Staff Mechanical Engineer - Future Opportunity

Intuitive•Sunnyvale, CA

4d•Onsite

About The Position

The Staff Mechanical Design Engineer independently owns technically demanding mechanical and electromechanical subsystems for robotic systems. The role leads subsystem architecture and detailed-design decisions, resolves complex multidisciplinary problems, and contributes to integration decisions beyond the assigned subsystem. It is a hands-on individual-contributor position 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, and verification documentation. Responsibilities include leading architecture decisions; designing precision mechanisms, joints, and actuation assemblies; selecting and sizing components; performing first-principles calculations and simulation; creating and releasing CAD models, drawings, and design documentation; and building, testing, debugging, and iterating prototypes. The role also supports validation, develops test methods and fixtures, investigates failures, and verifies corrective actions. The engineer works with suppliers and cross-functional partners to resolve technical issues, improve manufacturability and cost, and prepare designs for transfer. They lead technical reviews, guide engineering approaches, plan technical work across functions, set priorities, resolve risks, and mentor engineers. The position is on-site four days per week in Sunnyvale, California, with 10% travel, including occasional supplier and manufacturing-site visits. Work may include extended computer-based design and analysis, occasional lab work involving prototype assembly and mechanical testing, and occasional lifting and handling of up to 25 pounds. Intuitive may require current proof of vaccination against certain diseases, including COVID-19, depending on the role and customer requirements. Compensation is market-competitive and includes base pay, incentives, benefits, and equity; the posting does not provide numerical compensation ranges.

Requirements

Experience developing robotic or complex electromechanical products in a regulated industry, with demonstrated 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, and justifying decisions through analysis; integrating actuation and sensing; and collaborating effectively 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.
Typical minimum education and experience: Bachelor’s degree plus 12 years of relevant experience, Master’s degree plus 8 years, or PhD plus 5 years.
Comfortable occasionally working in lab environments, including prototype assembly and mechanical testing, and using standard mechanical tools and fixtures safely.
Able to occasionally lift and handle 25 pounds.

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 the responsible functions.
Lead subsystem architecture decisions, compare alternatives, and justify tradeoffs.
Design precision mechanisms, joints, and actuation assemblies.
Select and size components such as motors, bearings, transmissions, brakes, and sensors based on operating loads, motion requirements, and expected life.
Use first-principles calculations and simulation to establish 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/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.