Hinged Ankle-Foot Orthoses (AFOs) are commonly prescribed to manage conditions such as drop foot and hypertonicity by allowing controlled ankle motion that facilitates dorsiflexion during gait. However, obtaining a custom AFO through an orthotic clinic is costly, creating a financial barrier for many patients. There is a clear need for a more affordable and accessible device. This work focuses on the development of a fully parameterized AFO design that can be 3D printed and customized using a small set of easily measured lower-limb parameters, enabling people to access this device at low cost. The initial model was developed in Fusion 360 using leg circumference and foot measurements collected from a potential user. The structural components of the model, shell thickness, and alignment can be adjusted to accommodate variations in anatomy without requiring manual 3D design modifications. In addition, hinge components from an off-the-shelf knee brace were repurposed to function as the AFO's ankle joint. An initial prototype has been fabricated using PLA, with planned fabrication in PETG and TPU 95A to evaluate material-dependent performance. The iterative testing conducted thus far demonstrates that a 3D printed hinged AFO can improve gait patterns. Future improvements on the calf shell is necessary to optimize the AFO. Ultimately, this design will be released through an open-source product database to promote widespread adoption and allow others to refine the design.
