Staff Mechanical Engineer - Future Opportunity

Intuitive Surgical, Inc.; Sunnyvale (CA); On-site; USD 130,000 - 195,000; Full time

Job summary

Intuitive Surgical is seeking a Staff Mechanical Design Engineer to own demanding mechanical and electromechanical subsystems for robotic systems. You will lead subsystem architecture, mentor engineers, and collaborate across mechanical, electrical, controls, and quality teams.

Based in Sunnyvale, CA, the role is on-site four days a week, involves verification, design transfer, and creating manufacturing drawings with GD&T. A bachelor’s degree with extensive experience or higher is expected.

Qualifications

• Experience developing robotic or complex electromechanical products in a regulated industry.
• Working knowledge of design controls, risk management, verification and validation.
• Deep expertise in first-principles mechanics and precision mechanisms.
• 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.
• Hands-on prototyping experience, including assembly, testing, debugging, and rapid iterations.
• Proficient 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.

Responsibilities

• Own subsystem development from concept through verification and design transfer.
• Lead subsystem architecture decisions and tradeoffs.
• Design precision mechanisms, joints and actuation assemblies; select motors, bearings, transmissions, brakes and sensors.
• Use first-principles calculations to establish load paths, margins, and fatigue life.
• Create and release CAD models, drawings with GD&T and tolerance analysis.
• Build, test, debug and iterate prototypes; develop test methods and verify actions.
• Collaborate with suppliers, sourcing, and manufacturing to resolve issues and prepare designs for transfer.
• Coordinate with systems, electrical, controls, clinical, human factors and quality to resolve interfaces.
• Lead technical reviews and mentor engineers; plan work across functions.

Skills

Robotic/mechatronic product design

Design controls & risk management

First-principles mechanics

GD&T & tolerancing

Actuation & sensing integration

Prototyping & testing

CAD/Simulation/PLM tools (SolidWorks/…

Technical leadership & design reviews

FMEA & reliability assessments

Education

Bachelor's degree + 14 years experience

Master's degree + 10 years

PhD + 6 years

Master's or PhD in Mechanical Engineering

Tools

SolidWorks

ANSYS

Windchill

Job description

Company Description

At Intuitive, we are united behind our mission: we believe that minimally invasive care is life-enhancing care. Through ingenuity and intelligent technology, we expand the potential of physicians to heal without constraints. As a pioneer and market leader in robotic-assisted surgery, we strive to foster an inclusive and diverse team, committed to making a difference. For more than 25 years, we have worked with hospitals and care teams around the world to help solve some of healthcare's hardest challenges and advance what is possible. Intuitive has been built by the efforts of great people from diverse backgrounds. We believe great ideas can come from anywhere. We strive to foster an inclusive culture built around diversity of thought and mutual respect. We lead with inclusion and empower our team members to do their best work as their most authentic selves. Passionate people who want to make a difference drive our culture. Our team members are grounded in integrity, have a strong capacity to learn, the energy to get things done, and bring diverse, real world experiences to help us think in new ways. We actively invest in our team members to support their long-term growth so they can continue to advance our mission and achieve their highest potential. Join a team committed to taking big leaps forward for a global community of healthcare professionals and their patients. Together, let's advance the world of minimally invasive care.

Job Description

The Staff Mechanical Design Engineer independently owns technically demanding mechanical and electromechanical subsystems for robotic systems. You will lead subsystem architecture and detailed-design decisions, resolve complex multidisciplinary problems, and contribute to integration decisions beyond your assigned subsystem. This is a hands-on individual contributor role combining mechanical design ownership with technical guidance and mentorship. The role reports to a Manager of Mechanical Design Engineering in New Product Development.

Essential Job Duties

• 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 directly 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.

Qualifications

Required Skills and Experience

• 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, with 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.
• Proficient 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.

Required Education and Training

• Required: Typical minimum Bachelor's degree plus 14 years of relevant experience, or a Master's degree plus 10 years, or a PhD plus 6 years.
• Preferred: Master's or PhD degree in Mechanical Engineering or a related discipline.

Working Conditions

• On-site four days per week in Sunnyvale, CA.
• May involve extended periods of computer-based design and analysis work.
• Must be comfortable occasionally working in lab environments, including prototype assembly, mechanical testing, and safe use of standard mechanical tools and fixtures.
• Must be able to occasionally lift and handle 25 pounds.
• Travel: 10%, including occasional visits to supplier and manufacturing sites.

Preferred Skills and Experience

• 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.

Additional Information

Due to the nature of our business and the role, please note that Intuitive and/or your customer(s) may require that you show current proof of vaccination against certain diseases including COVID-19. Details can vary by role.

Mandatory Notices

U.S. Export Controls Disclaimer: In accordance with the U.S. Export Administration Regulations (15 CFR §743.13(b)), some roles at Intuitive Surgical may be subject to U.S. export controls for prospective employees who are nationals from countries currently on embargo or sanctions status.

Certain information you provide as part of the application will be used for purposes of determining whether Intuitive Surgical will need to (i) obtain an export license from the U.S. Government on your behalf (note: the government's licensing process can take 3 to 6+ months) or (ii) implement a Technology Control Plan ("TCP") (note: typically adds 2 weeks to the hiring process).

For any Intuitive role subject to export controls, final offers are contingent upon obtaining an approved export license and/or an executed TCP prior to the prospective employee's start date, which may or may not be flexible, and within a timeframe that does not unreasonably impede the hiring need. If applicable, candidates will be notified and instructed on any requirements for these purposes.

We will consider for employment qualified applicants with arrest and conviction records in accordance with fair chance laws.

Preference will be given to qualified candidates who do not reside, or plan to reside, in Alabama, Arkansas, Delaware, Florida, Indiana, Iowa, Louisiana, Maryland, Mississippi, Missouri, Oklahoma, Pennsylvania, South Carolina, or Tennessee.

This position may be filled at a different job level than listed here depending on business need and/or on the selected candidate's experience, knowledge and skills.

Compensation will be based primarily on the job level at which the role is filled and the candidate's qualifications, consistent with applicable law.

Accommodation & Accessibility Notice

Intuitive is committed to providing reasonable accommodations to qualified individuals with disabilities. If you require assistance or an accommodation during any part of the application or interview process, please contact People Services at (email protected) .

We provide market-competitive compensation packages, inclusive of base pay, incentives, benefits, and equity. It would not be typical for someone to be hired at the top end of range for the role, as actual pay will be determined based on several factors, including experience, skills, and qualifications. The target compensation ranges are listed.