The use of elastic elements in actuators can be effective in improving their performance. The present paper examines the different layouts of the elastic element in actuators, choosing the appropriate design, and then designing a series elastic actuator for use in an active knee orthosis. For this purpose, the design elements of actuators were extracted using the knee data for walking. In the next step, considering the effect of the spring stiffness on the energy consumption and actuator’s peak power, its optimum amount for gait was calculated. Afterwards, the effect of adding the spring has been shown at an optimal value. Since the human knee in a gait cycle involves position and force control, designing an efficient controller to track the force and position of the knee during the gait cycle is the next section of this study. Due to the specific application of this actuator, its volume and size are important for the user. For this reason, it is necessary to design and construct an actuator with a suitable size and weight, with good output. For this purpose, a lightweight and low volume actuator was fabricated.