Synopsis
My 12-week Work Integrated Learning (WIL) placement was completed with BioSpine, a Griffith university-partnered medical technology spinal rehabilitation research centre. BioSpine brings together researchers, clinicians, industrials designers and engineers to explore new frontiers in neuro-rehabilitation, working closely with patients recovering from spinal cord injuries. A major focus of BioSpine’s innovation lies in the development of brain-computer interface (BCI) devices and adaptive exercise technologies that enhance patient agency and recovery.
The team is currently advancing a 15-channel EEG headset, designed to enable patients to control rehabilitation equipment using brain activity. This technology is already being trialled with their existing ergometer bike system. My placement contributed to this ecosystem by supporting the early-stage development of a more advanced and modular ergometer platform, one that aligns with BioSpine’s long-term goal of a home-usable, multi-limb, multipurpose rehabilitation product.
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Placement Role and Responsibilities
I joined BioSpine as an Industrial Design intern, working largely independently under the guidance of a senior designer and clinical researchers. My main project involved the design and prototyping of a contralateral upper-and-lower-limb ergometer: an exercise device intended to assist users with spinal cord injuries in performing coordinated, cross-body movements while in a supported upright position. These types of movements are highly beneficial in neuroplastic rehabilitation, helping to activate and rewire motor pathways in the brain.
The project began with an exploration of the existing equipment and a clinical review of how patients currently interact with exercise systems. Through conversations with clinicians and feedback from past users of the bike, it became clear there was a need for a more flexible, adjustable, and mechanically expressive platform that could accommodate a range of user needs, body types, and therapeutic goals. These objectives were outlined and discussed before and at the beginning of my placement.
My responsibilities covered the full design process from ideation and sketching to CAD development, prototyping, and fabrication. Using SolidWorks, I produced detailed models and assemblies of the unit, including modular handle systems and frame structures that support a range of positions and force inputs. These were rendered in KeyShot for visual communication purposes and exported for 3D printing via Bambu Lab Studio and a Bambu Lab X1-Carbon printer. I sourced off-the-shelf components locally and fabricated several custom parts using steel, aluminium, PETG, carbon fibre and PLA filament, and embedded hardware to meet both functional and ergonomic constraints.
While my primary focus was design, I collaborated with BioSpine’s mechatronic engineer to ensure the product would be compatible with the lab’s data collection and control systems. For example, we discussed what kinds of resistance feedback, motion tracking, or motor functions might be integrated later, and how the physical build would allow for sensors and cabling to be integrated. Eventually the team aims to add load and angle sensors into the pedals, these objectives helped ensure the design wasn’t just aesthetically or mechanically sound, but also feasible for future expansion.
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Industry Context and Collaboration
BioSpine operates in a unique cross-disciplinary space between medical research, human-centered design, and engineering. Unlike a typical commercial product development environment, the timeline and priorities of my placement were shaped by research goals and clinical validation, rather than immediate commercialization. This meant that each design decision was made with careful attention to usability, accessibility, and adaptability, not just appearance or manufacturing efficiency.
Despite working independently most of the time, I maintained regular check-ins with my supervisor to align on goals, refine iterations, and receive technical feedback. Clinical staff provided input on user behaviour and accessibility requirements, which I used to guide key features. These small details helped build a more inclusive design language, aligned with the diverse motor capabilities of intended users.
This environment also required strong communication skills. Unlike design-centric teams, many of my collaborators came from clinical or engineering backgrounds, and my ability to explain design intent in clear, non-jargon-heavy terms proved critical. I routinely used sketches, exploded diagrams, and mock-ups to convey ideas, which helped bridge disciplinary gaps and foster productive discussions.
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Deliverables and Project Output
The primary deliverable of my placement was a fully functional, low-fidelity prototype of the contralateral ergometer, along with a supporting CAD package and visual documentation. These deliverables serve as a crucial first step for BioSpine’s broader effort to expand and test multi-limb rehabilitation strategies. The prototype will be used internally for further development and validation, particularly in determining optimal configurations and mechanical tolerances for future iterations.
In addition to the physical output, I provided a progress updates on my design rationale, component choices, and assembly considerations. All files were shared with the senior designer and mechatronic engineer for safekeeping and potential inclusion in upcoming grant or research reports.
While the reflection on my learning and personal growth is explored further below, I can objectively say that my placement experience embedded me meaningfully in an applied research context, one where industrial design directly intersects with health outcomes, human experience, and future-focused innovation.
