Expanding production of surgical devices required a highly complex facility upgrade and expansion.

Intuitive Surgical, Inc. chose Haskell as its design-build partner to deliver a new facility dedicated to the manufacture and assembly of parts, components and instruments for the da Vinci surgical system, which is used in minimally invasive surgery. The da Vinci surgical system has changed surgery in the same way the iPhone has transformed cellphone use, and the new facility, considered critical to Intuitive Surgical’s plans to expand production, needed to reflect the pioneering spirit and drive for excellence that are intrinsic in any of the products sold by Intuitive Surgical.

The project was built to rigorous structural standards and satisfied the stringent requirements of advanced manufacturing processes.

The project included upgrades to the existing Building 88-1, construction of Building 88-2 and preparation for the future Building 88-3. The two-story, 459,654-square-foot, two-story advanced manufacturing facility includes spaces for manufacturing, warehouse, offices, employee welfare, a cafeteria, mechanical mezzanines and mechanical/electrical.

The project was in a high-seismic region, and Haskell engineers surpassed local code requirements and designed according to requirements of the U.S. Code, ASCE 7-16. The structural design featured bracing to absorb forces and minimize damage. Castellated beams were used to allow mechanical and plumbing systems to thread through openings in the beam webs.

The advanced manufacturing facility required a robust HVAC and electrical system to provide the required level of air filtration in manufacturing zones, comfortable working conditions and reliable power. This led to the inclusion of ample maintenance areas for mechanical units, aesthetic single-point connections for utilities at manufacturing zones, highly efficient air-cooled chillers equipped with variable compressors and ventilators, and MERV15 HEPA filtration for controlled-environment rooms.

The resulting facility meets Intuitive Surgical’s current needs with an eye toward the future.

The completed project provided Intuitive Surgical with a safe, functional facility that met international design standards and uncluttered space for daily operations. By managing the rigors of construction compounded by the unique design components of this project, Haskell delivered a project that stands out as an exceptional advanced manufacturing facility that will meet Intuitive Surgical’s needs well into the future.