A kit for modeling a patients neck area and creating a neck brace that is sized specifically for an individual patient. Combinations of components are chosen to build the model according to the actual measurements of the patient. A front and back blank are molded to correspond to the model, typically by heat molding. Once cooled, the blanks are removed from the model and Velcro®, padding, and a Velcro® strap are added to form a custom cervical collar brace. The front and back blanks can be formed on preformed blank molds, or can involve a method of forming blank molds upon which front or back blanks or both can be formed. The method can involve applying a material, such as low density polyethylene, to the blank mold and conforming the material to the mold. The blank can then be cut from the material, typically along an outline or contours.
