A method for manufacturing a custom cranial remodeling device of a type comprising plastic material is provided. The method includes the steps of: providing a first database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a first type; providing a second database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a second type; providing a first program for creating trim lines for a cranial remodeling device of the first type, the first program utilizing the first database; providing a second program for creating trim lines for a cranial remodeling device of the second type, the second program utilizing the second database; generating a three-dimensional model of a desired head shape; forming the plastic material onto the model; and selecting one of the first or the second programs to generate trim lines for the cranial remodeling device.