Experimental stress analysis on various ankle-foot orthoses (AFOs) was conducted. A complete experimental testing system has been developed successfully. Results revealed that the peak stress in the orthoses occurred in the neck region. This was consistent with earlier Finite Element Analysis (FEA) (1,2) and clinical observation. Thus, failure in the neck region was common. Based on the present investigation, following suggestions has been made. AFO should be made asymmetrically and the lateral side of the neck region should be wider and/or thicker than the medial side.