XO Armor Technologies is redefining how athletes, patients, and first responders are protected, offering 3D-printed, custom-fit orthopedic braces, guards, and splints that can be scanned, modeled, and manufactured on-site in under an hour. Since 2019, the Auburn, Alabama-based startup has delivered over 8,000 medical and sports protection devices, partnered with more than 40 collegiate and professional teams, and raised $4.75 million across multiple funding rounds, all while expanding into healthcare and military markets.
What Is XO Armor? 3D Printing Meets Real-Time, Anatomical Customization
XO Armor leverages smartphone-based 3D scanning, proprietary adaptive modeling software, and in-house additive manufacturing to create personalized, anatomically precise protection for injuries and performance. Their service allows a trainer, clinician, or equipment manager to scan a body part using a phone or tablet, choose attributes (thickness, flexibility, coverage), and 3D-print the final product on-site in about 45 minutes.
Recent use cases include pro football linemen with fractured…
wrists returning to play, surgeons fitting custom post-op braces, special-ops soldiers training for deployment, and high school athletes needing adaptive splints or guards.The typical workflow provides a superior fit, fewer follow-up visits, and up to 80% time savings compared to traditional orthotic and casting processes.
The Origin Story & Founders XO Armor was born in 2019 when Auburn mechanical engineering professor Dr. Michael Zabala was asked to help provide a protective device for an injured Auburn football player who needed to play the next game.
After designing—and 3D-printing—a fit-for-purpose splint, the device became an on-field success. Joined by co-founder Dr.
Jacob Larson, Zabala spun the project out of the Auburn University Biomechanical Engineering Lab; the company grew through the New Venture Accelerator and added CEO Joseph Bingold, COO Erik Sjolseth, and CMO Sarah Cooley. Dr. Zabala explains:“We’re fusing engineering, injury science, and additive manufacturing…
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