Millions of people with disabilities, the elderly, and individuals suffering from physical deformities rely on assistive devices to perform basic actions and movements. With the increasing number of these individuals, lack of available medical equipment and assistive personnel, and the heaviness and cost of rehabilitative devices unsuited for personal use, there has been a growing interest in research for lighter, portable and cost-effective ankle-foot assistive devices.In this paper, a new prototype of an ankle-foot exoskeleton is engineered with low material usage and cost while maintaining structural integrity and providing the wearer with appropriate comfort and support. This ankle-foot exoskeleton was fabricated using printable materials including thermoplastic polyurethane (TPU) and polylactic acid (PLA). The printed pieces were combined with zinc-nickel hinge joints to create a one-degree-of-freedom (DOF) support system. Finite element analysis on both fabricated parts indicates a factor of safety of 4 at an applied load of 700N and 100N to the foot and calf sections respectively. A pressure insole system consisting of a silicone-based pressure mold, pressure force sensors, and a microcontroller was developed to map foot ressure during walking. The pressure insole sensor was subjected to standing and step motions to measure foot pressure. This exoskeleton was also subjected to actuation tests via a torque motor to obtain ankle trajectory profiles at various walking speeds.