Friday, August 06, 2010, Calgary, AB – For the second time in a decade, SAIT Polytechnic custom-designed new stainless steel tusk caps for Spike, the Calgary Zoo’s 28-year-old Asian bull elephant, who was fitted with the caps Wednesday by the zoo elephant care team during a procedure lasting more than two hours.

“Creating enormous artificial tusk caps strong enough to withstand the forceful use of a 12,000 pound elephant was not an easy task, but certainly worth all the effort,” said Brad Donaldson, Dean of SAIT’s School of Manufacturing and Automation.  “This project is a wonderful example of how specific manufacturing and trade skills can be used for innovative solutions in very unique circumstances.”

Tusks can grow 10 to 18 cm per year. As they increase in length, they may become caught in objects or cross over each other. In the wild, bulls commonly break or damage their tusks and the cracks which can occur may result in infections deep in the root of the tusk causing disability or even death.  In zoological settings, where health and dental care is available, infection or further injury can be prevented. 

“Spike’s first set of tusk caps were applied in July 2002 after he broke his left tusk during rough play with his tire,” said Dr. Doug Whiteside, Calgary Zoo Veterinarian. “Approximately 18 months ago, Spike then broke his right tusk just above the cap.  The decision was made to replace both caps to prevent further damage to his tusk that could potentially lead to infection.” 

The Calgary Zoo’s veterinary and elephant teams have worked closely with the SAIT team throughout the process of developing the tusk caps and applying them.  The Zoo’s eight-person elephant team have spent countless hours working with Spike using cooperative training to ensure the lengthy process of applying the new tusk caps went off without a hitch.

“He’s been a bit lop-sided for the last year with his right tusk prominently shorter than the left tusk, so there will be an adjustment period for him with things being evened out now,” said Whiteside.

More than 16 people volunteered approximately 300 hours in the collaborative process of creating the uniquely-shaped stainless steel caps weighing approximately 46 pounds each – undoubtedly the largest in the world. Faro Technologies assisted with detailed surface scanning of Spike’s tusks to provide three-dimensional information used to create computer-generated designs for the cap manufacturing and ensure a good fit as each tusk is unique in shape. PolyWorks created the models from the gathered data.  Wooden prototypes were then developed to reflect the internal dimensions and size of the tusks to ensure a proper fit for Spike before machining, welding and finishing the final version of caps.  Sandvik Coromant, Encore Metals and Lab Machine Works provided the tools, stainless steel and machining, and, as in 2002, 3M supplied a mammoth quantity of dental crown kits and epoxy to ensure the tusk caps remain in place.

The removed section of tusk and old caps will be used for educational purposes at the zoo.

SAIT Polytechnic is one of Canada’s most exciting destinations for post-secondary education, offering more than 100 career programs that position people for success in technology, trades and business. A leader in innovation, SAIT also collaborates with industry on applied research and delivers corporate training worldwide. SAIT is a member of Polytechnics Canada and one of Alberta’s Top 50 Employers for 2011.

Please note facts and information may change in older archived materials.

If you require assistance with this or any other press release contact SAIT Corporate Communications.