Jared MaffucciSenior Mechanical Engineer | Hardware Product Development

Senior Mechanical Engineer | Hardware Product Development

I turn ambitious product ideas into hardware teams can build, test, and scale.

Senior mechanical engineer with 8+ years taking consumer, electromechanical, industrial, and high-reliability hardware from requirements through CAD, prototyping, DFM, validation, and production improvement.

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North County San Diego · open to employment and selected consulting work

Each image opens its detailed study. On small screens, swipe or use the arrow keys to review all four.

SolidWorks render of a sculpted luxury medical-ID bracelet with a concealed NFC information interface and hinged closure.Luxury wearable and packagingSolidWorks render of a custom carbon-fiber Toyota Supra hood with broad compound curvature and a raised surface feature.Toyota Supra hood surfacingSolidWorks render of a paired set of black trapezoidal exhaust tips for a Mercedes-Benz CLS 63 AMG.Mercedes-AMG exhaust tipsMatte SolidWorks render of a curved Porsche HVAC duct with compound surfaces and circular end interfaces.Porsche HVAC duct development

Independent CAD studies · client work remains confidential

8+ yearsIn mechanical engineering and hardware product development
10,000+ hoursSOLIDWORKS across CAD, surfacing, drawings, and simulation
Five yearsIn aerospace and advanced-communications R&D
B.S.M.E. · CSWPColorado State University · verified credential

Selected engineering records

What the work required, what it produced, and what remained open.

Three anonymized records show the engineering challenge, my role, measurable scope, delivered outputs, and actual maturity. Detailed independent CAD studies remain on the Work page.

Paused · supplier-quote-ready + DFM-ready

Multi-Variant Mechanical Platform and Supplier Readiness

Defined shared mechanisms and interfaces across four variants, structured a 312-row BOM with 199 purchased-component lines, and established CTQs, first-article planning, and supplier RFQ controls. The paused program reached quote-ready and DFM-ready maturity.

312-row controlled BOM199 purchased componentsVariant requirements
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Active architecture + prototype development

Thermal Consumer Product Architecture

Developed shell, liner, thermal-cartridge, and top-interface architecture through eight controlled CAD revisions addressing containment, sealing, condensation, assembly, service, and user interaction. The program remains in active architecture and prototype development.

8 archived CAD revisionsContainment + sealingCondensation controls
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Ended · editable CAD delivered

Complex Geometry Reconstruction and Design-Intent CAD

Converted imperfect scan and mesh evidence into editable SolidWorks geometry and neutral STEP data through gap repair, continuity reconstruction, and design-intent recovery. The engagement concluded with delivery of editable CAD.

Supplied scan + mesh evidenceGap and continuity repairDesign-intent recovery
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View All Engineering Work

What I own

Mechanical ownership from product architecture through manufacturing handoff.

I keep architecture, detailed design, verification, and manufacturing aligned from the first decision through handoff.

Controlled freeform surface continuityA symmetric freeform canopy with explicit boundaries, coherent isoparametric curves, a central G2 seam, and continuous reflection bands.FREEFORM CAD / CONTINUITY + REFLECTION CONTROLG2SYMMETRY / CONTROLLED SEAMCONTROL NET + BOUNDARIESCONTINUOUS REFLECTION FLOWNO KINKS · NO ORPHAN EDGES · NO DISCONNECTED PATCHESConceptual capability visualization

Product definition + architecture

Turn user, business, interface, and manufacturing constraints into measurable requirements, alternatives, and a defensible system direction.

Review capability
Synchronized twin-screw lift architectureA controlled front-elevation schematic showing two guided lead screws driven one-to-one by a continuous cross shaft and paired bevel gears.KINEMATIC ARCHITECTURE / CONTROLLED SCHEMATICAPPLIED LOADMANUAL INPUTCONTINUOUS 1:1 CROSS-SHAFTBEVEL PAIR ABEVEL PAIR BTWO SCREWS · FOUR GUIDES · ONE CONSTRAINED VERTICAL DOFConceptual capability visualization

Mechanical design + integration

Resolve mechanisms, structures, enclosures, interfaces, ergonomics, thermal paths, fastening, assembly, and service as one product system.

Review capability
Qualitative equipment-frame deformation and stress responseA wide symmetric equipment frame is restrained at two mounting feet and bends under a distributed center payload. Deflection increases at midspan while stress intensifies around the support transitions.STRUCTURAL RESPONSE / SYMMETRIC EQUIPMENT FRAMEDISTRIBUTED PAYLOADTWO FIXED MOUNTING FEET · MIDSPAN DEFLECTION AMPLIFIEDSUPPORT STRESSSYMMETRIC RESPONSEQUALITATIVE RESPONSE · NOT REPORTED SOLVER MAGNITUDESConceptual capability visualization

Prototypes + analysis + validation

Use first principles, FEA, CFD, tolerance analysis, question-focused prototypes, and test planning to expose risk and close decisions.

Review capability
Additive fixture with controlled interfacesA printed fixture base with four heat-set inserts, two dowel locators, a removable machined nest, and exact projected alignment lines.ADDITIVE PROTOTYPE / DATUMS + INSERTS + FIT-CHECK NESTDATUM A / PRINTED BASE PLANE4X HEAT-SET INSERT + MATCHED CLEARANCE2X DOWEL LOCATORMACHINED NEST REMOVES VERTICALLY · SIX PROJECTED INTERFACES REMAIN COINCIDENTConceptual capability visualization

DFM + suppliers + release + improvement

Carry the design into drawings, BOM data, CTQs, supplier reviews, inspection, manufacturing handoff, and controlled product improvement.

Review capability

Professional experience

Career depth across advanced equipment, product development, and aerospace R&D.

Employer and role names are public; current-employer and client-controlled programs remain confidential.

Sep 2025–Present

Nordson Electronics Solutions

Senior Mechanical Engineer, New Product DevelopmentLead mechanical NPD across requirements, architecture, design, analysis, suppliers, manufacturing definition, and validation planning for complex electromechanical equipment.

2023–Present

Independent Product Development Consulting

Mechanical Product Design Engineer and Consultant · Part-Time / ConcurrentSupport cross-market hardware programs from incomplete intent through stage-appropriate engineering evidence.

Jul 2018–Jun 2023

Viasat Inc.

Mechanical Engineer, Space Systems R&DDeveloped high-reliability aerospace hardware under coupled structural, thermal, vibration, packaging, manufacturing, and interface constraints.
View Professional Experience

Engineering Lab

Transparent first-order tools with assumptions and limits made explicit.

Use each tool to screen decisions and plan the next model or test; none replaces design verification.

Tolerance Stack Calculator

Compare worst-case and RSS accumulation with signed contributors and an exportable working record.

Open tool

Bolt Preload and Torque Estimator

Screen installation torque, axial preload, tensile stress, and yield utilization with explicit model assumptions.

Open tool

Mechanical Design Review Checklist

Review requirements, interfaces, loads, mechanisms, tolerances, production, validation, and release evidence.

Open tool
Open Engineering Lab

For employers

Bring senior mechanical product-development ownership into the team.

A useful first note includes the role, the product or program, and the mechanical decisions the hire would lead.

Discuss an Employment OpportunityView Experience