Sea Turtle with Shell Injury Gets Custom 3D-Printed Harness

Tortellini the sea turtle overcomes buoyancy issues thanks to innovative collaboration between Kansas City Zoo and National Security Campus scientists.

Mar. 21, 2026 at 1:56am

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A rescued sea turtle named Tortellini, who suffered a boat strike injury to her shell, has been outfitted with a custom 3D-printed harness to help her swim normally. The harness, designed by scientists at the Kansas City National Security Campus, allows Tortellini to overcome buoyancy issues caused by trapped air bubbles under her damaged shell. After nearly a year of collaboration between the zoo and the research facility, the final harness was successfully fitted on Tortellini, enabling her to swim, rest, and exhibit natural turtle behaviors that were previously hindered by her condition.

Why it matters

This innovative partnership highlights the potential for cross-disciplinary collaboration to solve real-world challenges faced by rescued and rehabilitated wildlife. The 3D-printed harness technology could have applications for other animals with similar buoyancy issues, demonstrating the value of applying scientific expertise to benefit the local community and environment.

The details

Tortellini the sea turtle was found off the coast of Florida in 2020, suffering trauma to the back of her shell likely caused by a boat propeller. After receiving treatment, she was deemed non-releasable and sent to the Sobella Ocean Aquarium at the Kansas City Zoo in 2023. Due to the injury, air bubbles became trapped under her shell, causing her back end to float upward and making it difficult for her to swim normally. Zoo staff tried various solutions, but ultimately turned to the Kansas City National Security Campus (KCNSC) for help. In 2024, KCNSC scientist Holly Weber noticed Tortellini's buoyancy issues and proposed designing a custom 3D-printed harness, an idea her colleagues enthusiastically supported. After nearly a year of collaboration, testing, and refining the design, the final harness was successfully fitted on Tortellini, allowing her to swim, rest, and exhibit natural behaviors without the hindrance of her buoyancy issues.

  • Tortellini was found off the coast of Florida in February 2020 with shell injuries.
  • Tortellini was sent to the Kansas City Zoo's Sobella Ocean Aquarium in August 2023.
  • KCNSC scientist Holly Weber noticed Tortellini's buoyancy issues during a visit to the zoo in 2024.
  • The prototype harness was introduced in December 2025 after nearly a year of development.
  • The final 3D-printed harness was successfully fitted on Tortellini in early 2026.

The players

Tortellini

A rescued sea turtle who suffered a boat strike injury to her shell, causing buoyancy issues that hindered her natural swimming and resting behaviors.

Stu Clausen

The aquatics curator at the Kansas City Zoo who worked with the KCNSC team to find a solution for Tortellini's buoyancy problems.

Holly Weber

A scientist at the Kansas City National Security Campus (KCNSC) who noticed Tortellini's buoyancy issues and proposed the idea of designing a custom 3D-printed harness.

Dan Bowen

The chief scientist at KCNSC who enthusiastically supported the project to help Tortellini swim better.

Sean Putney

The executive director and CEO of the Kansas City Zoo, who praised the partnership with KCNSC and the potential for future collaborations to help other animals.

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What they’re saying

“This was too cool to pass up. Not only was this something KCNSC could do, but it also would be really valuable to the community. And the idea of helping this cute turtle swim better just melts your heart.”

— Dan Bowen, Chief Scientist, Kansas City National Security Campus

“I've been doing this a long time, almost 35 years, and this is the most personally rewarding project I've ever worked on. It's so thrilling to see her be able to have turtle behaviors. Sleep on the bottom of the pool, not have to wedge herself under a rock; it's wonderful.”

— Holly Weber, Scientist, Kansas City National Security Campus

“This partnership was a perfect fit. It touches your heart when you have a local group that is willing to be involved, and who knows, maybe we'll have some things they can do to help other animals down the road!”

— Sean Putney, Executive Director and CEO, Kansas City Zoo

What’s next

The 3D-printed shell model and prototype harness have been gifted to the Kansas City Zoo, allowing staff to educate visitors about the device and the collaborative effort that went into its development. The zoo and KCNSC are exploring potential future partnerships to apply this innovative technology to help other animals in need.

The takeaway

This heartwarming story demonstrates the power of cross-disciplinary collaboration to solve real-world challenges and improve the lives of rescued wildlife. The custom 3D-printed harness not only enabled Tortellini to swim and behave naturally, but also showcased the potential for scientific expertise to benefit local communities and the environment.