{"id":1924482,"url":"https://alion.io/job/intuitive-surgical-staff-mechanical-design-engineer","title":"Staff Mechanical 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":68,"ghost_share":0,"stale_share":0.985,"repost_share":0,"time_to_fill_p50_days":28,"computed_at":"2026-10-17T05:46:00Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"staff","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":125000,"max_usd":245000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":1259},"experience_years_min":12,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-10-05T17:13:01Z","employer_posted_date":"2026-10-05","last_verified_at":"2026-10-18T22:44:28Z","board_verified":true,"closed_at":null,"days_open":13,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":13},"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\nAt Intuitive, we believe that minimally invasive care is life-enhancing care. By combining ingenuity\nand intelligent technology, we expand the potential of physicians to heal without constraints. We\nare looking for team members with exceptional character who have the capacity to simplify\ncomplex problems and the energy to deliver solutions urgently to our patients.\nIntuitive Accessories are the interface between all aspects of the da Vinci system and enable safe\nand effective robot-assisted surgery. Our customers interact directly with Accessories in every\nsurgical procedure, and they serve a critical role in customer satisfaction and patient outcomes.\nThe Staff Mechanical Design Engineer for Single-Port (SP) Accessories will support development\nand production of existing and new products. This position requires a hands-on, technically strong\nengineer to dive deep into solving engineering challenges, and to provide high-level assessment\nof risks and opportunities. Projects will include a mix of sustaining existing products and new\nproduct development, including improvements for cost savings and manufacturability to enable\nsignificant volume growth, enhancements to increase customer satisfaction, and improving\nreliability.\nEssential Job Duties\nDrive Design efforts to optimize performance,\nmanufacturability and reliability of existing and future Da Vinci SP Accessories.\nDevelop components and product mechanical drawings in a regulated environment for\nhigh volume manufacturing processes, including plastic injection molding, thermoset\ncompression molding, extrusion, and machining.\nDesign for manufacturing and automation, sterilization processes, and biocompatibility.\nWork cross-functionally with Manufacturing Engineers, Systems Analysts, Clinical\nDevelopment Engineers, Human Factors Engineers, and Supplier Engineers.\nReview and understand product functional requirements and design specifications.\nProvide mechanical engineering sustaining support for resolution of manufacturing and\nfield issues.\nInvestigate and determine root cause of design, manufacturing, or material issues.\nResearch, understand, and design to relevant product-specific international standards.\nDevelop, implement, test, and document solutions that meet clinical, functional, and\nproduct requirements.\nPerform and document risk analyses (FMEA) and implement effective mitigations,\nfollowing design control processes.\nHelp identify and develop vendors to manufacture components.\nDevelop initial fixtures and processes to assemble components.\nDevelop product and component verification testing and product validation testing\nSupport production of final product by troubleshooting process and component problems\nProvide engineering support to Manufacturing, Materials,\nTest Engineering, and Service to facilitate transfer of\ndesigns.\nDevelop, implement, test and document solutions for these\nopportunities according to corporate standard and departmental operating procedures\nMentor other engineers and champion best practices for mechanical design\n Required Skills and Experience\nProficiency using CAD to design and document mechanisms; SolidWorks strongly preferred\nGood communication and documentation skills\nExperience in designing high volume consumable medical products\nStrong working knowledge of GD&T\nExperience with complex interface compatibility and tolerance analysis\nDemonstrated knowledge of high-volume component manufacturing processes (including\ninjection molding, plastics films, extrusions, thermoforming, and plastic bonding methods)\nDemonstrated knowledge of materials (preferably plastics, silicones, polyurethanes,\nisoprenes) and material properties. Ability to apply knowledge of engineering materials and\ncomponent selection criteria to product designs through strong concept development, design\nanalysis, hands-on prototyping, and reliability testing skills.\nDemonstrated ability to think at a systems level, interface between multiple design groups,\nand negotiate conflicting requirements.\nComfortable with all phases of the product development lifecycle including design,\nimplementation, debug, verification, qualification, and transfer.\nA passion for solving tough technical problems - Strong\nmechanical intuition and persistence to drill down to pinpoint\nroot cause of problems, solving problems using fundamental\nprinciples.\nAbility to communicate effectively (written, oral) across\nfunctions, including presenting to a technical audience\nPrior experience working in medical device or other regulated industry\nRequired Education and Training\nMinimum education: BS in Mechanical Engineering required, MSME preferred. Biomedical or\nother engineering discipline may be acceptable with appropriate mechanical experience.\nMinimum 12 years of hardware product design experience preferred with undergraduate\ndegree; minimum 8 years with graduate degree\nWorking Conditions\nAbility to lift 30 lbs. without assistance.\nPreferred Skills and Experience (As applicable - Specific skills, knowledge, and experience that\nare not required to perform the job, but are desirable to have)\nComfortable operating machine shop tools/equipment, Rapid prototype equipment (3-d\nprinters, laser cutters etc.), measurement and test equipment\nKnowledge in additional manufacturing processes such as extrusion, blow molding,\nultrasonic welding, RF welding, heat staking, and laser welding\nComfortable with concepts of design input, design output, traceability, and risk analysis\nAbility to handle ambiguity effectively and oversee multiple projects at once\nKnowledge of ISO requirements and GMP guidelines. Experience with FDA regulations\nand medical device design control a strong plus\nExperience leading departmental or cross-functional\nprojects/initiatives from concept through completion\nKnowledge of sterilization methods, biocompatibility, and\npackaging of medical devices\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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