Fabrication of AFOs starts with making an impression of the limb. From this negative mold, a positive plaster model of the limb is made and modified. The more accurate this impression is, the easier the laboratory procedures will be.

The fabrication of the orthosis can be started when modifications are completed. The proper thermoplastic material is selected and cut to the correct dimensions for forming. The type and thickness of the plastic used is based on the requirements of the individual child. This plastic is heated in an oven until it reaches its liquid state. At this time it is stretched over the model and sealed, and vacuum is applied. Vacuum is maintained until the plastic has set.

After this initial set takes place, the orthosis must remain undisturbed for 24 hours to allow the stresses in the plastic to normalize (anneal).

The AFO is then trimmed out, the edges of the orthosis are shaped to allow the brace to fit comfortably inside a child's shoe or sneaker, and then they are finished by sanding and buffing to achieve a smooth edge. Once the AFO is finished, the velcro strapping system is designed, fabricated and attached. At this point the AFO is ready for fitting to the child.

While AFOs look similar, each is highly individualized because of the modifications necessary to apply the precise corrective pressures each child requires.