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 workstreams from requirements and architecture through detailed CAD, analysis, design review, production definition, supplier coordination, and validation planning.
  • Resolve coupled mechanism, structural, thermal, fluid, packaging, service, and manufacturability constraints in complex electromechanical equipment.
  • Coordinate mechanical decisions across connected engineering, manufacturing, quality, supplier, and service interfaces while maintaining clear ownership and review boundaries.
2023–PresentIndependent Product Development ConsultingMechanical Product Design Engineer and Consultant | Part-Time / Concurrent
  • Deliver direct mechanical design and product-development support across consumer, prosumer, ergonomic, home-improvement, electromechanical, industrial, and precision-mechanical programs.
  • Translate incomplete concepts or physical interfaces into requirements, alternative architectures, parametric CAD, calculations, prototypes, drawings, and stage-appropriate supplier packages.
  • Support mechanism design, DFM/DFA, physical-hardware reconstruction, complex surfacing, tolerance review, simulation, troubleshooting, fixtures, and product improvement.
Jul 2018–Jun 2023Viasat Inc.Mechanical Engineer, Space Systems R&D
  • Developed high-reliability aerospace and advanced-communications hardware under coupled thermal, vibration, structural, modal, packaging, documentation, procurement, and manufacturing constraints.
  • Owned mechanical design and analysis details from concept through released definition while coordinating electrical, RF, systems, manufacturing, and supplier interfaces.
  • Built the high-reliability foundation now applied across consumer, electromechanical, industrial, and consulting work.

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.

Paused · supplier-quote-ready + DFM-ready

Multi-Variant Mechanical Platform and Supplier Readiness

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

Active architecture + prototype development

Thermal Consumer Product Architecture

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

Ended · editable CAD delivered

Complex Geometry Reconstruction and Design-Intent CAD

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