OU engineering students design holiday-shaped treats for rescued sea turtle at SEA LIFE Michigan

Oakland University engineering students brought holiday cheer beneath the waves this season by designing and fabricating custom holiday-themed food molds for a rescued green sea turtle at SEA LIFE Michigan Aquarium.

SEA LIFE Michigan Aquarium’s rescued green sea turtle, Benson — along with other marine animals in the Tropical Ocean Exhibit — enjoyed festive “cookies” shaped like a gingerbread man and snowman. The enrichment treats were created through a semester-long senior design collaboration between Oakland University students and SEA LIFE Michigan’s marine biology team.

Ten Oakland University seniors worked closely with aquarium staff to research, design, and manufacture durable, food safe silicone molds using 3-D printing and casting techniques. Once completed, the molds were filled with a frozen gel made from algae, seafood proteins, and vegetables, then carefully lowered by divers into the aquarium’s 120,000-gallon Tropical Ocean Habitat.

“We used 3-D-printed plastic to create a structure for a food safe silicone solution, and then placed a 3-D-printed figure on top to give the mold its festive shape,” said Isabella Calabrese, Oakland University senior engineering major. “To avoid air bubbles and increase durability, we created a makeshift vacuum chamber using a vacuum pump and a large metal pot.”

The molds were designed with precise draft angles and fine details so the frozen food could be released easily while remaining clearly recognizable underwater.

OU Senior Design students were given a behind-the-scenes tour at Sea Life to better understand the inner workings of the aquarium.

“Our first step was extensive research and analysis to determine the right materials and processes,” said Olivia Bowman, Oakland University senior engineering major. “We 3-D printed test versions using PLA, coated them in epoxy, and created smaller prototype molds to make sure the design and materials worked before scaling up. We ultimately chose food-grade silicone because it’s flexible, durable, and able to capture fine detail, which makes it much easier to release frozen food while still holding its shape underwater.”

That careful, step-by-step approach helped ensure the molds would perform reliably in a demanding, real-world environment.

“It’s very important to pay attention to detail when creating 3-D designs in order to manufacture accurate and smooth castings,” said Trystan Rexrode, senior design student.

The Tropical Ocean Exhibit is home not only to Benson, but also to sharks, stingrays, and thousands of tropical fish — many of which eagerly cleaned up crumbs Benson left behind during his holiday feast.

“The Oakland University students did an excellent job researching food safe materials and collaborating with our team to understand our needs,” said Lauren Grauer, head marine biologist and curator at SEA LIFE Michigan. “Once the molds were complete, our marine biologists filled them with a special gel and froze them to increase longevity. The result was both festive and functional.”

Beyond seasonal fun, the treats served an important enrichment purpose.

“This feed isn’t just festive — it’s a meaningful enrichment activity,” said Samantha Averitt, SEA LIFE marine biologist and Oakland University alumna. “Picking at the ‘cookies’ encourages natural foraging behavior, which is especially important for Benson. We’re incredibly thankful to the engineering students at my alma mater for making this possible.”

Benson is a juvenile green sea turtle rescued from the Florida coast after being struck by a boat, resulting in severe injuries to his shell and spine. Due to his condition, he is unable to regulate his buoyancy and requires lifelong care. He is one of two rescued green sea turtles at SEA LIFE Michigan Aquarium.

Students involved in the project emphasized the impact of seeing their work applied in a real-world setting.

“Seeing something you designed come to life — and watching a sea turtle interact with it — is incredibly rewarding,” said Dillon Poliss, senior engineering major.

The Oakland University students who contributed to the project include Isabella Calabrese, Ashley Noyes, Raffy Karoumi, William Kosarek, Trystan Rexrode, Brenden Simms, Amila Rupasinghe, Andrew DeGroot, Dillon Poliss, and Olivia Bowman. The project was supported by Oakland University senior design faculty and completed in close collaboration with SEA LIFE Michigan throughout the semester.

The partnership highlights Oakland University’s commitment to experiential learning, interdisciplinary collaboration, and community engagement — demonstrating how engineering innovation can create meaningful impact beyond the classroom.

“This project is a great example of how Oakland University’s senior design program connects classroom learning with real-world impact,” said Jason Wu, professor of mechanical engineering. “Our students worked closely with industry professionals, navigated real constraints such as food safety, materials, and manufacturing limits, and delivered a solution that is now being used to support animal care, conservation, and public education."