Purpose – The purpose of this paper is to determine the most‐practical means of transforming computer‐aided‐design models of custom clubfoot pedorthoses into functional pedorthoses for testing on patients in a clinical trial.Design/methodology/approach – The materials used in conventional orthosis fabrication are not yet available for solid free‐form fabrication; therefore, to fabricate the pedorthoses, several approaches were considered, including direct manufacturing, additive‐based moulding, laser cutting of foam and combinations of several of these approaches.Findings – The chosen approach of additively manufacturing the custom hard shell, and moulding the polyurethane‐foam insert, resulted in accurate, durable and effective pedorthoses that fit well, and could be adjusted as needed. The pedorthoses that were produced are currently being tested on the respective patients for their improvement in mobility and degree of clubfoot correction, and will continue through early 2010.Practical implications – A...