Waterproof, custom-fit

3D-printed casts

now available in Sydney

ActivArmor casts help you shower, swim, and stay active while you heal,

without the itch, smell, or bulk of a traditional cast.

Request an Appointment

Support · Active · Lifestyle

Waterproof & Hygienic

Custom 3D-Printed Fit

Breathable Lattice Design

Lightweight & Durable

How ActivArmor Works

Step 1

Assessment & Scan – Your clinician confirms ActivArmor is suitable for your injury and takes a 60‑second 3D scan of your limb using an iPhone.

Step 2

Custom Design & 3D Printing – Your cast is digitally designed and 3D‑printed to match your anatomy and treatment plan.

Step 3

Print & Fitting – Your ActivArmor cast is printed and fitted immediately at Engadine and adjusted as needed while you heal.

Who Can Benefit?

Active adults who need to keep working, parenting, or training. Return to work faster
Professional & non-professional athletes
Children and teens who struggle with itchy, bulky casts
Patients with skin or hygiene concerns under traditional casts
Patients that may struggle with cast claustrophobia
Upper limb and selected lower limb injuries where immobilisation is required
Final suitability is always determined by your treating doctor

Professional athletes such as Blayke Brailey, hooker for the NRL Cronulla Sharks & NSW State of Origin player.

Adult with bilateral forearm fractures able to shower and work

Long-arm cast for a complex elbow

and forearm injury

Wrist fracture protected in a lightweight, breathable ActivArmor cast

Teen with forearm fracture returning to sport in a waterproof cast

10+ Years Proven Technology

ActivArmor casts are used in leading US health systems, US military medical Centres, the NFL & Major Sporting Leagues

Available in 9 countries, and available here locally, through ActivArmor Australis.

ActivArmor International

7,600+ Custom Casts
1,200 referring physicians, to-date
ZERO recorded adverse effects

Ready for a better cast experience?

Get Your ActivArmor Cast

Engadine Town Square

21/101 Caldarra Avenue, Engadine NSW 2233

Serving patients from across Sydney

Available in Sydney

Bill La Palombara leads ActivArmor Australis through Southern Sports Physiotherapy in Engadine and provides Sydney patients with access to custom 3D-printed ActivArmor casts.

He has 30 years of physiotherapy and casting experience, with additional expertise in ActivArmor 3D-printed casting since 2020. His career includes physiotherapy roles with;

- NRL: Cronulla-Sutherland Sharks and St George Illawarra Dragons.

- Motorsport: Head Physiotherapist at the Australian MotoGP and World Superbikes.

- National Sports: Physiotherapist to the NSW Men's and Women's Baseball squads, alongside numerous amateur football and rugby union clubs.

"After 30 years of casting experience, ActivArmor is simply the best immobilisation option I have seen. Each cast is individually 3D scanned and fabricated to fit your exact anatomy — lighter, waterproof, hygienic, and ready within 72 hours. No saw at removal, no skin breakdown, no compromise on your lifestyle during recovery. For my patients — especially children — it is a genuine game changer." - Bill La Palombara

Get ActivArmor

The Key Benefits of ActivArmor Casts

Waterproof & Hygienic Cast - shower, swim, and stay active while you heal
Breathable & Durable Cast - open lattice design helps keep skin cooler & dryer
Adjustable Cast - Easily adjustable cast for comfort. Accommodates swelling / atrophy
Versatile Cast - Locked-on for compliance or converted by your clinician into a removable splint
Custom Cast - Designed specifically for your unique injury condition & lifestyle. A cast that fits precisely to your anatomy
Affordable Cast - Cost effective premium cast option with clear upfront pricing
Custom Colours - A choice of colours so your cast feels more "You"

#1 World Leading

Waterproof Casts

ActivArmor

Waterproof Casts

The Digital Cast &

Splint Revolution

★ ★ ★ ★ ★

We decided to use the ActivArmor cast because we have a very active 14 year old boy and he was going to be in a cast for 6 weeks. ActivArmor gave him freedom that a plaster cast did not allow for. ActivArmor allowed for him to shower, hang out in the hot tub, hang out with his friends and not worry about protecting a plaster cast from his surroundings.

Georgia Schelk

Mum

★ ★ ★ ★ ★

My wife is claustrophobic and even though many people do not understand how a cast could cause such issues. It can! It’s real! I’m not being dramatic! My wife would be half asleep and wake up panicking. She ripped off her traditional cast multiple times till I found ActivArmor. No more panick attacks and ripping it off. She is able to get it wet, it’s breathable and no rash or skin burns. Best choice ever!

M Michaels

★ ★ ★ ★ ★

This cast provided me with my life back. I will need to be immobilized for life and with this ActivArmor long-arm cast... I can shower and swim like any other person. I am thankful for this company and technology!