AFO Designer

About the role

The AFO Designer fabricates and finishes custom ankle-foot orthoses and related lower-extremity bracing from clinician-prescribed work orders. You work under the Lead 3D Designer's quality standards, operating CAD/CAM and traditional fabrication equipment to produce devices that are dimensionally accurate and clinically appropriate.

Responsibilities

• Fabricate custom AFOs (solid, articulated, floor reaction, carbon fiber, SMO) from Hike Clinical work orders.
• Operate 3D scanning and CAD/CAM systems to produce device designs from digital patient models.
• Perform thermoplastic and carbon fiber layup, trimming, padding, and finishing to Hike design standards.
• Conduct quality checks on finished devices against work order specifications before shipment.
• Flag clinical specification issues or material constraints to the Lead 3D Designer before fabrication.
• Maintain accurate production records in the Hike system, linking each device to its patient, work order, and quality check.
• Participate in design reviews and continuous improvement sessions with the Lead 3D Designer and clinical team.

Requirements

• 2+ years fabricating custom AFOs or lower-extremity orthotics in an O&P lab or clinical setting.
• Hands-on experience with thermoplastic and/or carbon fiber AFO fabrication — draping, forming, trimming, riveting, padding.
• Familiarity with CAD/CAM fabrication and 3D scanning preferred; willingness to learn required.
• Detail-oriented: you catch dimensional issues before they leave the floor, not after.
• ABC or BOC certification (or in progress) preferred; relevant apprenticeship or lab technician background also considered.
• Comfortable in a fast-paced production environment where quality standards are non-negotiable.

Compensation

Compensation Range: $70K - $105K