Senior Mechanical Design Engineer

Job Description

Primary Function of Position

The Multiport Endoscope R&D group at Intuitive Surgical is a dynamic, multidisciplinary team focused on advancing 2D and 3D endoscopic vision systems for next-generation robotic platforms. Our mission is to push the boundaries of visual perception in surgery, driving innovations that enable unparalleled precision and surgical outcomes.

We are seeking a hands-on, technically skilled Senior Mechanical Design Engineer to drive the design of opto-electro-mechanical components and subsystems. You will be responsible for taking designs from concept through prototype development, validation, and into scalable manufacturing. This role is a highly technical individual contributor position. Day-to-day job responsibilities demand the design of precision components and sub-assemblies, requirements and spec development, building prototypes, rigorous characterization of component designs, and the assurance of component and sub-assembly design and assembly process reliability.

Essential Job Duties

• Design and develop high-precision mechanical components and assemblies, with emphasis on thermal, mechanical, and material performance for medium- to high-volume manufacturing.
• Own SolidWorks CAD database creation and maintenance, including parts, assemblies, and fully dimensioned drawings within a PDM environment.
• Author and maintain functional, cosmetic, and assembly specifications. Conduct DFMEAs and implement design controls.
• Develop and execute test protocols to validate designs, define output specifications and ensure margin compliance.
• Troubleshoot and root-cause design, manufacturing, and material failures; recommend and implement corrective actions.
• Document and present findings through test reports, technical design reviews, and presentations to cross-functional teams.

Qualifications

Required Skills and Experience

CAD & Product Development:

• Advanced proficiency in SolidWorks 3D CAD, including parts, assemblies, and detailed drawings in a PDM-controlled environment.
• Skilled in conducting 2D/3D tolerance analyses, statistical stack-up evaluations, with proven understanding of GD&T and functional dimensioning.
• Demonstrated experience in using CAD-integrated and/or standalone simulation tools (e.g., FEA, thermal analysis) to guide design recommendations.

Mechanical Design & Manufacturing:

• Demonstrated expertise in mechanical design for a range of medium to high volume manufacturing processes, including plastic injection molding, stamping, metal injection molding, casting, and precision machining.
• Exceptional understanding of tight-tolerance fabrication and precision mechanical assembly techniques.
• Experience designing mechanical control mechanisms or assemblies for human-machine interfaces (HMI), including tactile feedback and actuation features.

Design Quality & System Integration:

• Track record of driving DFM, DFA, and DFS initiatives across complex subassemblies.
• Cross-functional experience integrating electromechanical systems, including PCB mechanical design and optical or sensor components.

Testing & Root Cause Analysis:

• Experience developing and executing engineering verification plans, engineering test protocols, and root cause analysis for design, material, and process issues.
• Proficient in analyzing test data to inform design iteration and reliability improvements.

Communication & Project Execution:

• Excellent communication and documentation skills; able to clearly articulate design rationale, test results, and trade-offs.
• Exceptional multitasking ability with demonstrated ownership of complex projects in fast-paced R&D settings.

Required Education and Training

• BS or MS in Mechanical Engineering, Mechatronics, Robotics, Biomedical Engineering or related engineering discipline.
• Minimum 8 years of experience in design for high-volume production with at least 1-2 new products from concept to launch.

Preferred Skills and Experience

• Proficient in designing cosmetic-grade mechanical parts with an emphasis on visual appeal, surface finish, mold flow, and visual defect mitigation. Familiar with best practices for defining cosmetic requirements, visual inspection standards, and surface texture callouts for molded or finished parts.
• Proficiency in metrology tools such as CMM and OMM; ability to interpret FAI data and drive corrective actions.
• Hands-on experience collaborating with PCB designers and understanding of PCBA integration.
• Exceptional foundation in experimental design (DoE), statistical methods, and data interpretation.
• Familiarity with material selection, design for reliability, and lifecycle durability.
• Experience working in FDA-regulated environments (QSR 21 CFR Part 820, ISO 13485) is highly desirable.
• Prior work on fixture/tooling design for prototype assembly or pilot manufacturing is a plus.