This master’s thesis aims to review the recent research on ankle-foot orthosis using conventional manufacturing and 3D manufacturing method. This master’s thesis report also discusses the challenges that come in the design faced by the AFO users and work mainly to explore the suitable design for additive manufacturing (AM) 3D printing techniques to manufacture the ankle-foot orthosis, and it must follow the exact need of the user and manufacturer to improve aesthetics, the strength of the ankle-foot orthosis. Considered the needs of the user and manufacturer in mind, the thesis conducted two interviews, one with the AFO user and the other with the manufacturer. Based on the interviews, the thesis went through the creative phase by making brainstorming sketches of additive manufacture dynamic AFO design, but it was first sketched and then modelled by considering all the requirements of design for additive manufacturing(DFAM) in SOLIDWORKS software, then made the STP file out of it and did the analysis of the AFO in ABAQUS software to find the strength, stress, deformation and stiffness analysis considering the anisotropic material used in FDM process, and then finally get the STL file out of it to make it ready for 3D printing by using FDM printer by considering all the pre-processing and post-processing printing parameters including building orientation, support, production time. Results from the research showed that most researchers used conventional manufacturing method by vacuum forming the thermoplastic sheet around the leg and created custom-fit orthosis, and it was successful according to few publications, but it was a time-consuming, manual process to manufacture AFO and some of the researchers used fused deposition modelling process (FDM) additive manufacturing (AM) 3D printing process, and it was successful according to few publications, and at the same time it didn’t work according to most publications, but it helps to improve the production time, material using appropriate manufacturing process. The findings of the thesis also presented the stress, deformation, and stiffness value based on the analysis, and it was 8.632mm, 14.79MPa, and 5.79N/mm. Finally, the thesis discussed the pre-processing and post-processing parameters of AM 3Dprinting the AFO part. The thesis is conducted by the students of the master’s program at Jönköping University. Additive manufacturing 3D printing technologies are ways to answer a lot of these issues.