Sr Mechanical Design Engineer

It started with a simple idea: what if surgery could be less invasive and recovery less painful? Nearly 30 years later, that question still fuels everything we do at Intuitive. As a global leader in robotic-assisted surgery and minimally invasive care, our technologies—like the da Vinci surgical system and Ion—have transformed how care is delivered for millions of patients worldwide.

We’re a team of engineers, clinicians, and innovators united by one purpose: to make surgery smarter, safer, and more human. Every day, our work helps care teams perform with greater precision and patients recover faster, improving outcomes around the world.

The problems we solve demand creativity, rigor, and collaboration. The work is challenging, but deeply meaningful—because every improvement we make has the potential to change a life.

Primary Function of Position

The Endoluminal instrument design group at Intuitive is a dynamic and multidisciplinary team developing tools for the next generation of minimally invasive surgical robotics. We are seeking a Senior Mechanical Engineer with a focus on injection molding technology to conceptualize, develop, and verify new mechanical design concepts for the next generation of minimally invasive robotic flexible instruments. You will leverage your creativity and engineering analysis to the design of kinematics and user interfaces to ensure mechanical robustness from concept through verification and scaled manufacturing. The successful candidate will have both the technical depth to resolve complex mechanical, materials and manufacturing design issues and the ability to work in an interdisciplinary team to troubleshoot to root cause higher level system issues. This requires in-depth collaboration with cross-functional teams that will routinely leverage your technical and interpersonal skills as you develop a shared understanding of the new product requirements.

Essential Job Duties

Mechanical Design

Own mechanical assemblies for new instruments, focus on injection molding, from

concept through commercialization that meet demanding performance,

manufacturability, and reliability constraints using knowledge and experience to select

the optimal material and process (metal vs. plastic, molded vs. extruded vs. MIM vs.

formed, etc.).

Understand and design to optimize interfaces with mechanic, electronic, optic, and seal

elements.

Rapid development and iteration of proof-of-concept and high-fidelity prototypes of candidate architectures to satisfy requirements.

Complete detailed drawings and robust tolerance analysis and update designs accordingly.

Define engineering requirements and ensure candidate designs are backed by robust data prior to design freeze.

Perform detailed 2D/3D tolerance analysis, FEA/simulation, and statistical modeling to

ensure robust design margins.

Troubleshoot component and prototype performance issues with speed, rigor, and

cross-functional collaboration.

Develop test methods, fixtures, and measurement tools to evaluate the performance of

robotic catheters and sub-assemblies.

Provide written protocols, reports, drawings, specifications, presentations, and perform

technical design reviews to solicit feedback on design activities on an ongoing basis.

Manufacturing, DFM/DFA, and Supplier Engagement

Lead DFM/DFA discussions with cross-functional teams to understand key drivers of

product performance, durability, and ease of assembly.

Partner with suppliers on development and troubleshooting efforts to supply reliable,

complex components and assemblies.

Support transition to manufacturing, ramp-to-production, and lifecycle reliability

improvements.

Investigate and determine root cause of emerging design or manufacturing defects.

Technical Leadership

Utilize best-in-class mechanical design practices, precision engineering, tolerance-

driven design, and robust system integration.

Interface with clinical and human factor engineering to inform designs and identify user

needs.

Mentor and guide engineers on best practices in design and engineering with a

particular focus on designing for injection molding.

Support intellectual property creation and technical documentation.

Minimum Bachelor's Degree in Mechanical Engineering or

similar technical field

Experience with designing products in a regulated industry – familiarity with the concepts

of design inputs, design outputs, traceability, and risk analysis.

Experience with metals, plastics, fabrication methods outside of injection molding such

as castings, extrusions, sheet metal, bonding and adhesives.

Experience in several of these areas: concept development, design analysis, hands-on

prototyping, hands-on fabrication, and performance and reliability testing.

Comfortable with ambiguity and able to build clarity and consensus among cross-

functional stakeholders.

Comfortable coding in Python, Matlab, C/C++, Labview, Arduino or similar tools.

Experience with statistics and design of experiments.

Firsthand machining experience and familiarity with test and metrology equipment.

Demonstrated ability to think at a systems level, interface between multiple design

groups, and negotiate conflicting requirements.

Knowledge of component manufacturing processes such as injection molding, extrusion,

machining, wire EDM, MIM, heat treatment, electropolishing, laser welding, etc

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.

Intuitive is an Equal Opportunity Employer. We provide equal employment opportunities to all qualified applicants and employees, and prohibit discrimination and harassment of any type, without regard to race, sex, pregnancy, sexual orientation, gender identity, national origin, color, age, religion, protected veteran or disability status, genetic information or any other status protected under federal, state, or local applicable laws.

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.

We will consider for employment qualified applicants with arrest and conviction records in accordance with fair chance laws.

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.

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.