Thermal Design Engineer 3

Socket.dev; Sunnyvale (CA); On-site; USD 130,000 - 180,000; Full time

Job summary

Intuitive Surgical in Sunnyvale, CA seeks a Thermal Design Engineer to own the thermal architecture for Da Vinci Vision hardware. You will lead airflow, heatsinks, and cooling strategies while coordinating with mechanical, optical, electrical, and software teams.

The role requires 3+ years in thermal engineering, CFD/FEA modeling, and experience with medical device design controls. Travel up to 10% may be expected; vaccination considerations apply.

Qualifications

• BS in Mechanical Engineering or related field; thermals focus preferred.
• 3+ years in thermal engineering for electronics cooling and testing.
• Strong knowledge of heat transfer, fluids, and thermal management.

Responsibilities

• Own thermal design, analysis, testing, performance, and compliance for vision hardware products.
• Develop thermal solutions including heat sinks, heat pipes, vapor chambers, TIMs, and fans.
• Create analytical, CFD, and FEA models and correlate with lab data.
• Plan thermal characterization, validation, and accelerated life testing.
• Define thermal limits and protection with electrical/software teams.
• Specify/qualify components and engage suppliers as needed.
• Collaborate with mechanical, optical, electrical, systems, software, and manufacturing teams.
• Support DFM/DFA for transfer from development to production.

Skills

Thermal engineering

CFD analysis

Heat transfer

Electronics cooling

Thermal testing

Python

Cross-functional collaboration

Problem solving

Education

Bachelor's in Mechanical Engineering

Master's degree (preferred)

Tools

SolidWorks

CATIA

ANSYS Icepak

FLOTHERM / Fluent

Job description

Primary Function of Position:

We are seeking a Thermal Design Engineer to join the Da Vinci Vision Hardware R&D team and partner in the architecture, development, verification, and transfer of next-generation vision systems from concept through launch.

This role will serve as the thermal engineering owner and subject matter expert for endoscope, illumination, and computing products, with accountability for thermal architecture, performance, reliability, testing, and compliance. The successful candidate will ensure products are thermally robust, meet all applicable requirements, and maintain sufficient operating margin throughout their lifecycle.

In addition to thermal leadership, this individual will contribute to broader mechanical and opto‑mechanical design efforts as program needs require.

Roles & Responsibilities:

• Own thermal design, analysis, testing, performance, and compliance across vision hardware products and systems.
• Develop thermal solutions including airflow management, heat sinks, heat pipes, vapor chambers, TIMs, and active cooling systems.
• Create analytical, CFD, and FEA thermal models and correlate results with laboratory testing.
• Plan and execute thermal characterization, validation, accelerated life testing, and model correlation activities.
• Define thermal limits, derating strategies, and protection approaches with electrical and software teams.
• Specify and qualify thermal components and collaborate with suppliers.
• Leverage and manage external engineering resources and contractors as needed to supplement internal capacity.
• Create and review CAD designs, drawings, assemblies, tolerances, and related documentation.
• Partner closely with mechanical, optical, electrical, systems, software, and manufacturing teams.
• Support DFM/DFA activities to ensure successful transfer from development to production.

Skills, Experience, Education, & Training:

• BS in Mechanical Engineering, Thermal Sciences, Physics, or related field.
• 3+ years of experience in thermal engineering, electronics cooling, CFD, or thermal test and validation.
• Strong understanding of heat transfer, fluid mechanics, airflow, and thermal management.
• Experience with CFD tools such as ANSYS Icepak, FloTHERM, FLOEFD, Fluent, or similar.
• Experience with thermal testing, instrumentation, and model correlation.
• Direct experience with heat sinks, heat pipes, vapor chambers, TIMs, fans, and high‑power electronics cooling.
• Familiarity with advanced thermal materials and technologies.
• Proficiency in SolidWorks, CATIA, or equivalent CAD tools.
• Programming experience with Python, MATLAB, or similar scripting languages is a plus.
• Demonstrated use of AI tools to improve engineering workflows and productivity.
• Strong problem‑solving, communication, and cross‑functional collaboration skills.
• Thrives in ambiguous, fast‑paced development environments and demonstrates excellent organizational skills, with the ability to manage multiple projects and shifting priorities simultaneously.
• Prior experience with the Design Control processes for medical devices and clinical application of surgical instruments is a plus.
• Prior experience with Agile Change Control and SAP is a plus.
• Ability to travel up to 10% of the time.

What Success Looks Like:

• Delivers thermally robust, compliant products with appropriate performance margin.
• Translates ambiguous requirements into practical thermal solutions and validated designs.
• Effectively connects simulation, testing, CAD, and manufacturing constraints to drive decisions.
• Serves as the trusted thermal engineering expert across multiple Vision Hardware programs.
• Contribute to broader mechanical and opto‑mechanical design efforts when required.

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.

Intuitive is an Equal Opportunity Employer.We provide equal employment opportunities to all qualified applicants and employees, and prohibit discrimination and harassment of any type, without regard to race, sex, pregnancy, sexual orientation, gender identity, national origin, color, age, religion, protected veteran or disability status, genetic information or any other status protected under federal, state, or local applicable laws.

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 employeeswho 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’sstart 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 dependingbusiness 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 thecandidate’s qualifications, consistent with applicable law.

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.

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 [e-mail].

It started with a simple idea: what if surgery could be less invasive and recovery less painful? Nearly 30 years later, that question still fuels everything we do at Intuitive. As a global leader in robotic‑assisted surgery and minimally invasive care, our technologies—like the da Vinci surgical system and Ion—have transformed how care is delivered for millions of patients worldwide.

We’re a team of engineers, clinicians, and innovators united by one purpose: to make surgery smarter, safer, and more human. Every day, our work helps care teams perform with greater precision and patients recover faster, improving outcomes around the world.

The problems we solve demand creativity, rigor, and collaboration. The work is challenging, but deeply meaningful—because every improvement we make has the potential to change a life.

If you’re ready to contribute to something bigger than yourself and help transform the future of healthcare, you’ll find your purpose here.