Jared MaffucciSenior Mechanical Engineer | Hardware Product Development

Experience · Jared Maffucci

Senior Mechanical Engineer | Hardware Product Development

Eight-plus years turning uncertain product intent into architecture, mechanisms, analysis, CAD, prototypes, manufacturing definition, and corrective engineering across consumer, industrial, ergonomic, electromechanical, and high-reliability hardware.

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Professional profile

Senior product-development leadership with hands-on mechanical depth.

I am most valuable where the problem crosses boundaries: user experience, mechanisms, structures, thermal or fluid behavior, electronics packaging, tolerances, suppliers, cost, service, and validation.

I can frame the work at the program level and still own the details that make the product real. Teams get clear requirements, credible alternatives, explicit assumptions, disciplined execution, and a design record that supports review, release, production, and future improvement.

What I can own

  • Complete mechanical product-development workstream
  • Product architecture and high-risk subsystem decisions
  • Mechanism, structure, enclosure, or electromechanical integration
  • Prototype, validation, DFM/DFA, supplier, and release execution
  • Corrective engineering, cost, reliability, and performance improvement

Experience

A career built around increasingly complete ownership of physical products.

Sep 2025–PresentNordson Electronics SolutionsSenior Mechanical Engineer, New Product Development
  • Lead mechanical architecture for precision dispensing hardware, resolving mechanism, alignment, packaging, manufacturing, and service risks through trade studies, prototypes, and supplier evaluation.
  • Resolved a multi-machine vacuum reliability problem through component selection and mechanical integration changes; released preassembled field and production upgrade kits.
  • Replaced unreliable camera-based identification with a compact industrial code-reading subsystem. Owned hardware selection, read geometry, configuration, validation on representative hardware, and handoff to controls and software teams.
  • Use thermal and internal-flow models, operating data, and correlation plans to guide heat-path and cooling decisions.
2023–PresentIndependent Product Development ConsultingMechanical Engineering & Product Development Consultant · Part-time / concurrent
  • Defined a four-product adjustable platform, connecting mechanisms and load cases to cost, guarding, manufacturing, supplier RFQs, inspection, and verification plans.
  • Developed compact electromechanical enclosures with component layouts, heat-sink integration, wiring access, assembly interfaces, BOMs, and editable handoff documentation.
  • Developed a modular thermal consumer-product concept through successive CAD revisions addressing replaceable components, thermal contact, closures, sealing, and condensation.
  • Reconstructed fit-critical freeform geometry as editable SOLIDWORKS models, recovering design intent and delivering a client-approved replica with complex interface curvature.
Jul 2018–Jun 2023Viasat Inc.Mechanical Engineer, Space Systems R&D
  • Engineered compact spacecraft payload hardware with precision mounts, fixed and deployable mechanisms, thermal conduction paths, and EMI-gasketed interfaces.
  • Guided design decisions with structural, modal, shock, contact, and thermal FEA; supported environmental testing and anomaly investigation.
  • Released 100+ engineering drawings with ASME Y14.5 GD&T, tolerances, materials, and process requirements; coordinated supplier feedback and controlled changes.
  • Rearchitected spacecraft power/data interconnects as modular subassemblies to simplify harness installation and assembly access.
  • Designed a digital-microscope inspection system with repeatable positioning and image acquisition for RF harness connector FOD inspection.

Selected engineering work

Public examples connect technical scope to real maturity boundaries.

The public work record shows the challenge, role, actions, artifacts, outputs, and material limit without exposing clients or proprietary product detail.

Architecture + supplier definition

Four-product platform architecture

Architecture, requirements, shared interfaces, BOM strategy, CTQs, first-article planning, supplier RFQ controls, and validation gates.

Concept + prototype definition

Modular thermal product development

Mechanical architecture, interface definition, controlled CAD iteration, configuration development, and prototype and patent support.

Editable CAD delivered

Fit-critical geometry reconstruction

Surface reconstruction, design-intent recovery, editable SolidWorks definition, and neutral-data delivery.

Technical scope

Mechanical engineering from controlling physics to controlled release.

Mechanical systems

Mechanisms, precision motion, structures, enclosures, electromechanical packaging, thermal and fluid hardware

Product development

Requirements, architecture, concept selection, trade studies, risk retirement, prototyping, validation, and release

Engineering definition

Parametric CAD, complex surfacing, GD&T, tolerance analysis, drawings, BOM structure, and configuration control

Analysis + evidence

First-order calculations, FEA, CFD, load paths, boundary conditions, test planning, troubleshooting, and corrective action

Production readiness

DFM/DFA, materials and processes, supplier reviews, inspection strategy, service access, cost, and change control

Technical communication

Design reviews, decision records, technical packages, cross-functional alignment, and direct stakeholder communication

Education + technical foundation

Verified credentials and working toolset.

Education

B.S. Mechanical Engineering

Colorado State University · 2018

Core platform

10,000+ hours in SOLIDWORKS

Parametric CAD, complex surfacing, assemblies, drawings, simulation, flow analysis, rendering, and technical documentation.

Execution model

Direct, stage-accurate ownership

Hands-on engineering, transparent assumptions, disciplined reviews, confidentiality, and explicit validation boundaries.

Direct conversation

Bring Jared Maffucci into the team.

Include the company, role title or posting, the product or program, and the mechanical decisions the hire would lead. Additional approved work samples can be reviewed during a qualified discussion.

Discuss an Opportunity