Staff Mechanical Design Engineer

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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.

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 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.

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.