The ankle-foot of human body is a multi-joint structure that accommodates complex foot motion. Abnormality to the ankle-foot due to injury or disease can result in abnormal gait motion. In such cases, physiotherapist has to assist hemiplegic patients (ankle dorsiflexor muscles with lack of dorsiflexion assist moment) in rehabilitation therapy by using gait training in parallel bars. Physiotherapist has to support hemiplegic patient to position foot and also supports their stand balance. This prolongs multiple task puts extra burden to physiotherapist which gives side effect such as muscular strain or bone fracture while doing the task. Consequently, the motion of the foot patients did not follow the normal gait pattern. Therefore, there is a need to develop an effective ankle foot orthosis (AFO) to solve the long issue-problem. This research was undertake to embark on the modeling and designing of new ankle foot orthosis (AFO) using active control system which later could be used to help patients with ankle dorsiflexor muscles problem. The work was carried out in four stages involving modeling and simulation of DC motor, algorithm development, design and fabrication of the orthosis and finally, evalaution of the product and its functions. The orthosis was tested on healthy volunteer and the results show that the objective to develop and fabricate a new type of robust ankle foot orthosis which can control movement has been achieved successfully.