Reusable surgical instrumentsSurgical instruments are critical tools in orthopedic surgeryOrthopedic surgery; yet their progressive microstructural degradation from repeated clinical use can pose hidden risks to biomaterialBiomaterials integrity and patient safety. The present study investigates how cyclic sterilization, and handling can lead to surface deterioration and persistent contamination, facilitating bacterial adhesion and biofilm formationBiofilm formation. XRF, optical and electron microscopy were employed to assess surface and compositional changes in a single clinically used awl. The XRF results indicated a composition consistent with AISI 431 martensitic stainless steelStainless steel, and microscopy documented rim notching at the distal edge together with adherent granular residues within the lumen and at the transition into the distal rim. The analyses revealed localized surface damage consistent with material loss, as well as irregular deposits adhering to the metallic surface. Such degradation features are clinically relevant: physical defects may diminish functional efficiency and generate foreign particles, while persistent residues may reduce cleaning effectiveness and provide substrates for microbial colonization. These findings indicate that standard reprocessing may not fully restore instruments to their as-designed state. The findings support further investigation into reuse thresholds and optimized sterilization protocols, with direct implications for infection control, material longevity, and surgical outcomes in orthopedics and other settings where device sterility and integrity are essential. Observations are limited to one clinically used instrument and will be expanded with quantitative replication and residue chemistry in future work.