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Orthopedic Instrument Design Challenge

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Chris Gorzynski

Project Timeline

Dec 2025 - Dec-2025

OVERVIEW

Completed a time-constrained mechanical design challenge focused on developing an interbody inserter and implant engagement features for posterior lumbar fusion (PLIF) surgery. The task required designing an instrument capable of rigid implant engagement, mallet impaction, controlled release, and a 90-degree implant rotation within an 11 mm × 11 mm surgical window. The design was completed within a 48-hour deadline, emphasizing clear load paths, separation of axial and rotational forces, manufacturability, and surgeon usability. Multiple concepts were explored before converging on a final design that balanced mechanical simplicity and ease of sterilization while meeting all stated functional and dimensional requirements.

HighlightS

-Completed an end-to-end surgical instrument concept within a 48-hour design window under strict size and functional constraints

-Designed a lumbar interbody inserter concept with controlled engagement, impaction, rotation, and release

-Developed multiple engagement and release concepts and converged on a final manufacturable design

-Produced clear hand sketches and CAD models to communicate design intent within a rapid design timeline

SKILLS

SolidWorksConcept GenerationDesign Under Time ConstraintsMechanical DesignDesign for ManufacturabilityFailure Mode IdentificationEngineering Drawings

ADDITIONAL CONTENTS

Instrument Design Challenge Background Notes and Concept Sketches

https://drive.google.com/file/d/1ANI_J9cfvC4JXgLv9aJPAvoni5iTV0wx/view?usp=sharing

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Chris Gorzynski

Aspiring Design Engineer

I recently graduated from Cal Poly with a Bachelor of Science in Biomedical Engineering and a focus on mechanical design. Through academic and industry projects, I’ve gained hands-on experience in CAD modeling, prototyping, and design iteration. I’m seeking an entry-level design or product development engineering role in the medical device or biotechnology space.