Engineering with Empathy: All-Women Senior Design Team Creates 3D-Printed Vest to Help Injured Sea Turtle

At the intersection of innovation and compassion, a senior design team of three women — Polina Bragina, Molly Rubin and Anna Koulakova — developed a custom-weighted vest to help Chestnut, a sea turtle who has spent more than a decade battling positive buoyancy.

The disorder, caused by a boat strike early in her life, left her floating uncontrollably at the water’s surface, unable to swim comfortably or dive.

Chestnut was originally found stranded on November 8, 2010, near Zach’s Bay in Jones Beach State Park after cold-stunning and sustaining a boat strike to her back. The New York Marine Rescue Center (NYMRC) responded immediately and began treatment. Because the injuries left her unable to dive, forage or evade predators properly, she was officially deemed non-releasable by federal authorities.

Now, the approximately 15 year-old Chestnut resides at the NYMRC in Riverhead. While she will never return to the wild, this engineering solution may offer her a better quality of life.

With support from project advisor Leana Grotz and the resources of The Space — the College of Engineering and Applied Sciences’ interdisciplinary makerspace housed in the MACH 1 Innovation Hub — this team of mechanical engineering students spent the past year designing a successful vest to improve Chestnut’s mobility, comfort and long-term health. 

Designing for Chestnut wasn’t a simple task. Previous weighted vests clipped under her belly, causing irritation and frustration. NYMRC biologist Jill Pryor explained that Chestnut would become restless and constantly try to remove anything that went under her belly. With that in mind, the students took an entirely different approach, which involved creating a vest that relies on side tension and avoids the underside of her shell altogether.

Still, refining a shell-mounted system came with its own challenges. “The most challenging part was designing the clips that would securely attach to Chestnut’s shell and hold the weight of the vest without slipping or causing discomfort,” said Polina.

During early fitting trials, the team found that their original design didn’t match the shell’s edge well and lacked the grip needed to stay in place. To solve the problem, they molded the edge of Chestnut’s shell using air-dry clay to get more accurate measurements. Bragina then redesigned the clip into a single, solid piece that integrated with the nylon adjusters for better stability, while also accounting for the asymmetrical shape of Chestnut’s shell.

Koulakova, who also led design refinements, emphasized how crucial comfort was to the final design. “We used rubber padding and leveraged the mound on her shell caused by the buoyancy bubble to help the vest stay in place,” she said. “Combined with tension from the nylon straps and Polina’s redesigned clips, we were finally able to create something that wouldn’t slip or upset her.”

Because Chestnut is still young and growing, the team made the vest adjustable in both size and weight, allowing future modifications as her needs evolve.

“Working in The Space gave us access to the tools and environment we needed to prototype and refine our design efficiently,” said Bragina. “We were able to 3D print custom parts, meet regularly as a team, and problem-solve in real time.”

The convenience of having regular access to 3D printing helped them stay on track during weekly visits with Chestnut. “Because of Leana’s 3D printing support, we were able to print new clips every week without worrying about time delays. The Space made our design meetings more comfortable and productive,” Koulakova said. 

The project wasn’t only about engineering, it was about teamwork and trust. “We’re all engineers at the end of the day, but we are close friends too,” said Koulakova. “As students, we bonded over being women in a department filled with mostly men. As the years went by, we studied together regardless of the challenges we faced in academics. Our bond made this challenging project a smoother ride, no matter the obstacles we and Chestnut faced. I’m proud of my team, and I’m proud to have made a positive impact for Chestnut and her marine science team.”

The strength of that bond was especially meaningful for the group as an all-women team in a male-dominated field. “I found it both comfortable and empowering to be working with only other women,” said Rubin. “Some of the best communication and cohesion I’ve seen happens in these teams. I’m proud of our work and what it means — not only for Chestnut, but for future engineers who look like us.”

Grotz, who leads The Space, guided the team throughout their year-long effort. “This team tackled an incredibly complex problem — not just engineering-wise, but emotionally and ethically,” she said. “They showed what it means to be thoughtful, capable engineers who care about the world around them.”

The vest will now be used in monitored sessions to help Chestnut regain strength and improve mobility. While she may never swim in the open ocean again, her quality of life is already improving thanks to the empathy, ingenuity and determination of this student team.

For the College of Engineering and Applied Sciences at Stony Brook University, this project stands as a powerful example of what’s possible when students are equipped with hands-on tools, real-world problems and a collaborative space to explore solutions. It’s also a celebration of women in STEM — leading with heart, skill and impact.