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. If one player needs a solution, thousands more do too. Everyone should have access to custom protection, wherever and whenever an injury strikes”.
How It Works: Precision & Speed for Sports, Medical, and Military
With XO Armor, the conventional weeks-long wait for a splint, brace, or guard is now replaced by a same-day, adaptive process—no need for manual casting, off-the-shelf compromises, or iterative fittings. Clinics and sports teams can license the platform as part of an annual subscription, training their staff and installing on-site Bambu Lab 3D printers. Designs can be further customized for function, flexibility, breathability, and even color or team branding.
XO Armor’s cloud-based model allows for unlimited file storage, rapid reprinting, and remote engineer support. Over 40 teams across college football, the NFL, Major League Baseball, rugby, and even military training bases are now clients.
How Much Has XO Armor Raised? Investors & Growth
As of August 2025, XO Armor has raised at least $4.75 million over five rounds, with its latest (August 2025) led by Benson Capital, Clifford Capital, and Blue Cross Blue Shield of Alabama. Early funding came from Auburn University innovation grants, Innovate Alabama matching, and DOD-sponsored research. New funding will boost AI-enabled software and on-site printing at health systems and sports franchises.
XO Armor also secured important partnerships with Certor Sports, TruFit, and Henry Schein (healthcare distribution), accelerating access for rehab clinics and orthopedics groups nationwide.
Momentum and the Road Ahead
With rapid scaling in collegiate, pro, and healthcare markets, XO Armor is well-positioned as a next-generation leader in digital orthopedics and athletic protection. In the company’s own words: “We don’t just build products—we build confidence, mobility, and resilience when it matters most”. As the sporting, medical, and defense sectors invest in smarter, faster care, XO Armor is poised to make custom, high-performance protection truly on-demand and available everywhere.
