{"id":1410372,"url":"https://alion.io/job/intuitive-surgical-senior-thermal-design-engineer","title":"Senior Thermal Design Engineer","company":{"id":3128,"name":"Intuitive Surgical","domain":"intuitive.com","url":"https://alion.io/company/intuitive","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"SmartRecruiters","truth_index":{"grade":"B","score":75,"open_postings":73,"ghost_share":0,"stale_share":0.986,"repost_share":0,"time_to_fill_p50_days":28,"computed_at":"2026-10-26T05:57:25Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Sunnyvale, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":162000,"max_usd":306000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":6333},"experience_years_min":8,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"ANSYS","optional":false},{"name":"FMEA","optional":false},{"name":"GD&T","optional":false},{"name":"MATLAB","optional":false},{"name":"Python","optional":false},{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-09-28T13:19:48Z","employer_posted_date":"2026-09-28","last_verified_at":"2026-10-26T20:47:43Z","board_verified":true,"closed_at":null,"days_open":28,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":28},"description":"It started with a simple idea: what if surgery could be less invasive and recovery less painful? Nearly 30 years later, that question still fuels everything we do at Intuitive. As a global leader in robotic-assisted surgery and minimally invasive care, our technologies-like the da Vinci surgical system and Ion -have transformed how care is delivered for millions of patients worldwide.\nWe’re a team of engineers, clinicians, and innovators united by one purpose: to make surgery smarter, safer, and more human. Every day, our work helps care teams perform with greater precision and patients recover faster, improving outcomes around the world.\nThe problems we solve demand creativity, rigor, and collaboration. The work is challenging, but deeply meaningful-because every improvement we make has the potential to change a life.\nIf you’re ready to contribute to something bigger than yourself and help transform the future of healthcare, you’ll find your purpose here.\n Primary Function of Position\nThe Senior Thermal Design Engineer is expected to use machine design and analytical skills to conceptualize, develop and verify new mechanical designs. They must utilize creativity and sound engineering judgment in the design of structures, kinematics, robotic actuation and sensing solutions. They are responsible for key system components and will interface with suppliers and manufacturing to build high-quality hardware prototypes and productize new designs. They will be expected to excel in a focused, high-energy, collaborative work environment with a team of talented engineers. They should be capable of making sound decisions when faced with the time pressures, ambiguous, and incomplete information typical of research and development.\nEssential Job Duties\nSystem thermal design, analysis and testing\nInfluencing assembly architecture and designing mechanical assemblies, with careful consideration for kinematics, drivetrain components, servo motors, sensors, safety mechanisms, and failure contingencies\nRapid development and iteration of full-scale prototypes of candidate architectures and mechanism designs to satisfy requirements\nCreate product functional requirements and design specifications, authoring concept and design documentation for a regulatory controlled environment\nPerform design FMEA\nDesigning for reliability, cost and manufacturability\nDeveloping and performing component verification testing and product validation testing\nSupporting final product delivery by troubleshooting process, component and system issues.\nCollaborating with vendors, suppliers and manufacturing in the prototype and design-transfer phase.\nProviding technical guidance and mentorship for team members.\n Qualifications\nRequired Skills and Experience\nExperience/ownership with product development lifecycle phases including design, analysis, debug, verification, transfer to manufacturing, and sustainment\nBackground in thermal system architecture, design and analysis including associated simulation environments\nTechnical expertise with one or more of the following: mechanism design, servo motors, brakes, encoders, harmonic drives and alternatives, sensors, robotics\nAnalysis potentially including statics, dynamics, kinematics, stress, fatigue and reliability\nDesign, analyze and document components, structures, and mechanical assemblies in SolidWorks or similar CAD software\nStrong understanding of component or material selection criteria, and design for reliability and manufacturability\nDemonstrated knowledge of a wide variety of component manufacturing processes\nProficient in GD&T and tolerance stack analysis\nStrong hands-on prototyping skills such as 3D Printing and machine shop equipment\nDesigning and executing experiments on strength or function\nCapable of using MATLAB to create or modify test scripts and system software\nDemonstrated excitement to learn and quickly analyze tough technical problems, thinking creatively and fundamentally about the solution\nAbility to communicate effectively, both written and orally\nSelf-driven with the ability to excel in a high-energy, small, focused team environment, to maintain a strong sense of shared responsibility and reward\nAbility to lead and mentor other engineers\nRequired Education and Training\nMinimum BSME\nMinimum 8 years of relevant experience\nWork experience in mechatronics, robotics, surgical or medical devices a plus. FDA or other regulated industry preferred.\nPreferred Education, Skills and Experience\nMS Mechanical Engineering\nSurgical or medical device experience, regulated industry experience\nExpertise in ANSYS, MATLAB, and PYTHON\n 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.\nIntuitive 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.\nMandatory Notices\nU.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.\nCertain 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).\nFor 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.\nWe will consider for employment qualified applicants with arrest and conviction records in accordance with fair chance laws.\nPreference 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.\nThis position may be filled at a different job level than listed here depending on\nbusiness need and/or on the selected candidate’s experience, knowledge and skills.\nCompensation will be based primarily on the job level at which the role is filled and the\ncandidate’s qualifications, consistent with applicable law.\nAccommodation & Accessibility Notice:\nIntuitive is committed to providing reasonable accommodations to qualified individuals with disabilities. If you require assistance or an accommodation during any part of the application or interview process, please contact People Services at .\nWe 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. 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