Looking a BILLion dollars! Exotic bird fitted with a 3D printed beak in life-saving operation 



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An exotic bird has been fitted with a 3D printed beak after his own was ravaged by cancer. 

Workers at Jurong Bird Park noticed the animal had a 3.15-inch (8cm) gash on his bill and the cancerous beak – known as a casque – was removed.

Two birds had already died from the condition so vets made the decision to fit the 22-year-old Jary, a Great Pied Hornbill, with a custom-made alternative.

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Jary, a 22-year-old Great Pied Hornbill, was fitted with a 3D printed beak after his own was ravaged by cancer (pictured)

Jary, a 22-year-old Great Pied Hornbill, was fitted with a 3D printed beak after his own was ravaged by cancer (pictured)

The lifesaving operation required engineers and veterinarians to work together on the procedure. 

Images and video of the operation show Jary undergoing several scans and having the new beak screwed into place.   

Analysis of the old beak confirmed that the malformation was a result of cancer.  

The bird was given the name Jary because it means ‘helmeted warrior’ in the ancient Norse language. 

The 46g (1.6 oz) prosthetic was installed during hour-long surgery at a specialist facility in Singapore and the operating doctors revealed it was a complete success.

Dr Xie Shangzhe, assistant director, conservation, research and veterinary services at Wildlife Reserves Singapore said: ‘This case is a great example of how veterinarians and engineers can work together to utilise science and technology for the treatment of diseases such as cancer in all species, including birds.

‘Together, we achieved the best possible outcome.

‘Jary was eating normally the day after the surgery, and recently also started rubbing the prosthetic casque on its preening glands, which secretes yellow pigment.

‘These natural behaviours are good indications that he has accepted the prosthesis as part of him.’

Workers at Jurong Bird Park noticed the animal had a 3.15-inch (8cm) gash on his bill and the cancerous beak - known as a casque - was removed (pictured) 

Workers at Jurong Bird Park noticed the animal had a 3.15-inch (8cm) gash on his bill and the cancerous beak – known as a casque – was removed (pictured) 

The bird (pictured) was given the name Jary because it means 'helmeted warrior' in the ancient Norse language 

The bird (pictured) was given the name Jary because it means ‘helmeted warrior’ in the ancient Norse language 

The lifesaving operation required engineers and veterinarians to work together in order to successfully perform the procedure

The lifesaving operation required engineers and veterinarians to work together in order to successfully perform the procedure

Images and video of the operation shows Jary undergoing several scans and having the new beak screwed into placecon

Images and video of the operation shows Jary undergoing several scans and having the new beak screwed into placecon

Analysis of the beak confirmed that the malformation was a result of cancer and Jary's casque would have to be removed to save his life 

Analysis of the beak confirmed that the malformation was a result of cancer and Jary’s casque would have to be removed to save his life 

Two hornbills at the park died due to cancer. One was unsuccessfully treated with chemotherapy and the other animal had an aggressive form of cancer which progressed too rapidly for treatment

Keepers noticed a cut on Jary’s beak which revealed the tissue below was being ‘eaten away’ by the disease.

The bird underwent a CT-guided biopsy at the Veterinary Emergency and Speciality Hospital, and a tissue sample was extracted. 

Dr Hsu Li Chieh removed Jary's casque with an oscillating saw (pictured) in preparation for the fitting of the prosthetic 

Dr Hsu Li Chieh removed Jary’s casque with an oscillating saw (pictured) in preparation for the fitting of the prosthetic 

Dr Xie Shangzhe, assistant director, conservation, research and veterinary services at Wildlife Reserves Singapore said: 'This case is a great example of how veterinarians and engineers can work together to utilise science and technology for the treatment of diseases such as cancer in all species, including birds'

Dr Xie Shangzhe, assistant director, conservation, research and veterinary services at Wildlife Reserves Singapore said: ‘This case is a great example of how veterinarians and engineers can work together to utilise science and technology for the treatment of diseases such as cancer in all species, including birds’

Jary was eating normally the day after the surgery, and recently also started rubbing the prosthetic casque on its preening glands, which secretes yellow pigment

Jary was eating normally the day after the surgery, and recently also started rubbing the prosthetic casque on its preening glands, which secretes yellow pigment

Dental resin was applied to the new casque to seal any gaps and increase the chances that Jary  would accept his new beak 

Dental resin was applied to the new casque to seal any gaps and increase the chances that Jary  would accept his new beak 

WHAT IS 3D PRINTING AND HOW DOES IT WORK?

First invented in the 1980s by Chuck Hull, an engineer and physicist, 3D printing technology – also called additive manufacturing – is the process of making an object by depositing material, one layer at a time.

Similarly to how an inkjet printer adds individual dots of ink to form an image, a 3D printer adds material where it is needed, based on a digital file.

Many conventional manufacturing processes involved cutting away excess materials to make a part, and this can lead to wastage of up to 30 pounds (13.6 kilograms) for every one pound of useful material, according to the Energy Department’s Oak Ridge National Laboratory in Tennessee.

By contrast, with some 3D printing processes about 98 per cent of the raw material is used in the finished part, and the method can be used to make small components using plastics and metal powders, with some experimenting with chocolate and other food, as well as biomaterials similar to human cells.

3D printers have been sued to manufacture everything from prosthetic limbs to robots, and the process follows these basic steps:

· Creating a 3D blueprint using computer-aided design (CAD) software

· Preparing the printer, including refilling the raw materials such as plastics, metal powders and binding solutions.

· Initiating the printing process via the machine, which builds the object.

· 3D printing processes can vary, but material extrusion is the most common, and it works like a glue gun: the printing material is heated until it liquefies and is extruded through the print nozzle

· Using information from the digital file, the design is split into two-dimensional cross-sections so the printers knows where to put the material

· The nozzle deposits the polymer in thin layers, often 0.1 millimetre (0.004 inches) thick.

· The polymer rapidly solidifies, bonding to the layer below before the build platform lowers and the print head adds another layer (depending on the object, the entire process can take anywhere from minutes to days.)

· After the printing is finished, every object requires some post-processing, ranging from unsticking the object from the build platform to removing support, to removing excess powders. 

The patient is now being monitored closely and is under close observation in Jurong Bird Park’s Avian Hospital’s outdoor ward. 

Jary’s prosthetic will remain in place until he manages to grow another casque of his own.  

Great Pied Hornbills are classified as ‘Near Threatened’ in The International Union for Conservation of Nature’s Red List of Threatened Species.

The Great hornbill is native to the Indian subcontinent and Southeast Asia and is renowned for its impressive size and colouration. 

Animals can live very long lives, with some living for nearly 50 years in captivity. 

Jurong Bird Park currently houses four male and six female Great Pied Hornbills and they live for an average of 40 years.

Jary is now being monitored closely and is under close observation in Jurong Bird Park's Avian Hospital's outdoor ward

Jary is now being monitored closely and is under close observation in Jurong Bird Park’s Avian Hospital’s outdoor ward

Jary's prosthetic will remain in place until he manages to grow another casque of his own. Great Pied Hornbills are classified as 'Near Threatened' in The International Union for Conservation of Nature's Red List of Threatened Species

Jary’s prosthetic will remain in place until he manages to grow another casque of his own. Great Pied Hornbills are classified as ‘Near Threatened’ in The International Union for Conservation of Nature’s Red List of Threatened Species

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