A three-dimensional surface scan of an exoskeleton wearer is performed to generate three-dimensional surface data, and a three-dimensional surface model of the exoskeleton wearer is generated from the three-dimensional surface scan data. A three-dimensional exoskeleton model is generated from the three-dimensional surface model. At least one three-dimensional exoskeleton component is printed from the three-dimensional exoskeleton model, and a custom-fit exoskeleton is assembled using the at least one three-dimensional exoskeleton component.
