In most cases, malformed ears of neonates can be effectively treated by fitting a suitably shaped orthosis. In this study, a finite element analysis system was developed to evaluate the contact force between the orthosis and auricle. In order to reduce the contact force, two methods for modifying orthosis shape were developed. One entailed the addition of a detour curve, while the other canceled out the insertion of the nodal point where maximum force exceeded the limit during the incremental step of finite element analysis. Moreover, two small sensors were developed, one using a silicon tube and the other a strain gauge, for mounting on the orthosis and measuring contact force. Straight, curved and maximum force-restricted orthoses were manufactured for an adult auricle. Simulation and insertion experiments using silicon tube and strain gauge sensors were performed. Results demonstrated that the strength of contact force between the orthosis and auricle decreased from straight type, through curved type to the maximum force-restricted type.