Almost a million people in the US alone use a lower limb orthosis. These devices range from shoe insoles to full leg frames with custom fit bracing. When connecting mechanical hardware to the biological limb of an individual, two factors are of primary importance -- comfort for the user and structural support, both of which are realized through the interface with the users leg, the brace. Traditional methods of manufacturing this brace are hands on, labor intensive processes that generally include structural supports mechanically fastened to composite braces. The proposed manufacturing method includes customizing the bracing geometry for an optimized fit through 3D scanning and 3D printing technology, customizing the integration of the orthopedic support specifically to the patient's needs, and integrating a plastic core framework to a composite shell to combine both the support and the brace in the same lightweight structure taking full advantage of the composite material properties. This process uses many of the same tools that are present in an orthopedic sizing and manufacturing lab and would allow for dramatic improvements in performance without dramatic changes required by clinicians.