Senior Mechanical Design Engineer at Intuitive — Sunnyvale, CA

Key Responsibilities

Mechanical Design & Subsystem Ownership

• Lead the mechanical design of components, mechanisms, and subsystems supporting optics, illumination, electronics packaging, sealing, sterilization, and thermal performance.
• Translate system and subsystem requirements into detailed mechanical designs, specifications, and drawings.
• Drive detailed design execution from concept through prototype build, verification, and manufacturing transfer.
• Apply precision engineering principles, tolerance-driven design, and best practices for robust mechanical integration.

Cross-Functional Collaboration

• Work closely with Optics, Electrical Engineering, Firmware, Manufacturing, Reliability, Test, and Materials teams to resolve design tradeoffs and integration challenges.
• Actively participate in design reviews, risk assessments, and failure analysis discussions.
• Communicate technical concepts clearly across disciplines a

Prototyping, Testing & Analysis

• Build and iterate on proof-of-concept and engineering prototypes.
• Perform detailed 2D/3D tolerance analysis, stack-up modeling, and basic FEA/simulation to validate design margins.
• Develop and execute verification plans, DOEs, and durability testing to validate performance over the product lifecycle.
• Troubleshoot design and prototype issues using data-driven root-cause analysis.

Manufacturing, DFM/DFA & Supplier Engagement

• Drive DFM/DFA/DFS for assigned components and subsystems to enable scalable manufacturing.
• Collaborate with suppliers on fabrication, finishing, and joining processes (precision machining, molding, casting, coatings, bonding, etc.).
• Support supplier qualification, manufacturing ramp, and yield improvement activities.
• Partner with Manufacturing and Quality to support design transfer, sustaining engineering, and reliability improvements.

Documentation & Compliance

• Generate complete engineering documentation including drawings, tolerance analyses, specifications, test reports, and DHF content.
• Support regulatory and quality-system requirements throughout development.
• Contribute to intellectual property through invention disclosures and technical documentation.

Mentorship & Technical Growth

• Mentor junior engineers through design execution, best practices, and technical problem solving.
• Contribute to continuous improvement of design processes, tools, and standards within the team.

Required Skills & Experience

Technical Expertise

• Strong experience designing precision mechanical components and assemblies for electro-mechanical or opto-mechanical systems.
• Proficiency in SolidWorks 3D CAD, including complex assemblies, GD&T, and functional dimensioning.
• Solid understanding of tolerance analysis, stack-up modeling, and mechanical simulation tools.
• Experience applying DFM/DFA principles for complex or high-volume assemblies.
• Hands-on understanding of mechanical–optical interfaces, electronics packaging, thermal effects, and sterilization-driven design constraints.
• Experience designing fixtures, jigs, and basic calibration or alignment tools.

Execution & Collaboration

• Proven ability to independently own and execute complex mechanical designs.
• Strong problem-solving skills and comfort working in fast-paced, iterative development environments.
• Effective written and verbal communication skills for cross-functional collaboration.
• Ability to manage multiple technical efforts while maintaining clarity and accountability.

Education & Experience Requirements

• BS or higher in Mechanical Engineering, Mechatronics, Robotics, Biomedical Engineering, or a related discipline.
• 7–12 years of mechanical design experience in medical devices, robotics, imaging systems, or similarly demanding fields.
• Demonstrated experience across multiple phases of the product lifecycle: concept, design, prototyping, verification, and manufacturing transfer.
• Medical device experience preferred but not required.

Mandatory Notices