Senior, Packaging Design Engineer

Intuitive; Sunnyvale (CA); On-site; USD 140,000 - 200,000; Full time

Job summary

Intuitive in Sunnyvale is seeking a Medical Device Packaging Design Engineer to lead the design, verification, and launch of packaging for sterile and non-sterile devices, including surgical instruments and electromechanical capital equipment.

You will collaborate with Product Management, Human Factors, Regulatory, and Manufacturing to translate clinical and user needs into packaging specs that meet FDA and ISO 11607 requirements and enable scalable manufacturing.

Responsibilities

• Lead the design, optimization, verification and documentation of complex mechanical packaging systems for new product introductions and existing products.
• Apply analytical skills and detailed engineering analysis (tolerance stack, FEA, process simulation) to ensure fit, form and function.
• Plan, execute and document comprehensive packaging testing protocols (ISTA/ASTM, seal strength, peel force, burst, leak).
• Rapidly develop and iterate full-scale prototypes; perform risk analyses and develop design requirements.
• Conduct material evaluation and selection; interface with suppliers to qualify components for volume manufacturing.
• Represent Packaging Design Engineering on cross-functional project teams for next-generation products.
• Collaborate with Product Management, Human Factors and Clinical Development Engineering to translate requirements into specs.
• Work with manufacturing and automation teams to develop fixtures and assembly processes; support production as needed.
• Direct design changes, process improvements, and cost reductions aligned with regulatory and sustainability goals.

Job description

Job Description

Primary Function of Position

The Medical Device Packaging Design Engineer is a critical engineering role responsible for the design, development, verification, and launch of next-generation mechanical packaging systems for sterile and non-sterile medical devices such as surgical instruments, disposables, and electromechanical capital equipment. This individual will use sound engineering judgement and independently drive new product development (NPD) and sustaining engineering efforts through cross functional collaboration, ensuring designs meet stringent clinical, functional, global regulatory (FDA, ISO 11607, EU), and quality requirements. The successful candidate excels in a fast-paced environment, applying strong technical depth to resolve complex problems and ensure successful, compliant and scalable product launches.

Essential Job Duties

Design, Development, and Verification

• Lead the design, optimization, verification (including engineering testing) and documentation of complex primary, secondary, and tertiary mechanical packaging systems and components (e.g., trays, blisters, pouches, cartons, corrugated shippers, foam) for new product introductions (NPI) and existing products.
• Apply analytical skills and detailed engineering analysis (e.g., tolerance stack analysis, structural FEA, and process simulation) to ensure the fit, form, and function of complex packaging designs.
• Plan, execute, and document comprehensive packaging testing protocols (e.g., transit/distribution testing (ISTA/ASTM), seal strength, peel force, burst, leak) according to industry and regulatory standards.
• Rapidly develop and iterate full-scale prototypes of candidate designs that satisfy rigorous design requirements and user needs. Analyze and test components, including performing risk analyses and developing design requirements.
• Conduct advanced material evaluation and selection, interfacing with suppliers to qualify new packaging components and technologies for volume manufacturing.
• Represent Packaging Design Engineering on cross-functional project teams, leading the design and development of mechanical packaging systems for next-generation surgical and energy products.
• Work closely with Product Management, Human Factors and Clinical Development Engineering to translate clinical requirements and user needs into functional and technical specifications for packaging.
• Collaborate with manufacturing and automation teams to provide technical expertise to assist with the development of fixtures and assembly processes in as needed.
• Direct design changes, process improvements, and cost reductions aligned with regulatory, risk, and sustainability goals.

Cross-functional Collaboration and Leadership

• Collaborate cross-functionally with Process Engineering, Quality Assurance, Manufacturing Operations, and Logistics teams to ensure seamless packaging integration and robust transfer to production.
• Interface with manufacturing to create product assembly and packaging tooling, fixtures, and instructions.
• Drive continuous improvement initiatives for packaging processes, materials, cost-effectiveness, and sustainability.
• Mentor junior engineers and provide technical guidance, inspiring the team toward successful project completion.

Regulatory Compliance and Sustaining Support

• Ensure all designs and processes meet FDA, ISO 11607, and other global international standards, maintaining audit readiness for engineering functions.
• Support the quality and regulatory processes, which may include reviewing and approving submissions for packaging in regulatory filings (e.g., 510(k)).
• Provide mechanical engineering sustaining support for resolution of supply chain, manufacturing, and field issues for both the device and its packaging.
• Support production of the final product by troubleshooting process and component problems for mechanical packaging systems.
• Own packaging components and assemblies from concept through design verification, qualification, and commercial transfer.
• Perform root cause analysis and implement corrective/preventive actions (CAPA) for packaging design related non-conformances.
• Contribute to design processes, including Failure Modes and Effects Analyses (FMEA), to mitigate risks related to product damage and sterility.