Anne, if it causes pain just being on, it is ill-fitted and you should not let them bully you into "just dealing with it". Plastic does not 'break in', leather does.

If this is a pre-manufactured AFO, go back to your neuro and insist on an Rx for a fitted, custom one.

The process for mine was this: They cast my leg and ankle much like they do for a broken bone. The cast set and was sawed off. It was used as a mold for high-heat plastic setting. A couple days later, at my follow-up appointment, the PT spent a good bit of time checking ALL the contact points and custom installed the hardware & padding with additional fittings between each step.

Because I'm stubborn about socks in summer, the only discomfort it gives me is on my very bony ankle and at the ball of my foot after a lot of use.

For the skin contact issue, I line it with a bandana and that does the trick.