Sr. Design Engineer - New Products

6317-Synthes USA Products Legal Entity•West Chester, PA

About The Position

The Sr. Design Engineer – New Products supports the design and development of orthopedic implants, surgical instruments, and associated products, from early concept through design transfer and product launch. This senior technical contributor works with Product Development Engineering, Manufacturing, Quality, Regulatory, suppliers, and other cross-functional partners to turn product requirements and clinical needs into robust, manufacturable designs. The role calls for expertise in PTC Creo Parametric 3D CAD modeling, engineering drawings, GD&T, tolerance analysis, design for manufacturability, and PLM/change-control processes. The engineer independently manages complex design assignments, resolves technical design challenges, and helps establish best practices across Design Engineering. The position is based in West Chester, Pennsylvania, or Zuchwil, Switzerland. The successful candidate develops and iterates mechanical designs, supports verification and testing, and contributes to industrialization, design transfer, and commercial launch. They maintain accurate product definitions and documentation in Creo and Windchill/PLM systems and ensure models, drawings, specifications, and product configurations meet applicable procedures and standards.

Requirements

Bachelor’s degree in Mechanical Engineering, Product Design Engineering, Biomedical Engineering, or a related engineering discipline, or an equivalent combination of technical education and relevant industry experience.
For Switzerland, a completed technical/design engineering apprenticeship with relevant HF/FH-level advanced education or equivalent professional experience is an alternative.
Typically 5 or more years of relevant experience in mechanical design, product development, or design engineering.
Demonstrated experience developing complex orthopedic devices using Creo Parametric CAD software.
Strong experience creating production-level engineering drawings and applying GD&T.
Experience supporting products through multiple phases of a structured product-development lifecycle.
Working knowledge of PTC Creo Parametric 3D CAD software and Windchill/PLM systems.
Working knowledge of GD&T and engineering drawing standards, tolerance stack analysis, mechanical design principles, and Design for Manufacturing and Assembly.
Working knowledge of machined and manufactured components and metals and polymers commonly used in orthopedic products.
Working knowledge of design verification, engineering testing, rapid prototyping, engineering change management, and product configuration and documentation control.

Nice To Haves

Experience in the medical device, orthopedic, surgical instrument, or another highly regulated industry.
Experience designing orthopedic implants and/or surgical instrumentation.
Experience working directly with manufacturing suppliers.
Experience with design verification and product testing.
Experience supporting geographically distributed or global development teams.

Responsibilities

Develop concepts and detailed mechanical designs for orthopedic implants and surgical instruments.
Create and maintain PTC Creo 3D CAD models, assemblies, engineering drawings, and product documentation through the development lifecycle.
Translate product requirements, clinical needs, and engineering inputs into manufacturable product designs.
Support projects from concept development through design iteration, verification, design transfer, and commercial launch.
Evaluate design alternatives based on performance, manufacturability, quality, cost, schedule, and technical risk.
Iterate designs based on engineering testing, surgeon or user feedback, manufacturing input, and cross-functional reviews.
Apply GD&T, dimensional tolerancing, and tolerance stack analysis to verify functional requirements and establish design tolerances.
Apply Design for Manufacturing and Assembly principles and engineering judgment to improve producibility, quality, cost, reliability, and product function.
Conduct technical design reviews and provide feedback on designs produced by internal and external Design Engineering resources.
Identify opportunities to standardize components, design approaches, drafting methods, and engineering practices.
Partner with Product Development Engineers to convert concepts and requirements into detailed product definitions.
Collaborate with Manufacturing Engineering and suppliers to support reliable, efficient production and resolve design, manufacturing, and drawing issues.
Support prototyping, engineering builds, design verification, product testing, risk-management activities, tolerance reviews, and technical problem solving.
Provide CAD and design support during industrialization and design transfer.
Create and maintain product definitions in PTC Creo Parametric and Windchill/PLM systems.
Ensure CAD models, drawings, specifications, and related documentation are accurate, consistent, complete, and compliant with procedures and standards.
Support engineering changes and maintain product configuration throughout development.
Follow established naming, modeling, drawing, revision, and product-structure practices; maintain high standards for CAD model quality and drawing clarity.

Benefits

Consolidated retirement plan (pension) and savings plan (401(k)), subject to plan terms.
Eligibility to participate in the Company’s long-term incentive program.
Vacation: 120 hours per calendar year, subject to policy and date of hire.
Sick time: 40 hours per calendar year, with different amounts for employees residing in Colorado or Washington, subject to policy and date of hire.
Holiday pay, including floating holidays: 13 days per calendar year.
Work, Personal and Family Time: up to 40 hours per calendar year.
Parental Leave: 480 hours within one year of the birth, adoption, or foster care of a child.
Bereavement Leave: up to 240 hours for an immediate family member and 40 hours for an extended family member per calendar year.
Caregiver Leave: 80 hours in a 52-week rolling period.
Volunteer Leave: 32 hours per calendar year.
Military Spouse Time-Off: 80 hours per calendar year.