Sr Mechanical Design Engineer

Job Description Primary Function of Position

The Endoluminal instrument design group at Intuitive is a dynamic and multidisciplinary team developing tools for the next generation of minimally invasive surgical robotics. We are seeking a Senior Mechanical Engineer with a focus on injection molding technology to conceptualize, develop, and verify new mechanical design concepts for the next generation of minimally invasive robotic flexible instruments. You will leverage your creativity and engineering analysis to the design of kinematics and user interfaces to ensure mechanical robustness from concept through verification and scaled manufacturing.

The successful candidate will have both the technical depth to resolve complex mechanical, materials and manufacturing design issues and the ability to work in an interdisciplinary team to troubleshoot to root cause higher level system issues. This requires in-depth collaboration with cross‑functional teams that will routinely leverage your technical and interpersonal skills as you develop a shared understanding of the new product requirements.

Mechanical Design

• Own mechanical assemblies for new instruments, focus on injection molding, from concept through commercialization that meet demanding performance, manufacturability, and reliability constraints using knowledge and experience to select the optimal material and process (metal vs. plastic, molded vs. extruded vs. MIM vs. formed, etc.).
• Understand and design to optimize interfaces with mechanic, electronic, optic, and seal elements.
• Rapid development and iteration of proof‑of‑concept and high‑fidelity prototypes of candidate architectures to satisfy requirements.
• Complete detailed drawings and robust tolerance analysis and update designs accordingly.
• Define engineering requirements and ensure candidate designs are backed by robust data prior to design freeze.
• Perform detailed 2D/3D tolerance analysis, FEA/simulation, and statistical modeling to ensure robust design margins.
• Troubleshoot component and prototype performance issues with speed, rigor, and cross‑functional collaboration.
• Develop test methods, fixtures, and measurement tools to evaluate the performance of robotic catheters and sub‑assemblies.
• Provide written protocols, reports, drawings, specifications, presentations, and perform technical design reviews to solicit feedback on design activities on an ongoing basis.
• Manufacturing, DFM/DFA, and Supplier Engagement
• Lead DFM/DFA discussions with cross‑functional teams to understand key drivers of product performance, durability, and ease of assembly.
• Partner with suppliers on development and troubleshooting efforts to supply reliable, complex components and assemblies.
• Support transition to manufacturing, ramp‑to‑production, and lifecycle reliability improvements.
• Investigate and determine root cause of emerging design or manufacturing defects.
• Technical Leadership
• Utilize best‑in‑class mechanical design practices, precision engineering, tolerance‑driven design, and robust system integration.
• Interface with clinical and human factor engineering to inform designs and identify user needs.
• Mentor and guide engineers on best practices in design and engineering with a particular focus on designing for injection molding.
• Support intellectual property creation and technical documentation.