Critical Reflection
My 12-week internship at BioSpine marked a significant turning point in my development as an industrial designer. As someone entering the world of mechanical and medical product design for the first time, the experience was both intimidating and transformative. Throughout the placement, I worked on the design and development of a custom upper and lower limb ergometer attachment, intended to retrofit onto an existing THERA-Trainer lower limb system. This device supported BioSpine’s rehabilitation goals by encouraging coordinated contralateral movement, targeting Central Pattern Generators (CPGs) to promote neural recovery in people with spinal cord injuries.
One of the biggest challenges I faced was learning through manufacturing mistakes. I discovered early on that design decisions can’t be made in isolation from fabrication methods, something that becomes incredibly clear when you’re working within a tight budget and tight tolerances. For instance, in an attempt to improve durability and visual appeal, I tried to use carbon fibre for certain components. However, the material turned out to be far too rigid and brittle for this application. Rather than enhancing the prototype, it caused parts to snap under pressure. This moment was pivotal, it forced me to reconsider materials, adapt the design, and remain flexible in my problem-solving approach.
While I had a good theoretical foundation, this was the first time I’d been involved in such a mechanical project from start to finish. The freedom I was given came with a steep learning curve, but it also meant I had the chance to take full ownership of the process. The clinicians were especially helpful in grounding my design decisions. From them, I learned the value of restraint, how it’s easy to over-engineer a product or include features that won’t be used. They were also famously tough on prototypes, joking that if something can be broken, they’ll find a way to do it. That made them the perfect testers.
In terms of skills, the placement turbocharged my proficiency in CAD and 3D modelling. SolidWorks became second nature, I was constantly iterating, mock-upping and adjusting based on real-world testing. I also became much more consistent with top-down modelling, which allowed me to quickly go back and revise individual measurements that would update and fit the entire assembly. On the prototyping side, I significantly levelled up my 3D printing workflow. Prior to this internship, I had some experience with desktop printing, but now I routinely consider tolerances, layer lines, part orientation, strength, material efficiency, and how to minimise support structures. I used a Bambu Lab X1-Carbon extensively, a printer brand I already owned, which helped me confidently take the lead in integrating it into BioSpine’s prototyping process. I even taught my seniors tips and tricks from the online 3D printing community that they hadn’t seen before.
The fabrication aspect extended beyond additive manufacturing. For the first time, I worked with steel and aluminium components, learning how to adjust designs on the fly when parts weren’t the right size or tolerances didn’t match up. I had to drill, cut, and modify pieces using local tools, all while ensuring the prototype remained functional and safe. This hands-on work made me much more conscious of how materials behave in the real world.
Communication was another big area of growth. Presenting ideas to clinicians and non-designers forced me to adapt my language, use visual aids, and sketch ideas rapidly on whiteboards to get feedback. I learned to focus conversations on what mattered to each individual, asking the right questions, respecting their time, and making decisions based on their domain knowledge. Later in the project, I even presented my prototype to key funding figures, which taught me how to pitch concisely and professionally to a different type of stakeholder.
I worked largely independently, which at first was a surprise. The team trusted me to manage my own time and problem-solving process. While this freedom was daunting, it ultimately became a strength. I pushed myself beyond expectations, often exceeding the brief in terms of detail and refinement. That independence helped me grow in confidence, not just in design ability, but in my decision-making and initiative.
My university training gave me a solid base to work from. My 3D design and modelling courses were particularly useful, especially when integrating existing parts into new assemblies or creating exploded views for documentation. I regularly found myself applying skills I had learned in class, whether it was using rendering software, setting up a 3D printer, or modelling real-world hardware. That said, there were gaps I had to bridge. I struggled with file organisation, keeping track of versions, naming conventions, and file paths across a shared drive. I also had to teach myself how to design replaceable parts, accommodate snap fits, and plan for future modularity, things I hadn’t deeply explored in coursework. Designing for future iterations was a whole new concept for me to work around as often within the education environment a project won't be explored beyond the due date.
Reflecting on the entire experience, I’m proud of the prototype I produced. It looks refined, functions well, and became a central talking point with clinicians and participants. I was able to receive some very excited feedback from future users who can't wait for the day the BioSpine system and I contributed to is in their home. I was also proud to contribute knowledge to the team, whether it was SolidWorks techniques or 3D printing strategy, and have some of my ideas adopted over the original concepts. I felt like a valuable contributor, not just a student learning on the sidelines.
This placement has shifted my thinking about where I want to go in design. I used to see science and research-driven projects as too complex or inaccessible, but now I know I have the skills to contribute to that space. I can see myself designing tools for medicine, research, or even outer-space, where innovation happens at the intersection of technology and human need.
If I could give my past self one piece of advice before starting this internship, it would be: don’t be intimidated, just start. You’ll learn by doing, and the sooner you dive in, the sooner you’ll find your footing.