Sr Mechanical Design Engineer

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.

Essential Job Duties

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.

Required Skills and Experience 

• 6+ years of mechanical design experience inclusive of plastic injection molding (PIM),

metal injection molding (MIM), and/or machining. Hands on plastic injection molding

experience is highly desirable, including but not limited to Scientific Injection Molding

(SIM) principles, plastic DFM, Silicone molding (LSR and/or compression molding).

• A passion for solving tough technical problems - strong mechanical intuition and

persistence to drill down to pinpoint root causes, solving problems using fundamental

principles.

• Self-driven to achieve individual and collaborative results in a high-energy, small,

focused team environment, to maintain a strong sense of shared responsibility and

shared reward, and to foster a positive and encouraging group culture.

• Proven expertise designing precision mechanisms and high-tolerance assemblies from

rapid prototyping to high volume manufacturing.

• Demonstrated ability to design precision mechanisms with complex tolerance stack-ups;

proficiency using CAD for complex assembly (SolidWorks strongly preferred).

• Experience with GD&T and other related ASME/ISO drafting standards and tolerance

stack analysis.

• Strong command of 2D/3D statistical tolerance analysis, system stack-up modeling, and

mechanical simulation tools.

• Experience with Finite Element Analysis, particularly using ANSYS.
• Mechanical design and analysis skills, including statics, dynamics, kinematics, and

strength of materials.

• Inclination towards hands-on engineering with the ability to work well in a team

environment.

• Strong written and verbal communication skills, including cross-functional presentation

and management-level technical communication.

• Excellent organizational skills; able to manage multiple fast-paced efforts simultaneously

while maintaining clarity of goals and priorities; strong documentation habits

• Flexible to changing priorities and able to balance and prioritize multiple and competing

demands based on organizational goals and needs.

Required Education and Training 

Minimum Bachelor's Degree in Mechanical Engineering or

similar technical field

Working Conditions 

• In-Office

Preferred Skills and Experience

• Experience with designing products in a regulated industry – familiarity with the concepts

of design inputs, design outputs, traceability, and risk analysis.

• Experience with metals, plastics, fabrication methods outside of injection molding such

as castings, extrusions, sheet metal, bonding and adhesives.

• Experience in several of these areas: concept development, design analysis, hands-on

prototyping, hands-on fabrication, and performance and reliability testing.

• Comfortable with ambiguity and able to build clarity and consensus among cross-

functional stakeholders.

• Comfortable coding in Python, Matlab, C/C++, Labview, Arduino or similar tools.
• Experience with statistics and design of experiments.
• Firsthand machining experience and familiarity with test and metrology equipment.
• Demonstrated ability to think at a systems level, interface between multiple design

groups, and negotiate conflicting requirements.

• Knowledge of component manufacturing processes such as injection molding, extrusion,

machining, wire EDM, MIM, heat treatment, electropolishing, laser welding, etc