the cost. Zero workflow change.
Flat subscription pricing with unlimited materials. Your existing staff operates the system. No new hires needed. The 3D printer fits in a standard clinical space.
Calculate Your Savings
See how XO Armor compares to traditional custom DME on cost, turnaround, and clinical outcomes.
Traditional Custom DME
XO Armor
Real-world results depend on practice volume, local payer contracts, and implementation compliance
Common Questions
Under one hour from scan to finished device. The patient walks out of the same visit with a custom-fitted 3D-printed orthotic.
One-fifth the price of traditional custom DME. The flat subscription model includes unlimited materials, so your per-device cost drops as volume increases.
15 to 20 minutes. The guided modeling software walks your team through each step. Hand therapists, orthotists, and clinical staff can all operate the system without specialized training.
Yes. XO Armor devices are reimbursable through CPT codes and L-codes for durable medical equipment. Same-visit delivery also reduces no-show follow-ups and improves collection rates.
Upper extremity (hand splints, wrist braces), lower extremity (ankle-foot orthoses, foot supports), sports medicine (protective padding, return-to-play devices), and post-surgical (immobilization splints, recovery braces).
The printer fits in a standard clinical space. No dedicated room required. No special ventilation. No significant power requirements beyond a standard outlet.
NFL teams, collegiate athletic programs, the U.S. military (XO Armor received a $1.5M SBIR award from the Department of Defense), and 30+ clinical practices across orthopedics, hand therapy, podiatry, and sports medicine.
See It In Action
Scan to print same day. One-fifth the cost. Staff learns in 15 minutes. Schedule a demo and see the workflow in your clinic.