Turtle with Buoyancy Issues Gets Custom 3D-Printed Harness

Tortellini the sea turtle is now swimming with ease thanks to a specialized harness developed by Kansas City scientists.

Mar. 21, 2026 at 5:56am

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Tortellini, a sea turtle residing at the Kansas City Zoo's Sobela Ocean Aquarium, was found off the coast of Florida in 2020 with trauma to her shell, likely caused by a boat propeller. Due to the extent of her injuries, she was deemed nonreleasable and sent to the zoo in 2023. The injury caused air bubbles to get trapped under her shell, making her back end float upward. After trying various solutions, the zoo partnered with scientists at the Kansas City National Security Campus to develop a custom 3D-printed harness to help Tortellini achieve a more neutral buoyancy and swim normally.

Why it matters

This collaborative effort between the zoo and local scientists highlights the innovative ways in which technology and community partnerships can be leveraged to improve the welfare of rescued animals. Tortellini's story also sheds light on the challenges faced by marine life due to human activities like boating, and the importance of rehabilitation efforts for injured wildlife.

The details

The scientists at KCNSC worked closely with the zoo staff for nearly a year to design and 3D-print a custom harness for Tortellini. They explored various materials, did a 3D scan of her shell to create a model, and carefully tested prototypes before introducing the final version. When they put the harness on Tortellini, she immediately seemed comfortable and was able to swim and rest on the bottom of her habitat without any buoyancy issues.

  • Tortellini was found off the coast of Florida in February 2020.
  • Tortellini was sent to a rehabilitation facility for treatment.
  • Tortellini was deemed nonreleasable and arrived at the Kansas City Zoo in August 2023.
  • In 2024, KCNSC scientist Holly Weber noticed Tortellini's buoyancy issues and pitched the idea of a custom harness.
  • The final version of the 3D-printed harness was introduced in December 2025.

The players

Tortellini

A sea turtle residing at the Kansas City Zoo's Sobela Ocean Aquarium who was found off the coast of Florida in 2020 with trauma to her shell, likely caused by a boat propeller.

Kansas City Zoo

The zoo where Tortellini has been living since August 2023, after being deemed nonreleasable due to the extent of her injuries.

Kansas City National Security Campus (KCNSC)

A group of scientists who partnered with the Kansas City Zoo to develop a custom 3D-printed harness to help Tortellini achieve a more neutral buoyancy and swim normally.

Holly Weber

A scientist with the Kansas City National Security Campus who noticed Tortellini's unusual swimming and pitched the idea of a custom harness.

Dan Bowen

The chief scientist at the Kansas City National Security Campus who supported the project to help Tortellini.

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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 were gifted to the zoo so staff can teach visitors about the device and the work that went into it.

The takeaway

This collaborative effort between the Kansas City Zoo and local scientists demonstrates the power of community partnerships in finding innovative solutions to help injured wildlife. Tortellini's story highlights the importance of rehabilitation efforts and the potential for technology to improve the welfare of rescued animals.