Abstract: A process for treating femoral fractures in children includes diagnosing a patient with a femoral shaft fracture and enclosing the affected limb in a splint. The process further includes scanning the unaffected limb with a three-dimensional scanner and obtaining measurements of the unaffected limb that may be used to form a brace for the affected limb. In addition, the process includes fabricating an orthosis to support the affected limb based on the scan and measurements taken of the unaffected limb, and applying the orthosis to the affected limb.