Senior Mechanical Design Engineer

Intuitive•Sunnyvale, CA

11d

About The Position

This role focuses on leading the mechanical design of components, mechanisms, and subsystems for robotic-assisted surgery technologies. The engineer will be responsible for the entire design execution process, from concept to manufacturing transfer, ensuring precision, robustness, and integration with other system components. Collaboration with cross-functional teams, prototyping, testing, analysis, and supplier engagement are key aspects of this position. The role also involves documentation, compliance, and mentoring junior engineers.

Requirements

Strong experience designing precision mechanical components and assemblies for electro-mechanical or opto-mechanical systems.
Proficiency in SolidWorks 3D CAD, including complex assemblies, GD&T, and functional dimensioning.
Solid understanding of tolerance analysis, stack-up modeling, and mechanical simulation tools.
Experience applying DFM/DFA principles for complex or high-volume assemblies.
Hands-on understanding of mechanical–optical interfaces, electronics packaging, thermal effects, and sterilization-driven design constraints.
Experience designing fixtures, jigs, and basic calibration or alignment tools.
Proven ability to independently own and execute complex mechanical designs.
Strong problem-solving skills and comfort working in fast-paced, iterative development environments.
Effective written and verbal communication skills for cross-functional collaboration.
Ability to manage multiple technical efforts while maintaining clarity and accountability.
BS or higher in Mechanical Engineering, Mechatronics, Robotics, Biomedical Engineering, or a related discipline.
7–12 years of mechanical design experience in medical devices, robotics, imaging systems, or similarly demanding fields.
Demonstrated experience across multiple phases of the product lifecycle: concept, design, prototyping, verification, and manufacturing transfer.

Nice To Haves

Medical device experience preferred but not required.

Responsibilities

Lead the mechanical design of components, mechanisms, and subsystems supporting optics, illumination, electronics packaging, sealing, sterilization, and thermal performance.
Translate system and subsystem requirements into detailed mechanical designs, specifications, and drawings.
Drive detailed design execution from concept through prototype build, verification, and manufacturing transfer.
Apply precision engineering principles, tolerance-driven design, and best practices for robust mechanical integration.
Work closely with Optics, Electrical Engineering, Firmware, Manufacturing, Reliability, Test, and Materials teams to resolve design tradeoffs and integration challenges.
Actively participate in design reviews, risk assessments, and failure analysis discussions.
Communicate technical concepts clearly across disciplines.
Build and iterate on proof-of-concept and engineering prototypes.
Perform detailed 2D/3D tolerance analysis, stack-up modeling, and basic FEA/simulation to validate design margins.
Develop and execute verification plans, DOEs, and durability testing to validate performance over the product lifecycle.
Troubleshoot design and prototype issues using data-driven root-cause analysis.
Drive DFM/DFA/DFS for assigned components and subsystems to enable scalable manufacturing.
Collaborate with suppliers on fabrication, finishing, and joining processes (precision machining, molding, casting, coatings, bonding, etc.).
Support supplier qualification, manufacturing ramp, and yield improvement activities.
Partner with Manufacturing and Quality to support design transfer, sustaining engineering, and reliability improvements.
Generate complete engineering documentation including drawings, tolerance analyses, specifications, test reports, and DHF content.
Support regulatory and quality-system requirements throughout development.
Contribute to intellectual property through invention disclosures and technical documentation.
Mentor junior engineers through design execution, best practices, and technical problem solving.
Contribute to continuous improvement of design processes, tools, and standards within the team.