FIDIM Uni

I have never personally used a 1-piece AFO, but one was recently requested. As such, I have not as yet tested this design on myself. It should be fairly strong though. I just took FIDIM 3, stuck the top and bottom together and smoothed/thinned the hinge and bumper areas. I intentionally left the ankle area somewhat bulbous. Since I don't have castings of your legs, I can't be sure that it is sized appropriately. It is better to have some extra space in there than not enough, believe me. Your ankle bone suddenly ramming into hard plastic is…unpleasant. I know…

You may need to spread the upper apart to accommodate your calves. If so, you can either use the ‘grab’ and ‘elastic deform’ tools in Blender's (free) sculpting mode to adjust these, or get a heat gun from the hardware store. Wear leather gloves, heat them up with the heat gun, and spread them apart. The Wagner Furno 300 and the Harbor Freight Warrior are two cheaper heat guns. They look like hair dryers, but they