Yeah that's where we learned Mayuri modifies his zampato after every time he brings it out in bankai. Also has Mayuri been NOT paying attention to Orihime because when Aizen brought her to Hueco Mundo he pretty clearly made it known she makes things as if they never happened/existed.

Even if Ichigo get his bankai repaired, he'll still be an equivalent of a high ranking officer. I mean he was at least twice that of a captain with a full undamaged outfit. That being said if Ichigo develops his Quincy powers he could envelope external reishi along his sword to make it more powerful.