A method for manufacturing a custom wearable medical device, such as an orthosis (e.g., an ankle brace, etc.), includes use of scanning processes. A digital model of a surface may be generated from data corresponding to a body part for which the customer wearable medical device is to be fabricated, and then applied to a digital device model to define a custom digital device model. The digital device model and, thus, the custom digital device model may include one or more standard features. The custom digital device model may be used with an automated manufacturing process to make some or all of the custom wearable medical device. In some embodiments, additive manufacturing processes may be used to form a portion or all of the custom wearable medical device.
