The Breakthrough at Auckland Bioengineering Institute

The University of Auckland's Auckland Bioengineering Institute (ABI) is at the forefront of a transformative project aimed at improving the lives of children with cerebral palsy (CP) in New Zealand. Led by PhD candidate Sara Chami, this initiative combines virtual reality (VR), 3D scanning and printing, and real-time gait analysis to create custom ankle-foot orthoses (AFOs), commonly known as leg braces. These devices are designed to enhance mobility while allowing kids to engage in everyday activities like running, biking, and playing sports.

Sara Chami, a clinical orthotist with experience fitting braces for CP children in Tehran, brought her expertise to ABI. Her frustration with traditional braces—often too rigid, causing blisters and discomfort—spurred this research. Recently featured on RNZ's Nine to Noon, Chami explained how her modular AFOs address these issues, offering hope to families across Aotearoa.

This work exemplifies how New Zealand's higher education institutions are driving health innovations through interdisciplinary bioengineering programs, blending engineering, medicine, and data science to tackle real-world challenges.

Understanding Cerebral Palsy and the Role of AFOs

Cerebral palsy is New Zealand's most common physical disability in childhood, affecting approximately one in 500 children, or about 10,000 New Zealanders overall. It stems from brain damage before, during, or shortly after birth, impacting muscle control, posture, and movement. For many, particularly those with spastic CP, weak ankles lead to toe-walking, falls, and progressive muscle contractures.

Ankle-foot orthoses are prescribed to about half of CP children to support the foot and ankle, improve gait stability, prevent deformities, and promote efficient walking. Traditional plaster casts and thermoformed plastic braces, however, are one-size-fits-most, heavy, and inflexible. Children often reject them during play, limiting physical activity essential for development and social inclusion.

Studies worldwide confirm AFOs enhance stride length, dorsiflexion, and energy efficiency in CP gait. In New Zealand, where active lifestyles are cultural norms, better orthotics could reduce reliance on wheelchairs or surgeries, fostering independence.

Sara Chami's Journey from Clinic to Cutting-Edge Research

Sara Chami's path to ABI began in Iran, where she fitted hundreds of AFOs for CP kids. Witnessing braces fail during active play inspired her PhD at the University of Auckland. Supervised by ABI experts, Chami's project recruits 10 children aged 6-16 for testing.

Her background in prosthetics and orthotics, combined with ABI's advanced facilities, positions her to bridge clinical needs and technology. This PhD exemplifies UoA's strength in translational research, where postgraduate students like Chami turn patient insights into scalable solutions, contributing to New Zealand's bioengineering talent pipeline.

Step-by-Step: Crafting Personalized Modular AFOs

The innovation starts with a weight-bearing 3D scan of the child's foot and ankle inside a custom impression box. Chami uses a handheld scanner while the child stands naturally. VR glasses allow real-time visualization on a laptop, ensuring scan accuracy without repositioning.

Software generates a digital model, optimized for the child's unique anatomy. The brace is 3D-printed in days: a shoe insole, below-knee cuff, and two carbon fiber rods linking them. Rods come in varying stiffness, enabling quick swaps.

Next, human-in-the-loop optimization: Children walk on a force-instrumented treadmill at varied speeds and slopes. Sensors capture gait data—ankle power, stride, balance. Algorithms suggest rod combinations, tested iteratively until optimal.

Parents adjust at home: stiffer rods for hiking, flexible for biking, none for sitting. This modularity empowers families, making orthotics adaptive tools rather than restrictions.

Photo by Laura Rivera on Unsplash

Gait Analysis and Real-Time Data Optimization

At ABI's state-of-the-art lab, real-time data is king. The instrumented treadmill measures ground reaction forces, joint angles, and muscle activation. Wearable inertial sensors, akin to NASA tech used in earlier ABI CP studies, track motion precisely.

Machine learning refines brace designs, predicting ideal stiffness from thousands of simulations. This data-driven approach ensures braces boost ankle power during push-off, mimicking healthy gait. Early trials show kids generating more propulsion, walking faster with less energy.

Such integration of AI and sensors highlights UoA's role in advancing computational bioengineering education, training students in tools vital for NZ's medtech sector.

Real-World Impact: Stories from Families and Clinicians

One parent shared on RNZ: "My child can now hike with us—something impossible before." Blisters vanished; compliance soared. Kids wear braces longer, building strength and confidence.

Clinicians note fewer surgeries, as braces prevent contractures. Globally, personalized 3D-printed AFOs improve comfort and gait per studies from China and Indonesia, validating Chami's method.

In NZ, where CP support strains public health, ABI's work could save costs while enhancing quality of life. For higher education, it showcases PhD-led innovation attracting Health Research Council (HRC) funding—over $2.5m recently to ABI projects.

Auckland Bioengineering Institute: NZ's Bioengineering Powerhouse

Established in 2000, ABI pioneers computational physiology, modeling organs like hearts and placentas. With 150+ researchers, it secures Marsden, HRC, and Endeavour funding—$34.8m to UoA in 2025 alone.

ABI's CP projects build on anti-gravity walkers simulating low gravity to retrain muscles. PhD programs like Chami's draw international talent, positioning UoA as NZ's top for engineering-health intersections. Graduates fuel medtech firms, boosting economy—UoA alumni contribute $13.3b annually.

Challenges and Solutions in Pediatric Orthotics

• Growth spurts: Modular design scales easily via new scans/prints.
• Compliance: Lightweight, shoe-compatible reduces rejection.
• Cost: 3D printing cuts materials; scalability lowers long-term expenses.
• Access: Potential clinic rollout nationwide via ABI partnerships.

Barriers like funding persist, but UoA's translational focus—e.g., $15m international collab—bridges lab to clinic.

Photo by Arno Senoner on Unsplash

Broader Implications for New Zealand Higher Education

UoA's ABI exemplifies NZ universities' shift to high-impact research amid funding pressures. Bioengineering PhDs like Chami's produce patents, startups, and policy influence, vital as NZ eyes medtech exports.

Government investments—TEC fees, research grants—enable such work, training diverse talent. For CP families, it's life-changing; for higher ed, proof of global relevance.

Future Outlook: Scaling and Global Reach

Chami aims for 10 study participants now, eyeing clinical trials next. Integration with ABI's VR rehab for brain injuries could expand. 3D printing hubs in NZ hospitals promise accessibility.

As NZ universities like UoA lead in personalized medicine, expect more VR-AI-3D synergies. This positions bioengineering grads for roles in growing sectors, from rehab robotics to prosthetics.

For aspiring researchers, ABI offers funded PhDs blending tech and humanity—shaping NZ's health future.