Principal I, Research & Development Process & Product Design (T)

Summary of Position: Alcon is hiring a Principal Engineer I to join our Surgical R&D organization. This role will convert complex industrial design concepts, SolidWorks models, and visual renderings into robust Creo Parametric master models that define the aesthetic exterior surfaces and packaging architecture of medical consoles, carts, and handpieces. The engineer will bridge industrial design intent and production-ready mechanical design, ensuring exterior skins, interfaces, and supporting components can be manufactured, assembled, controlled, and revised throughout product development. The ideal candidate combines advanced Creo surfacing and top-down design expertise with practical DFM experience for injection-molded plastics and cast components. The position will work closely with industrial design, mechanical engineering, human factors, manufacturing, suppliers, and quality partners to preserve the intended appearance while meeting functional, dimensional, manufacturing, and medical-device development requirements. Key Responsibilities: •Convert industrial design concepts from SolidWorks files, surface data, sketches, and renderings into controlled Creo Parametric geometry and production-intent master models. •Create and maintain aesthetic exterior skins for medical consoles, equipment carts, handpieces, and related surgical-system components. •Develop high-quality complex surfaces, transitions, parting strategies, shutoffs, interfaces, and split lines while preserving industrial design intent. •Establish and sustain top-down skeleton architecture, master-model methodology, published geometry, and interface control across modules and assemblies. •Derive production components and assemblies from the master model, including plastic housings, bezels, covers, handles, cast structures, and supporting mechanical parts. •Assess imported SolidWorks geometry for quality, continuity, manufacturability, and design intent; rebuild or optimize geometry in Creo when required for stable parametric control. •Partner with industrial designers to translate visual intent into measurable geometry, resolve design feasibility issues, and manage appearance-impacting changes. •Apply DFM/DFA principles for injection-molded plastics and cast components, including draft, wall thickness, ribs, bosses, tooling access, parting lines, sink-risk reduction, and assembly interfaces. •Perform fit, form, interface, clearance, and tolerance assessments to verify that exterior components integrate with internal structures, displays, controls, connectors, service features, and adjacent modules. •Create detailed models and drawings with appropriate GD&T, datum strategies, and tolerance analysis for supplier quotation, fabrication, inspection, and release. •Collaborate with suppliers and manufacturing teams to review tooling concepts, molding or casting feasibility, cosmetic requirements, secondary operations, and design changes.