Macaw receives world's first titanium 3D printed beak

This great 3D printing medical success was the result of a team effort by veterinary surgeon Roberto Fecchio, 3D designer and facial reconstruction specialist Cicero Moraes, and veterinary dentist Paul Miamoto.

This self-described team of “Avengers” from the Animal Care Center in Ipiranga, Sao Paulo, has been pioneering the use of 3D printing technology to save the lives of wild animals. Previously, they 3D printed a new shell for Freddy the tortoise, as well as a beak for an injured toucan, both of which were 3D printed in PLA plastic.

For this case, however, the team decided to perform a world first: a prosthetic beak 3D printed in titanium, rather than plastic. Macaws use their beaks to break open seeds and other hard shells, meaning they must be extremely durable and strong. Along with being biocompatible, lightweight, and rust-resistant, titanium is one of the strongest metals on Earth, making it the perfect material for this job.

Miamoto began by taking a series of photographs of the bird, which Moraes then converted into a digital 3D model using a specialised Blender add-on designed by Dalai Felinto at the request of Dr. Everton da Rosa. Experts at CTI then used the 3D model to 3D print a custom-fitted titanium beak.

The surgery, which took place on Thursday, 18th February at the Animal Care center in Sao Paulo, was performed by veterinarians Roberto Fecchio, Sergio Camargo, Rodrigo Rabello and Methus Rabello.

The 3D printed prosthetic was attached using bone cement and orthopaedic screws. “Just 48 hours after the surgery, Gigi is already showing great adaptation to the prosthetic!” wrote the Center for Research and Screening of Wild Animals at Unimonte University, where Gigi is recovering. “It is extremely rewarding to return the quality of life to an animal, and after seeing the before and after picture, there is a huge sense of accomplishment.”

The rescue team is also taking advantage of this 3D printing success story to bring awareness to the illegal trafficking of wild animals in Brazil. According to Fecchio, Gigi was rescued from captivity by the Municipal Police in Praia Grande (CGM/PG), and brought to Unimonte University. “Thank you for the excellent work of Dr. Roberto Fecchio and the entire staff for providing this quality of life for a beautiful animal that has suffered greatly in illegal captivity” said the university staff. “Do not encourage trafficking! It exists only if you buy.”

Even with her new beak, the veterinarians have said that Gigi would be unlikely to survive in the wild, due to having lived most of her life in captivity, however they are currently seeing if she can be adopted by a zoo.

It is becoming more and more common for dogs, cats, and other household pets to receive plastic 3D printed prosthetics or 3D printed wheelchairs, however there is no ‘one size fits all’ solution, and wild animals in particular often require specialised care that only experts can provide.

Luckily, stories such as Gigi the macaw’s, or Grecia the toucan’s, show that 3D printing technology can be adapted to a variety of needs in order to ensure that, despite the injuries inflicted on them through abuse or illegal trafficking, these beautiful wild animals can go on to live long and healthy lives.