Staff Mechanical Design Engineer - New Product Development

About the role

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. The role reports to a Manager of Mechanical Design Engineering in New Product Development.

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.

Required Skills and Experience

• 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.

Required Education and Training

• Required: Typical minimum Bachelor's degree plus 12 years of relevant experience, or a Master's degree plus 8 years, or a PhD plus 5 years.
• Preferred: Master's or PhD degree in Mechanical Engineering or a related discipline.

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.

Preferred Skills and Experience

The following skills and experience are not required but represent attributes of an ideal candidate.

• Experience developing Class II or Class III medical devices, particularly surgical robotics or medical device capital equipment.
• Direct application of standards and documentation frameworks such as ISO 13485, FDA QMSR (21 CFR Part 820), IEC 60601, ISO 14971, and DHF.
• Experience supporting production launch, manufacturing scale-up or post-launch reliability investigations, and applying those lessons to new product designs.

Additional Information

Due to the nature of our business and the role, please note that Intuitive and/or your customer(s) may require that you show current proof of vaccination against certain diseases including COVID-19. Details can vary by role.

Mandatory Notices

U.S. Export Controls Disclaimer: In accordance with the U.S. Export Administration Regulations (15 CFR §743.13(b)), some roles at Intuitive Surgical may be subject to U.S. export controls for prospective employees who are nationals from countries currently on embargo or sanctions status.

Certain information you provide as part of the application will be used for purposes of determining whether Intuitive Surgical will need to (i) obtain an export license from the U.S. Government on your behalf (note: the government's licensing process can take 3 to 6+ months) or (ii) implement a Technology Control Plan ("TCP") (note: typically adds 2 weeks to the hiring process).

For any Intuitive role subject to export controls, final offers are contingent upon obtaining an approved export license and/or an executed TCP prior to the prospective employee's start date, which may or may not be flexible, and within a timeframe that does not unreasonably impede the hiring need. If applicable, candidates will be notified and instructed on any requirements for these purposes.

Preference will be given to qualified candidates who do not reside, or plan to reside, in Alabama, Arkansas, Delaware, Florida, Indiana, Iowa, Louisiana, Maryland, Mississippi, Missouri, Oklahoma, Pennsylvania, South Carolina, or Tennessee.

This position may be filled at a different job level than listed here depending on business need and/or on the selected candidate's experience, knowledge and skills.

Compensation will be based primarily on the job level at which the role is filled and the candidate's qualifications, consistent with applicable law.

Accommodation & Accessibility Notice

We provide market-competitive compensation packages, inclusive of base pay, incentives, benefits, and equity. It would not be typical for someone to be hired at the top end of range for the role, as actual pay will be determined based on several factors, including experience, skills, and qualifications. The target compensation ranges are listed.