Sr NPI Manufacturing Engineer
Intuitive · Sunnyvale, CA, United States · Posted Jul 9, 2026
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Primary Function of Position
This highly skilled manufacturing engineer will support flexible instruments and accessories for the Ion platform. This engineer must be able to develop new and improved manufacturing processes by collaborating across functions to solve a wide variety of technical process and equipment problems. They will have demonstrated experience developing and improving flexible instruments and/or catheter manufacturing processes such as lamination, thermal bonding, injection molding and UV-cured adhesives.
Essential Job Duties
Contribute to the development of new manufacturing processes: Experience in early development of flexible instrument manufacturing processes, including process tradeoff assessments
Experience working with a wide range of plastic and metal joining processes, such as laser welding, adhesive bonding, lamination/plastic reflow, injection molding
Comfortable with experiment design (DOE) to identify and control critical process parameters – demonstrated successful transfer of complex manual processes to high volume, high capability
Experience developing flexible instrument/catheter manufacturing lines – establishing order of operations, building and testing prototypes, training operators, defining fixture/tooling requirements, and conducting process validation
Maintains connections with leading catheter manufacturing equipment suppliers and is aware of latest state-of-the-art processes and equipment
Proven track record of working upstream with product design engineers and can be the voice of manufacturing on product development teams
Support Ion manufacturing lines including: Establish regular communication with the production team to ensure they have the best support possible for both short and long term needs
Manage product reliability improvements from concept to implementation
Identify, design, qualify, document and introduce assembly/test fixtures and equipment
Improve process flows of Ion instrument manufacturing lines to optimize for manufacturability – e.g. reliability, efficiency, capacity, and safety
Execute and mentor others in manufacturing process validations, process FMEAs and other elements associated with production Master Validation Plans
Manage manufacturing strategy and production capability for Ion Instrument lines to minimize customer backorders
Maintain compliance with medical device quality system including corrective action closure, discrepant material disposition and Engineering Change Order (ECO) implementation
Provide technical support for failure analyses and root cause investigations of product failures
Contribute to the establishment of group and individual objectives consistent with overall product development goals, including priority setting, establishment of metrics, and effectively communicating progress
Provide resource budget estimates for product and process improvements, tooling development, and testing
Works with Quality and Regulatory to ensure that the team follows appropriate GMP, design history file (DHF), and device history record (DHR) guidelines per FDA requirements
Required Skills and Experience
Strong technical analytical skills and troubleshooting skills
Prior responsibility for validation/verification of processes, equipment and products
Strong organizational skills and proven ability to work on several fast-paced projects simultaneously
Prior experience with managing product and process changes
Prior experience with technical writing
Able to communicate effectively and professionally with cross-functional peers, executive leadership, internal customers and external suppliers
Required Education and Training
Minimum BS degree in Engineering discipline, MS preferred
Minimum 8 years of experience as design or manufacturing engineer supporting product with significant mechanical, electromechanical, or electro optical content.
Prior responsibility for validation/verification of processes, equipment and products
Working Conditions
None
Preferred Skills and Experience
Experienced in ISO 13485, ISO 9001, or medical device manufacturing environment, Six Sigma Black/Green Belt is a plus
Prior experience with Design Control processes for medical devices and/or clinical applications of the surgical instruments, and/or automated equipment design is a plus
Fundamental understanding of engineering plastics, especially medical grade polymers and metals is a plus (e.g. Nitinol, PTFE, Pebax, PET, Nylon)
Familiar with mechanical CAD software (SolidWorks) is a plus
Strong technical analytical skills, background in material bonding, catheters and vision-related products is a plus
Background in material bonding, catheters and vision-related products
Familiar with the fundamentals of injection molding
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.
Intuitive is a…