This paper describes research work directed towards the development and application of a design methodology to determine the optimal configuration of a powered upper-limb orthosis. The design objective was to minimize the orthosis complexity, defined as the number of degrees of freedom, while maintaining the ability to perform specific tasks. This objective was achieved in three stages. First, potential users of a powered orthosis were interviewed to determine their priority tasks. Secondly, the natural arm motions of able-bodied individuals performing the priority tasks were profiled using a video tracking system. Finally, a kinematic simulation algorithm was developed and employed in order to evaluate whether a proposed orthosis configuration could perform the priority tasks. The research results indicate that task functionality is overly compromised for orthosis configurations with less than five degrees of freedom, plus prehension. Acceptable task performance, based on the specific priority tasks considered, was achieved in the simulations of two different orthosis configurations with five degrees of freedom. In the first design option, elevation (rotation about a horizontal axis through the shoulder) and radidulnar deviation are fixed, while in the second option wrist flexion and radiduhar deviation are hed. A prototype orthosis is currently being developed using the first design option.