3D printing for disabilities

Project status: Active

Research area: Clinical Sciences > Orthopaedics

Developing and evaluating 3D-printed ankle-foot orthoses with novel features not currently available for children with cerebral palsy, with the goal of improving their mobility, function and comfort.

By reimagining orthotic care, we aim to transform the lives of children with CP, giving them greater freedom to move, play, and thrive.

Tackling the challenge of cerebral palsy (CP) mobility

Cerebral palsy (CP) affects over 17 million people globally, impacting 1 in every 700 births in Australia. For children living with CP, mobility challenges are a daily reality, often addressed through the use of ankle-foot orthoses (AFOs).

But current AFO solutions come with significant barriers. In Australia, the cost of fitting and manufacturing AFOs can exceed $2,500, placing a heavy financial burden on families, especially those in regional and remote communities.

Beyond cost, conventional AFOs offer limited adjustability and design flexibility, which can compromise comfort, function, and long-term outcomes.

Our vision

We’re working to develop next-generation, personalised AFO technologies that are:

More affordable and accessible to families across Australia and beyond

Customisable to meet the unique needs of each child

Designed to enhance comfort, mobility, and independence

Smarter, personalised orthotic technology

This project aims to develop 3D-printed ankle-foot orthoses (AFOs) with cutting edge features that are not available in conventional AFO design for children with CP.

Our research focuses on three key areas

Replicating conventional functionality
We’re developing and evaluating 3D-printed AFOs that match the performance of traditional devices, ensuring safety, reliability, and clinical effectiveness.
Personalised gait support
We’re designing innovative AFOs with variable material stiffness, allowing for customised control during different phases of walking. This means better comfort, improved mobility, and more natural movement for each child.
Smart motion tracking
We’re integrating motion sensors into AFOs to monitor how children move in real-world settings. These insights will help clinicians fine-tune treatment and track progress over time.

By combining advanced materials, digital design, and sensor technology, we aim to create AFOs that are more affordable, more adaptable, and more empowering for children and families.

Meet the research team

This project brings together a multidisciplinary team of experts committed to transforming orthotic care for children with cerebral palsy.

Our team includes:

Paediatric orthopaedic surgeons with deep expertise in clinical gait analysis and CP management

Engineers skilled in 3D scanning, CAD modelling, and advanced 3D printing technologies

Orthotists and biomechanics specialists focused on functional design and real-world performance

Together, we’re combining clinical insight with engineering innovation to develop next-generation AFOs that offer improved mobility, comfort, and independence.