As the holidays approach, the story of a male turtle named Charlotte brings a heart-warming message of hope through innovative collaboration among Connecticut’s Mystic Aquarium, New Balance, Adia and Formlabs. Together, experts have worked to address the unique medical condition positive buoyancy syndrome, more commonly referred to as “bubble butt syndrome,” and Charlotte is the centerpiece of this initiative.
Charlotte has struggled with abnormal buoyancy since he was struck by a boat, prompting a team of engineers and experts in 3D printing and computational design to develop a potential solution that could benefit other affected turtles around the globe.
Bubble butt syndrome typically occurs when the trauma from a collision results in slight deformation of a turtle shell, trapping air inside and preventing normal swimming posture. Unlike their normally buoyant counterparts, turtles suffering from this syndrome swim with their rear ends elevated, which can lead to complications such as pressure on internal organs and gastrointestinal issues.
A Collaborative Approach to Rehabilitation
In response to Charlotte's challenges, the veterinary team at Mystic Aquarium initially explored various methods to mitigate his buoyancy. However, attempts to attach weights directly to his shell resulted in irritation, while fabric and neoprene harnesses were easily damaged.
To overcome these obstacles, Mystic Aquarium reached out to Adia, a specialist in 3D design and integration. They sought to create a custom solution that would securely attach sufficient weight while comfortably fitting Charlotte’s unique shell geometry.
The challenge was not just creating a simple weight, but designing an effective harness that maintains comfort for Charlotte. Collaborating with computational design experts from New Balance and 3D printing company Formlabs, the team embarked on a journey to develop a tailored harness using selective laser sintering SLS.
Formlabs’ Alex Pestana told Machine Design, “SLS 3D printing was used for this project, which was perfect for this application since it provides very isotropic parts with a smooth finish. They chose the Formlabs Fuse Series because they needed to suit the scale of this project, tap into Formlabs’ SLS materials and create a design without support.”
READ MORE: Formlabs Introduces Fuse Blast for Automated SLS Post-Processing
Custom 3D Printing Solutions
By scanning Charlotte’s shell, the team was able to generate a highly accurate 3D model, which enabled them to create a custom harness that would not only fit snugly but also withstand the rigors of his aquatic environment. The application of SLS proved advantageous due to its ability to produce complex geometries without the need for support structures, while utilizing materials that offered optimal rigidity and flexibility for marine conditions.
“The team evaluated many different materials for the harness and ultimately selected Nylon 11 CF Powder,” Pestana said. “The carbon fiber-filled material is perfect for applications that require both superior stiffness and strength and is used to produce lightweight, rigid parts.” This material had the right weight and rigidity to suit this design.
Utilizing SLS technology allowed the team to iterate rapidly and develop a design specifically suited to Charlotte's needs. After thorough testing and refinement, the moment arrived when Charlotte donned his new harness, and the initial results have been promising. Charlotte adjusted well, which is very encouraging for his rehabilitation, noted a veterinarian from Mystic Aquarium.
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Scaling the Solution
As Charlotte becomes accustomed to the harness and regains his strength, the team plans to introduce weights to correct his buoyance gradually. The broader vision is to refine this process to make it widely accessible for other aquariums, too. “Adia and New Balance envision making this design a one-click print that can be used to help other turtles,” Pestana said.
The team's ultimate aim is to develop a streamlined platform where other facilities can upload a turtle’s 3D scan and utilize an online design tool to create a tailored harness. This could forever change the approach to treating bubble butt syndrome worldwide.
Charlotte’s journey is a testament to the intersection of technology and wildlife conservation, showcasing how advancements in 3D design and printing can offer hope and tangible benefits to marine life. With continued collaboration and innovation, there’s optimism that many turtles affected by similar conditions will soon receive the care they need to thrive once more.
