Senior Mechanical Design Engineer

Primary Function of Position

The Senior Mechanical Engineer reports to a Manager of Mechanical Design Engineering and plays a key role in the development, stabilization, and scaling of da Vinci robotic platforms. This individual applies broad experience and professional judgment to resolve complex mechanical and manufacturing challenges, with a focus on cost reduction and scalability. Success in this role depends on the ability to independently assess variable factors, drive decisions that align with program goals, and deliver high-quality, innovative engineering solutions that support Intuitive’s mission to advance minimally invasive care.

Essential Job Duties

• Lead mechanical design of components and subsystems for da Vinci systems, with emphasis on DFM, cost optimization, and scalability.
• Lead root cause investigations using structured problem-solving methods (e.g., 8D, DMAIC); support CAPA activities per quality system procedures.
• Drive cross-functional decision-making aligned with program goals, collaborating with Engineering, Clinical, Human Factors, Industrial Design, Manufacturing, Sourcing, Quality, and Regulatory.
• Partner with suppliers and Supplier Engineers to assess capabilities, resolve process issues, and ensure parts meet design specifications.
• Mentor junior engineers in mechanical design principles, structured problem-solving techniques, and documentation best practices to support team development.
• Generate and maintain design control documentation.
• Present impactful technical reviews to staff, leadership, and cross-functional teams, articulating trade-offs and design rationale.
• Contribute to risk management activities through structured risk analysis, mitigation planning, and reliability assessments using FMEA and other methods.

Required Skills and Experience

• Minimum of 8 years of related experience with a Bachelor’s degree, 6 years with a Master’s, or 3 years with a PhD.
• Strong foundation in mechanical design and analysis, including tolerance stack-ups, GD&T, FEA, materials selection, and DFM/DFA, with demonstrated ability to apply these principles to deliver robust, production-ready designs.
• Proficient with CAD, simulation, and PLM tools such as SolidWorks, ANSYS, Windchill.
• Demonstrated ability to lead root cause investigations.
• Effective communicator with experience influencing technical and business decisions through cross-functional presentations.
• Demonstrated experience mentoring junior engineers and collaboration across various functions.
• Candidates with strong mechanical fundamentals and a genuine interest in Intuitive’s mission and values are encouraged to apply, especially those eager to grow within the medical device industry and thrive in a purpose-driven, collaborative culture.

Required Education and Training

• Required: Bachelor’s degree in Mechanical Engineering or related discipline
• Preferred: Master’s or PhD degree in Mechanical Engineering or a related discipline

Working Conditions

• 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 lift and handle 25 pounds.
• Occasional travel to supplier and manufacturing sites may be required.
• This role follows a set schedule with a minimum of four days on-site per week in Sunnyvale.

Preferred Skills and Experience

• Experience in Class II/III medical device development, particularly in surgical robotics or capital equipment.
• Experience in regulated industries (e.g., medical devices, aerospace, automotive) with working knowledge of standards and documentation frameworks such as ISO 13485, FDA QSR, IEC 60601, ISO 14971, ASTM standards, DHF, FMEA, and V&V protocols.
• Experience with a variety of manufacturing processes, including castings, plastic injection molding (PIM), sheet metal fabrication, and machining.
• Experience supporting post-market performance through reliability engineering, serviceability design, or field failure analysis.

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

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.

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.