The increasing demand for custom-designed and personalized devices, coupled with the rising incidence of chronic diseases and disabilities, is fueling the growth of the prosthetics and orthotics market worldwide. This research presents a model that integrates quality function deployment (QFD), inventive problem-solving theory (TRIZ), and the analytical hierarchy process (AHP) to create innovative product designs, particularly for the development of ankle-foot orthosis. The Voice of the Customer (VOC) was captured to understand user needs and then converted into engineering characteristics using QFD. Design options were identified using QFD and further analyzed with TRIZ to explore innovative design alternatives. The AHP method was employed to evaluate the best design, considering both innovation and usability aspects. After determining the optimal design, it was realized through 3D printing technology, which combined reverse engineering and additive manufacturing techniques. This methodology enables the production of more personalized, functional, and efficient prosthetic devices, offering significant improvements in the design and development of ankle-foot orthoses. By utilizing these advanced techniques, this research contributes to the field of prosthetics and orthotics by ensuring that the devices are not only tailored to individual needs but also meet high standards of innovation and usability.