Traditionally fabricated knee-ankle-foot orthosis (KAFO) device that is used to aid in the mobility user is uncomfortable. Problems such as weight and enclosure in almost all the part of the leg make it strenuous and humid for the user to wear for a long time. Furthermore, in the traditional production method, it can take up to a week to fabricate. The aim of this study is to redesign the knee-ankle-foot-orthosis by using the application of topology optimization in order to reduce the material used on the product and to make it lightweight. The parameters of the KAFO were determined by using indirect method; similar to traditional method. The modelling and analysis of the KAFO is completed by using CAD and CAE software. Optimization of the product is performed by redesigning the shape and applying topology optimization function. It is able to reduce the maximum stress of the product by 22.56% and the volume by 4.33%. Application of the Voronoi pattern further reduces the mass of the KAFO and produces more organic looks to the product. SLS Lisa Pro 3D printer is used to produce the KAFO in a period of less than a week. This prove to be a viable alternative for producing customized KAFO.
