Max, a 20-year-old macaw from the Hyacinth Haven Bird Sanctuary in the Western Cape, has faced a challenging few years. He sustained damage to his beak in two separate altercations with other macaws. The first incident injured his upper beak, and in the second, it broke off entirely. With only his lower beak remaining, Max was unable to eat solid food. His owner, Trevor Glover—founder of the sanctuary—took him to Dr. Brendan Tindall at the Robberg Veterinary Clinic in Plettenberg Bay for evaluation and treatment. While they managed to help Max eat soft foods, the absence of his upper beak allowed the lower beak to grow unchecked. It eventually extended beyond the length of his tongue, preventing him from accessing his food. As a result, it had to be trimmed repeatedly.
Max was taken to the Onderstepoort Veterinary Academic Hospital (OVAH) for a CT scan to determine whether enough of his beak remained to attach a prosthesis. However, the resolution of the CT scanner at Onderstepoort was insufficient to make this determination. Fortunately, arrangements were made with Eugene Marais Radiology, where Dr. Craig Muller conducted a highly detailed scan. This scan confirmed that fitting a prosthesis would be possible.
Professor Gerhard Steenkamp, a veterinary specialist in dentistry and maxillofacial surgery at the Faculty of Veterinary Science at the University of Pretoria, led a team in designing and attaching Max’s new artificial beak. The team comprised a collaborative group of specialists from both academic and industry sectors.
To begin, impressions of the residual beak were taken, and both these impressions and the CT scans were sent to us at BunnyCorp for processing. At the i2P Lab at the Vaal University of Technology’s Science Park in Vanderbijlpark, we conducted an initial 3D scan of the impression as well as of the detached portion of the original beak. By combining these 3D scans with the CT scan, we digitally reconstructed the beak. Using this reconstruction, we designed a new artificial beak that followed the original shape while incorporating an additional back section to cover the residual beak and house the screws for attachment.
Once the CAD design was completed, samples were 3D-printed in resin to test the fit. Initial tests were conducted using a positive impression of the residual beak. The samples were then sent to Max for further fitting tests to ensure they would still align properly, considering the potential for continued growth of the residual beak. This process had to be repeated several times over the course of the project, as progress was delayed for nearly two years due to the pandemic. Ensuring a perfect fit remained a top priority throughout.
The next step involved producing the titanium version of the beak, as well as the surgical drill guides in nylon, and sourcing the specific screws required for the operation. The Centre for Rapid Prototyping & Manufacturing (CRPM) at the Central University of Technology (CUT) in Bloemfontein was engaged to 3D-print the titanium beak and guides. Their extensive experience in creating custom titanium implants for humans proved invaluable, and they also contributed to the design of the surgical drill guides.
The Carl and Emily Fuchs Foundation provided funding for the manufacturing of the prosthesis, while the National Department of Science and Innovation supported the MedAdd project, which supplied the latest additive manufacturing (3D printing) technology. The specialized locking screws needed for the procedure were sponsored by Saspine, a Pretoria-based company specializing in the human orthopedic field.
The surgery was performed at the Robberg Veterinary Hospital, with Dr. Tindall administering anesthesia and Prof. Steenkamp attaching the prosthesis, assisted by Dr. Cules van Heerden, a former University of Pretoria professor and specialist prosthodontist. The procedure lasted just over an hour, and within a day, Max was already eating solid food.
Max will remain under observation for a period to ensure there are no post-operative complications. He has since returned home, resumed eating normally, and has largely returned to his typical behavior.
This groundbreaking surgery is believed to be the first of its kind in South Africa and would not have been possible without the dedicated collaboration of a team of experts. Their combined efforts were essential to making this remarkable operation a success. We would like to express our gratitude to everyone who contributed, including those who sponsored both time and funds to make this achievement possible!