Staff Mechanical Design Engineer - New Product Development
Intuitive
Summary
The Staff Mechanical Design Engineer independently owns technically demanding mechanical and electromechanical subsystems for robotic systems. You will lead subsystem architecture and detailed-design decisions, resolve complex multidisciplinary problems, and contribute to integration decisions beyond your assigned subsystem. This is a hands-on individual contributor role combining mechanical design ownership with technical guidance and mentorship.
Job description
Primary Function of Position
The Staff Mechanical Design Engineer independently owns technically demanding mechanical and electromechanical subsystems for robotic systems. You will lead subsystem architecture and detailed-design decisions, resolve complex multidisciplinary problems, and contribute to integration decisions beyond your assigned subsystem. This is a hands-on individual contributor role combining mechanical design ownership with technical guidance and mentorship.
Essential Job Duties
- Own subsystem development from concept through verification and design transfer, including mechanical requirements, specifications, design-risk analyses and verification documentation.
- Support validation activities with the responsible functions.
- Lead subsystem architecture decisions. Compare alternatives and justify tradeoffs.
- Design precision mechanisms, joints and actuation assemblies.
- Select and size components such as motors, bearings, transmissions, brakes and sensors based on operating loads, motion requirements and expected life.
- Use first-principles calculations and simulation to establish load paths, component margins, structural stiffness, dynamic behavior and fatigue life. Check assumptions and correlate models with test results.
- Create and release CAD models, manufacturing drawings and design documentation.
- Apply GD&T and tolerance analysis to functional interfaces, assembly requirements and inspection.
- Build, test, debug and iterate prototypes.
- Develop test methods and fixtures, investigate failures, and verify corrective actions.
- Work directly with suppliers, supplier engineering, sourcing and manufacturing to resolve technical issues, improve DFM/DFA and cost, and prepare designs for transfer.
- Collaborate with systems, electrical, controls, clinical, human factors, manufacturing, supplier engineering/sourcing, quality and regulatory partners to resolve requirements and subsystem interfaces.
- Lead technical reviews and guide other engineers' design and analysis approaches.
- Plan technical work across functions, set priorities, resolve risks and mentor engineers through problem-solving.
Working Conditions
On-site four days per week in Sunnyvale, CA. May involve extended periods of computer-based design and analysis work. Must be comfortable occasionally working in lab environments, including prototype assembly, mechanical testing, and safe use of standard mechanical tools and fixtures. Must be able to occasionally lift and handle 25 pounds. Travel: 10%, including occasional visits to supplier and manufacturing sites.
Requirements
- Experience developing robotic or complex electromechanical products in a regulated industry, with demonstrated independent subsystem ownership from concept through design transfer
- Working knowledge of design controls, risk management, verification and validation
- Deep expertise in first-principles mechanics and precision mechanisms, with demonstrated ability to perform stiffness, dynamics and fatigue analysis
- Proficiency in GD&T, tolerancing, materials, DFM/DFA and manufacturing processes
- Experience designing rotary or linear joints, sizing components, and justifying decisions through analysis; integrating actuation and sensing; and collaborating effectively with controls and electrical engineers
- Hands-on prototyping experience, including assembly, testing, debugging, and rapid iterations
- Proficient with CAD, simulation, and PLM tools such as SolidWorks, ANSYS, and Windchill
- Demonstrated technical leadership through design reviews, cross-functional decision-making, stakeholder influence and engineer mentorship
- Experience with risk management activities including FMEA, risk mitigation, and reliability assessments
- Bachelor's degree plus 12 years of relevant experience, or a Master's degree plus 8 years, or a PhD plus 5 years
- Master's or PhD degree in Mechanical Engineering or a related discipline (preferred)
- Experience developing Class II or Class III medical devices, particularly surgical robotics or medical device capital equipment (preferred)
- Direct application of standards and documentation frameworks such as ISO 13485, FDA QMSR (21 CFR Part 820), IEC 60601, ISO 14971, and DHF (preferred)
- Experience supporting production launch, manufacturing scale-up or post-launch reliability investigations (preferred)
Benefits
- Medical, Dental & Vision
- 401(k) Matching
- Equity
- Incentives
Company overview
Intuitive Surgical, Inc., commonly known as Intuitive, is a global technology leader in minimally invasive care and the pioneer of robotic-assisted surgery. Founded in 1995 and headquartered in Sunnyvale, California, the company has revolutionized surgical procedures through its flagship da Vinci Surgical System and Ion endoluminal system. As a publicly traded company on NASDAQ (ISRG), Intuitive has established itself as the dominant player in robotic surgery, with over 15,000 employees worldwide and an installed base of thousands of surgical systems across more than 60 countries. The company's innovative platforms enable surgeons to perform complex procedures with enhanced precision, flexibility, and control through minimally invasive techniques. Intuitive's technology portfolio includes advanced vision systems, wristed instruments, and intelligent software that work together to optimize surgical outcomes. The company continues to expand its product offerings and geographic presence while maintaining a strong focus on clinical evidence, physician training, and patient safety. With annual revenues exceeding $8 billion, Intuitive represents a transformative force in modern healthcare, driving the adoption of robotic-assisted procedures across multiple surgical specialties including urology, gynecology, general surgery, and thoracic surgery.