After being viciously and senselessly attacked, Grecia the toucan was left without the majority of his upper beak. With no way to feed or care for himself, the outlook for Grecia’s future was grim. But the staff at the ZOOAVE Rescue Center in Costa Rica refused to give up on the bird and called on 3D Systems and partner Grupo SG to devise a custom solution.

In collaboration with a group of industrial designers, dentists and nanotechnology experts, 3D Systems transformed the 3D scans from Grupo SG into a viable prosthetic beak for Grecia. Using and end-to-end digital manufacturing workflow, the team started with Geomagic Wrap® software to convert 3D scan data from Grecia’s residual beak as well as the beak of an undamaged toucan into feature-based CAD models. These models were then imported into Geomagic® Freeform® organic 3D modeling software where the necessary mechanical features were incorporated. These features would allow the prosthetic to properly attach and function.

Après la finalisation du modèle 3D, le fichier a été envoyé vers l'imprimante ProX® SLS 500 de 3D Systems pour être imprimé en 3D avec du plastique DuraForm® ProX PA . L'équipe a sélectionné ce matériau pour sa robustesse, sa biocompatibilité et sa finition de surface lisse non susceptibles de favoriser la contamination ou la prolifération des bactéries. Après avoir été imprimée, la prothèse a été inspectée à l'aide de Geomagic® Control™ afin de s'assurer que ses dimensions correspondaient aux proportions prévues. Après cette vérification, il ne restait plus qu'à la mettre en place.

Thanks to his new prosthetic beak, Grecia can now feed and preen himself and he is a favorite among the residents at ZOOAVE Rescue Center.

Grecia’s recovery and the international movement against animal cruelty generated by this attack as well as the efforts in Costa Rica to change animal protection laws are documented as part of the Animal Planet Presents film, Toucan Nation.