Traditional Ankle Foot Orthoses (AFOs) is designed to work for different range of patients. They could not perform comfortable orthotic function arising due to individual differences. This problem can be solved by custom fit AFO’s but the current method involves a lot of manual labor. Rapid Prototyping and reverse engineering can be used on 3-D parts or models designed in CAD software to solve the problem. Through the help of 3-D scanning, customized AFO’s is designed to an individual foot’s anatomy. The scanned data was used to design an AFO structure. The designed structure was virtually tested for different materials and an analysis of the same was done.
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