Abstract
this paper presents the design challenges and methodological lessons learned from the development of two prototypes of the AlmatyAnkleExo, an ankle joint rehabilitation exoskeleton. Versions V1 and V2 were created without a comprehensive anatomical and biomechanical analysis of the ankle joint, which led to structural limitations, reduced comfort, and incomplete functional validation. A comparative review of these prototypes highlights the importance of considering joint anatomy, range of motion, and gait biomechanics at the early design stage. The study emphasizes that the absence of such analysis results in devices that are not fully adaptable to human anatomy and are less effective in rehabilitation scenarios. The findings suggest that integrating anatomical and biomechanical data into the design workflow, along with sensor-based feedback and adaptive control, is essential for achieving clinically viable ankle exoskeletons.