A system for creating cranial remolding orthoses comprises a controller in data communication with an additive fabricator and a scanner. The controller has access to a database of mappings of nonstandard cranial shapes to desired cranial shapes, to cranial scan data for a patient with an existing cranium shape, and to patient-specific information about the patient. The controller has design software for determining from the scan data a development path from the existing cranium shape to a desired cranium shape, the development path comprising a plurality of development path stages. Fabrication software in the controller allows it to instruct the fabricator for fabricating a cranial remodeling orthoses corresponding to the development path without requiring a physical model. The orthoses comprise a monolithic hollow core shell of thickness varying according to the desired remodeling of the cranium, an inner soft liner； and a fastener disposed for mounting the orthoses on the cranium of the patient.
