A method for manufacturing a custom orthosis, such as an ankle brace, includes use of scanning processes. A digital model of a surface may be applied to a digital orthosis model to define a custom digital orthosis model. The digital model and, thus, the custom digital orthosis model may include one or more standard features. The custom digital orthosis model may be used with an automated manufacturing process to make some or all of the custom orthosis. In some embodiments, additive manufacturing processes may be used to form a portion or all of the custom orthosis.
