The Secretary Bird is one of the most fascinating and beautiful wild birds in South Africa. Known for their exotic appearance and unique hunting habits, they are a sought-after species for birdwatchers. In 2019, they were even named Bird of the Year by BirdLife South Africa.
Our story centers on a particular Secretary Bird named Legs. A few years ago, she was found starving, with her foot caught in a snare. She was rescued and brought to the Eagle Encounters Wildlife Rehabilitation and Conservation Centre, located at the historic Spier Wine Farm in Stellenbosch. This non-profit organization, established in 2001, has been dedicated to wildlife rehabilitation.
Owner Hank Chalmers took Legs in and nurtured her back to health. Unfortunately, her foot was severely damaged and could not be saved. As a result, Legs lost her foot and had to adapt to life walking on a stump, with one leg shorter than the other.
Last year, during a visit to the facility, Dr. Coetzee the Beer, an avian veterinarian and owner of the Center for Avian, Reptiles, and Exotics (CARE) in nearby Klapmuts, realized that something might be done for Legs. Having collaborated with us on other projects, he was aware that we worked on a variety of cases using 3D printing technologies.
A visit to BunnyCorp was arranged, during which we took photos and measurements. A mold and positive cast of Legs’s stump were made and sent to us. The 3D scan was performed at the i2p Lab at the Vaal University of Technology’s Science Park in Vanderbijlpark, and the scanned data was used to create an accurate 3D model of the existing stump, simplifying our design of the new foot.
During the design process, we discussed a few technical considerations, such as adding padding inside the leg, but ultimately decided to try a direct fit with ventilation and drainage holes first. One concern was that if the foot became wet, the padding could absorb water, potentially causing issues with the leg. By incorporating drainage and air holes, water could not be retained, thus eliminating this problem. However, we needed to ensure that the leg would be checked regularly to monitor for any negative effects from the direct fit.
Another concern was that with padding, the leg would need to be removed and checked daily, which could be disruptive for the bird and dangerous for the staff, as the bird is capable of delivering a powerful kick. By opting for the direct fit, we made it possible for Legs to wear the prosthetic for a few days before it needed to be checked again.
For the foot, we decided on a simple design. A clawed foot was unnecessary, as Legs would not be returning to the wild. This allowed us to avoid a complex foot design, which might have been difficult for her to adapt to.
The 3D printing was carried out by the team at Promake International, specialists in advanced materials, medical manufacturing, and 3D printing in both South Africa and the UK. They created the leg using carbon fiber and sent it to us for the final stage. A mold was also 3D printed, and we cast a rubber foot over the end of the leg to provide a softer, more natural walk.
Dr Coetzee de Beer from CARE inspecting the leg with Mr Hank Chalmers handling Legs.
The prosthesis was flown to Cape Town, where we all gathered at Eagle Encounters to test it on Legs. Initially unsure of what was happening, Legs quickly adapted once she was placed on the ground, running and jumping. Though she still limped slightly, it was clear that it would take some time for her to adjust, rebuild her muscles, and correct her posture. After a few days, we met again to assess her progress. She was already improving, and although the rehabilitation process will take time, it appears she will be fine. We will continue to monitor her and make adjustments as needed, so stay tuned for more updates on Legs. Watch the video below to follow Legs’s journey!