Principal Mechanical Engineer Metals and Materials

Intuitive•Sunnyvale, CA

About The Position

Intuitive Surgical, Inc. produces the da Vinci® Surgical System, a minimally invasive robotic surgery system that uses highly complex mechanics, replaceable instruments and accessories, and enhanced three-dimensional visualization to extend surgical technique and precision beyond the limits of the human hand. The Principal Engineer will strive to create the safest and highest quality devices for minimally invasive surgery through rigorous and robust technical analysis. We are seeking a skilled Metals & Materials Technology Expert to join our Core Instruments team, focusing on the performance, reliability, and manufacturability of high-performance metallic materials used in robotic surgical instruments. The successful candidate must have strong technical depth and experience in metals, materials science, and reliability engineering to support the development and continuous improvement of surgical instruments for the da Vinci Surgical System.

Requirements

Deep expertise in metallurgy of high-performance alloys.
Strong working knowledge of material selection criteria as applied to precision mechanical components with a focus for design for reliability and manufacturability.
Proficiency in failure analysis and failure mechanics, including fatigue, fracture mechanics, fractography, and root cause analysis methodologies.
Hands-on experience with metallographic preparation, grain structure analysis, microstructural characterization, and analytical techniques (optical microscopy, SEM, EDS, XRD, hardness testing).
Experience with manufacturing processes for metals such as MIM (metal injection molding), precision machining, forging, sintering, brazing, laser welding, and heat treatment.
Proven experience developing products compliant with safety standards and regulatory requirements for medical devices (FDA, ISO 13485, ISO 14971).
Lead by having a breadth of technical knowledge that enables a top-level view of the entire project.
Act as an interface between various technical specialties.
Take ownership of issues that cross disciplinary boundaries to ensure the success of the project.
Contribute to design documentation throughout the entire product lifecycle such as risks, specifications, test protocols, results, and regulatory materials.
Hands-on engineering experience with a proven ability to work well in a team environment.
Proven expertise and desire to coach engineers to share knowledge and impart best practices.
Ability to communicate effectively (written, oral) across all levels and organizations.
Desire to learn and resolve complex and challenging engineering problems.
Ability to travel up to 10% of time
Bachelor’s or master’s degree in mechanical engineering, materials science and engineering metallurgical Engineering, or related discipline (or equivalent experience).
Advanced degree (M.S. or Ph.D.) strongly preferred.
Minimum 15 years of relevant engineering experience.

Nice To Haves

Significant focus on metals and materials in the medical device, aerospace, or precision manufacturing industry.
Experience with the full medical device product development process and volume manufacturing.
Design, analyze and document components, structures, and mechanical assemblies in SolidWorks or similar CAD software.
Experience with reprocessing and sterilization effects on metallic materials in reusable surgical instruments.
Familiarity with Weibull analysis, reliability modeling, and statistical methods for material and component life prediction.
Experience with computational materials tools (e.g. FEA).
Hands-on experience with robotic surgical instrument architectures.
Well regarded in the industry or academia as a subject matter expert in metals or materials science.
Experience with design transfer to manufacturing, including process validation, test engineering, and service support.
Expertise in high performance plastics such as PEEK, PEI, PPSU and their manufacturing processes.

Responsibilities

Evaluate, select, and qualify metallic materials for new and existing instrument designs, driving improvements in reliability, useful life, clinical performance, and cost.
Lead studies to characterize wear mechanisms, friction behavior, and surface interactions of instrument components under simulated surgical use conditions.
Conduct and direct failure analysis investigations on field returns and manufacturing rejects using fractography, metallographic analysis and other characterization techniques.
Develop and optimize surface treatments, coatings, and passivation processes to enhance corrosion resistance and extend instrument life through reprocessing cycles.
Design and execute material characterization test protocols, including hardness, tensile, fatigue, and corrosion testing, to support design verification and validation activities.
Innovate and improve existing material applications and manufacturing processes (e.g., MIM, machining, forging, laser processing) to enhance precision, efficiency, and safety.
Collaborate with cross-functional teams, including Mechanical Design, Manufacturing Engineering, and Quality Engineering to incorporate materials solutions into product lines and resolve production issues.
Develop simulation or characterization methodologies to model material behavior, predict component life, and inform design decisions.
Perform risk analysis and implement safety mitigations. This includes documentation of risks, requirements, and test protocols to support requests for approval by regulatory agencies such as the FDA.
Provide technical mentorship to engineering staff on metallurgy, materials science challenges, and design principles for metallic components.
Provide support for resolution of field and manufacturing issues, serving as the go-to subject matter expert for metals-related root cause investigations.
Contribute to patent development and IP strategy related to novel material applications, surface engineering, and instrument design.