### Charlotte the Sea Turtle: A Story of Resilience and Ingenuity
In 2008, Charlotte, a green sea turtle, endured a life-changing injury after being hit by a boat. The impact resulted in a condition referred to as “bubble butt syndrome,” which is a buoyancy disorder that hinders sea turtles from submerging. This ailment can be deadly, as it leaves turtles stranded at the surface, incapable of foraging, resting, or evading predators. Nevertheless, Charlotte’s journey took an remarkable turn, due to human assistance and state-of-the-art technology.
### A New Lease on Life
Following the incident, Charlotte was rescued and taken to Mystic Aquarium in Stonington, Connecticut. There, she received expert care and became a long-term resident, as her injuries prevented her from being released back into the ocean. For several years, Charlotte depended on conventional rehabilitation techniques, such as having weights attached to her shell with Velcro, to mitigate her buoyancy challenges. However, this approach was cumbersome and necessitated constant adjustments.
Charlotte’s existence transformed dramatically when a partnership formed between Adia, Formlabs, and New Balance Athletic. These organizations recognized the potential of utilizing advanced 3D printing technology to devise a tailored solution for Charlotte, turning her into an emblem of pioneering practices in animal care.
### Grasping Bubble Butt Syndrome
Bubble butt syndrome stems from gas accumulations that disturb a turtle’s buoyancy. These gas bubbles often arise from two main factors: consuming indigestible materials like plastics and sustaining injuries from boat collisions.
When turtles ingest plastic waste, such as fishing nets or rubber gloves, the debris can block their digestive system, causing gas to accumulate. This results in the turtle floating at an abnormal angle, typically with its rear lifted. In certain situations, dietary changes and fluid therapy can remedy the problem, allowing the turtle to be returned to the wild.
Conversely, injuries from boat strikes can lead to irreversible damage. The force of the impact may distort a turtle’s shell and trap air pockets within. In extreme cases, it can also harm the spinal cord, resulting in partial or full paralysis. For turtles like Charlotte, traditional rehabilitation techniques involve affixing weights to the shell to manage buoyancy. However, this approach is far from optimal, as it demands ongoing upkeep and modifications.
### Utilizing 3D Printing for Recovery
Understanding the constraints of conventional methods, Mystic Aquarium teamed up with Adia, Formlabs, and New Balance to create a more effective solution. The collective agreed to substitute the Velcro-and-weight system with a bespoke harness designed to hold adjustable weights.
The process initiated with a 3D scan of Charlotte’s shell, which became the blueprint for the harness design. New Balance’s computational design team encountered various challenges, including the necessity for a harness that could adapt to Charlotte’s growth and the movement of air bubbles beneath her shell. Additionally, years of swimming at an unusual angle had led to weakness in Charlotte’s hind flippers, necessitating a gradual rehabilitation process.
Once the design was complete, Formlabs utilized its Fuse 1 SLS (Selective Laser Sintering) 3D printer to fabricate the harness. The printer employed carbon fiber-reinforced nylon, a material selected for its adaptability, rigidity, and resistance to impacts. The outcome was a lightweight, robust harness that could be effortlessly modified to suit Charlotte’s requirements.
### A Bright Horizon for Charlotte and Others
Charlotte received her personalized harness in December 2024, and her caregivers report notable advancements. The harness has not only enhanced her movement but also enabled her to start using her hind flippers once more. This breakthrough has encouraged the team to investigate broader uses of this technology.
Adia, New Balance, and Formlabs are now working to refine the procedure for creating custom harnesses for other turtles experiencing similar issues. By establishing automated workflows and intuitive design tools, they aspire to make this technology available to aquariums and rehabilitation facilities globally.
### The Impact of 3D Printing in Animal Welfare
Charlotte’s tale illustrates the potential of 3D printing in tackling intricate challenges in animal rehabilitation. In contrast to traditional manufacturing methods, 3D printing facilitates highly customized, low-volume production at a comparatively low cost. This positions it as an ideal solution for crafting personalized medical devices for animals.
According to Alex Pestana, a Formlabs manager involved in the initiative, “We’re discussing designs that are very intricate and need to be tailored specifically to the animal and the injury or trauma the creature has experienced. Traditionally, crafting such designs was done by hand, which is labor-intensive and less efficient.”
The collaboration also highlights the significance of interdisciplinary alliances in enhancing animal welfare. By merging knowledge in design, manufacturing, and veterinary medicine, the team managed to create a solution that greatly improved Charlotte’s quality of life.
### A Vision for Tomorrow
While Charlotte’s harness symbolizes a major accomplishment, the team is already envisioning the future. Their aim is to create a system that streamlines the process of designing and producing custom harnesses.
