Staff Mechanical Design Engineer - New Product Development

Intuitive•Sunnyvale, CA

1d•$163,800 - $277,300•Onsite

About The Position

The Staff Mechanical Design Engineer independently owns technically demanding mechanical and electromechanical subsystems for robotic systems, leading subsystem architecture and detailed-design decisions, resolving complex multidisciplinary problems, and contributing to integration decisions beyond the assigned subsystem. This is a hands-on individual-contributor role combining mechanical design ownership with technical guidance and mentorship. The position reports to a Manager of Mechanical Design Engineering in New Product Development. The engineer owns subsystem development from concept through verification and design transfer, including requirements, specifications, design-risk analyses, verification documentation, and support for validation. The role designs precision mechanisms, joints, and actuation assemblies; uses first-principles calculations and simulation; creates and releases CAD models, manufacturing drawings, and design documentation; and builds and tests prototypes. The engineer collaborates with suppliers and cross-functional teams to resolve technical issues, improve manufacturability and cost, and prepare designs for transfer, while leading technical reviews and mentoring other engineers. The role is onsite four days per week in Sunnyvale, California. Work may include extended periods of computer-based design and analysis, occasional lab work involving prototype assembly and mechanical testing, and occasional lifting and handling of up to 25 pounds. Travel is 10%, including occasional visits to supplier and manufacturing sites.

Requirements

Experience developing robotic or complex electromechanical products in a regulated industry, with independent subsystem ownership from concept through design transfer.
Working knowledge of design controls, risk management, verification, and validation.
Deep expertise in first-principles mechanics and precision mechanisms, including demonstrated ability to perform stiffness, dynamics, and fatigue analysis.
Proficiency in GD&T, tolerancing, materials, DFM/DFA, and manufacturing processes.
Experience designing rotary or linear joints, sizing components, justifying decisions through analysis, integrating actuation and sensing, and collaborating with controls and electrical engineers.
Hands-on prototyping experience, including assembly, testing, debugging, and rapid iterations.
Proficiency with CAD, simulation, and PLM tools such as SolidWorks, ANSYS, and Windchill.
Demonstrated technical leadership through design reviews, cross-functional decision-making, stakeholder influence, and engineer mentorship.
Experience with risk management activities, including FMEA, risk mitigation, and reliability assessments.
A bachelor’s degree plus 12 years of relevant experience, a master’s degree plus 8 years, or a PhD plus 5 years.

Nice To Haves

Master’s or PhD degree in Mechanical Engineering or a related discipline.
Experience developing Class II or Class III medical devices, particularly surgical robotics or medical device capital equipment.
Direct application of standards and documentation frameworks such as ISO 13485, FDA QMSR (21 CFR Part 820), IEC 60601, ISO 14971, and DHF.
Experience supporting production launch, manufacturing scale-up, or post-launch reliability investigations, and applying those lessons to new product designs.

Responsibilities

Own subsystem development from concept through verification and design transfer, including mechanical requirements, specifications, design-risk analyses, and verification documentation; support validation activities with responsible functions.
Lead subsystem architecture decisions, compare alternatives, and justify tradeoffs.
Design precision mechanisms, joints, and actuation assemblies; select and size motors, bearings, transmissions, brakes, and sensors based on operating loads, motion requirements, and expected life.
Use first-principles calculations and simulation to assess load paths, component margins, structural stiffness, dynamic behavior, and fatigue life; check assumptions and correlate models with test results.
Create and release CAD models, manufacturing drawings, and design documentation; apply GD&T and tolerance analysis to functional interfaces, assembly requirements, and inspection.
Build, test, debug, and iterate prototypes; develop test methods and fixtures, investigate failures, and verify corrective actions.
Work with suppliers, supplier engineering, sourcing, and manufacturing to resolve technical issues, improve DFM/DFA and cost, and prepare designs for transfer.
Collaborate with systems, electrical, controls, clinical, human factors, manufacturing, supplier engineering and sourcing, quality, and regulatory partners to resolve requirements and subsystem interfaces.
Lead technical reviews and guide other engineers’ design and analysis approaches.
Plan technical work across functions, set priorities, resolve risks, and mentor engineers through problem-solving.