Founded by Dr. Michael Zabala at Auburn University, XO Armor was born from a real on-field need: fast, effective bracing that fits. Today, they combine 3D scanning, modeling software, and on-site printing to deliver precision-fit guards in under an hour.
Their products are trusted by athletes, clinics, and even military teams who need reliable support without the wait. Unlike off-the-shelf options, XO Armor’s gear is made to match your body. So it feels better, fits better, and performs when it matters most.
Whether it’s for injury prevention, post-injury recovery, or game-day protection, XO Armor keeps you moving with lightweight, breathable gear that’s built to last. From football fields to field hospitals, they’re changing how the world thinks about orthopedic care.
Table of Contents
How XO Armor Went From One Brace to a Breakthrough
XO Armor started back in 2019. Dr. Michael Zabala, a mechanical engineering professor at Auburn University, designed a custom brace to help a football player return to the field. That one moment sparked a bigger idea: what if you could create fast, custom-fit protection for anyone, right when they need it?
With support from Auburn’s New Venture Accelerator, XO Armor took off, quickly partnering with colleges and even NFL teams.
By 2024, they were thinking even bigger. XO Armor secured a $1.5M SBIR grant to build a mobile, offline-ready library of 5,000 printable devices. It’s a game-changer for military medics and field teams who need orthopedic gear on demand, without waiting on shipping or internet access.
Easy 4-Step Process: From Scan to Deliver
SCAN THE PATIENT: 30 SECONDS
Easily scan the affected area of the patient with the provided XO Armor scanner.
CUSTOMIZE SCAN: 3 MINUTES
Customize the scan by adding wound offset bubbles, adjusting coverage area, adding holes for straps, or a variety of other options.
PRINT DEVICE: 30-60 MINUTES
Automatically print with the XO Armor provided on-site 3D printer. Multiple material options. Print time depends on the size of the device.
PROVIDE TO PATIENT: 5 MINUTES
Remove the device from the printer, snap off supports, add desired padding or strapping, and provide to the patient.
XO Armor Technology Package
Compact On-Site 3D Printer – It fits easily in existing spaces. Easy to setup, extremely user-friendly
Laptop and Software – customize patient scans by modifying device coverage area, adding bubbles to accommodate bruising or bone issues, adding holes for strapping, or even completely customizing devices to meet the need
Handheld Scanner – scanning fast and easy. Leveraging the latest 3D image recognition capabilities of iPhone, users complete custom scans in under 30 seconds
In addition to custom device creation, they provide a catalog of hundreds of standard orthoses for on-site manufacturing.
| Thumb and Finger Splints | Hand and Wrist Splints | Foot and Ankle | Athlete Protection | Helmet Earhole Covers |
| Ring Splint | Palmar Splint with no thumb | Ankle Stirrups | Thumb Spica | Pair Riddell Speedflex |
| Mallet Finger Splint | Flat Print Palmar | Cleat Toebox Guard | AC Guard | Pair VICIS Zero2 |
| Finger Splint | Cockup Splint with No Thumb | Ankle Foot Orthosis (AFO) | Shin Guards | Pair Riddell Axiom |
| Wrist Stabilized Finger Splint | Palmar Splint with Thumb Support | Foot Guard | Face Mask | Pair Schutt F7 Pro |
| Guantlet Thumb Orthosis | Flat Print | Ankle Support Guard | Rib Guard | Pair Schutt F7 |
| Buddy Splint | Gauntlet Immobilization Orthosis | Pair Light Varsity LS2 |
Three Solutions
This company gives you total control over how you create and deliver orthopedic devices. Whether you need a fully custom fit, a moldable flat print, or a fast pre-sized option, there’s a workflow that fits your clinic or team.
Full Customization: Scan-to-Print
- Scan the patient or the athlete
- Customize with software
- Print on-site with 3D Printer
- Provide the device to the patient
Partial Customization: Flat Print-to-Mold
- Select device and size from the digital catalog
- Print on-site with their 3D printer
- Heat the device using a standard water bath
- Mold to fit the patient
Standard Device Printing: Select from Catalog
- Select a standard-size device from the digital catalog
- Print on-site with their 3D printer
- Add desired padding or straps
- Provide to the patient
Why Clinics, Teams, and Trainers Trust XO Armor
They build custom-fit protective gear for athletes in football, baseball, softball, rugby, basketball, and beyond. Each guard is 3D-scanned and precision-printed to match the athlete’s body. It gives them the perfect balance of protection, comfort, and mobility.
Reasons Athletic Trainers Love and Trust XO Armor:
- On-Demand, On-Site Protection
- Faster Recovery, Fewer Interruptions
- Cost Effective
- Unmatched Customization
- Lightweight & Durable
- No More Supply Chain Headaches
- Athletic Trainer Approved
- Multi-Sport Versatility
- Game-Day Ready
Where Shopify Falls Short for XO Armor
XO Armor’s helmet earhole covers have six types.
- Pair Riddell Speedflex
- Pair VICIS Zero2
- Pair Riddell Axiom
- Pair Schutt F7 Pro
- Pair Schutt F7
- Pair Light Varsity LS2
Each type has two options available.
Color: Black, Gray, White
Size: Medium, Large, XL
With Shopify’s default setup, XO Armor couldn’t let customers select multiple variants from one product page. Buyers could only choose one variant at a time. If they wanted more, they had to keep jumping between the product and cart pages. It created friction, slowed the process, and led to higher cart abandonment.
One workaround was to create separate product pages for each variant. However, that brought its own problems:
- Stock had to be tracked manually on each page
- Sales data was scattered, making it hard to see what was working
- Customers often landed on the wrong page or missed the right option altogether
- Every update, price change, sale, and discount code had to be done over and over again across pages
It was messy, time-consuming, and hurt both the customer experience and sales performance.
So, how did they solve it?
How XO Armor Fixed the Variant Mess with One Smart App
Shopify App Store is packed with tools built to solve real merchant problems. Like many smart brands, XO Armor turned to a third-party app to fix its variant struggles.
That’s where MultiVariants, a variant app, stepped in and made a big difference.
MultiVariants offer four display styles – List, Dropdown, Swatch, and Grid. List style worked best with their variant numbers. It looked neat and clean on their product page.
With MultiVariants’ seamless integration with DiscountRay, they’re offering discounts on their product page.
To get started, install the MultiVariants app from the Shopify App Store and open the dashboard.
Click “Create Ruleset.”
Add a title for your admin and storefront view.
Choose how you want MultiVariants to apply to your products.
In the layout section, pick a display style that fits your product variants. You can even use different styles for different options.
On the right, you’ll see a live demo preview.
Set any restrictions you need – like mix-and-match options, bundle or step quantities, min/max limits, or per-variant rules.
Everything is flexible and designed to fit the way you sell.
Conclusion
XO Armor is changing the way we think about orthopedic protection. By combining 3D scanning, smart design tools, and on-site printing, they deliver fast, custom-fit braces that work. No long waits, no off-the-shelf compromises.
From athletes and trainers to clinics and field medics, their solution fits right into real-world needs. It’s more than just gear; it’s a new way to provide care that’s faster, smarter, and built around the person wearing it. Whether it’s for recovery, prevention, or peak performance, XO Armor is making custom protection simpler, stronger, and more accessible than ever.
