Senior Mechanical Design Engineer

Intuitive•Sunnyvale, CA

About The Position

We are seeking a hands-on, deeply technical individual contributor who delivers complex mechanical design solutions for next-generation surgical robotics instruments platforms. This Senior Mechanical Design Engineer role within our Future Forward team requires strong technical fundamentals, hands-on problem-solving ability, and a collaborative mindset. You will make significant individual contributions across the product lifecycle, from concept generation through human cases, while helping to raise the technical bar of those around you.

Requirements

Bachelor’s or Master’s in Mechanical Engineering, Mechatronics, Systems Engineering, or related discipline (or equivalent experience).
A minimum of 6 years designing mechanical engineering products or relevant engineering experience (medical device industry preferred).
Expertise in the design of high-precision mechanisms, electromechanical systems, and complex tolerance stacks.
Demonstrated ability to drive new product ideas from concept to launch in regulated environments, with growing ownership and scope.
Demonstrated understanding of engineering fundamentals, including first-principles analysis, FEA, GD&T (ANSI Y14.5), materials, design for reliability and manufacturability, and statistical analysis.
Highly proficient in CAD (SolidWorks preferred): complex assemblies, production documentation, and DFM/DFA.
Proficient with rapid prototyping techniques.
Track record of strong individual technical contributions and effective collaboration in cross-functional teams.
Excellent communication, organizational, and documentation skills.
Able to manage multiple fast-paced projects simultaneously.

Nice To Haves

Advanced degree is a plus.
Experience with the full medical device product development process and volume manufacturing.
Experience with medical devices including FDA QSR 21 CFR Part 820, ISO 13485, IEC 60601, and other related external standards is a strong plus.
Experience with electromechanical design, including cable driven systems and small mechanisms, is a strong plus (Robotics experience preferred).
Hands-on experience with robotic system architectures, actuation, kinematics, and sensing.
Experience in design transfer to manufacturing, including test engineering and service.

Responsibilities

Work in a cross-functional project team to design and develop robotic surgical instruments.
Design and develop complex mechanical and electromechanical and robotic systems’ instruments for surgical applications.
Execute the end-to-end engineering process: translating user requirements and technical specifications into design solutions through concept generation, hands-on prototyping, testing, pre-clinical and verification/validation activities.
Contribute to sound technology and design decisions, balancing system reliability, manufacturability, risks, and clinical needs.
Generate and execute test methods to characterize product prototype designs and to determine root cause of design, manufacturing, or material defects.
Critically analyze test results and make design changes or recommendations to the design team.
Generate product requirements and functional specifications that drive product safety, performance, and durability for robotic instruments, subsystems, and systems.
Provide written protocols, reports, presentations, and perform technical design reviews to solicit feedback on design activities.
Development and documentation of mechanical design and manufacturing documentation including: inspection procedures, assembly instructions, manufacturing processes, test methods, purchase specifications, BOMs, component / assembly drawings per the company’s operating procedures.
Create and maintain SolidWorks CAD databases, including assemblies, components, and detailed drawings.
Actively contribute to multi-disciplinary R&D projects, taking ownership of assigned technical workstreams across the product lifecycle.
Provide technical guidance and informal mentorship to junior engineers within the team, reviewing technical output and sharing best practices.
Participate in and lead technical reviews and risk analyses within your area; support regulatory and standards compliance activities.
Work closely with software, electrical, systems, clinical, and manufacturing teams throughout product development.
Observe clinical procedures and collaborate with clinicians to inform design and use requirements.
Provide support for pre-clinical and clinical labs.
Present complex concepts and data clearly to technical and non-technical stakeholders.
Rapidly develop and iterate functional prototypes to evaluate design solutions and validate key technical assumptions.
Contribute to patent development and IP strategy.
Observe clinical cases and participate in interviews with clinical experts to inform designs.
Stay abreast of technological advancements and facilitate knowledge sharing across the team.