Jared MaffucciSenior Mechanical Engineer | Hardware Product Development

Selected engineering work

Selected Engineering Work

Three anonymized engineering records connect the challenge, my role, engineering actions, outputs, maturity, and what each public record proves. Independent CAD studies follow as a separate visual portfolio.

Review Selected WorkView ExperienceContact Jared

Three anonymized case records show the challenge, my role, the engineering work performed, the delivered outputs, and the maturity reached. Independent CAD studies follow.

3 recordsAnonymized, decision-led, maturity disclosed9 independent CAD viewsApproved bracelet, packaging, automotive, and HVAC studies
Product environments
Consumer + prosumer
Electromechanical + industrial
Aerospace + high reliability
Mechanical scope
Mechanisms + structures
Enclosures + interfaces
Thermal + fluid behavior
Evidence methods
Parametric CAD + surfacing
Analysis + prototypes
Test + inspection planning
Release systems
BOM + CTQ definition
DFM/DFA + suppliers
Configuration + improvement

Paused · supplier-quote-ready + DFM-ready

Multi-Variant Mechanical Platform and Supplier Readiness

Four related manual-adjustment products needed shared mechanisms and supplier definition without allowing common parts, purchased components, or assumptions to conceal variant risk.

SRCAn anonymized derivative of the controlled engagement record; native BOM, CTQ, inspection, RFQ, and client geometry remain private.

My role

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

Engineering actions

  • Developed manual hand-crank and handwheel architecture with guarded access.
  • Separated shared requirements and interfaces from variant-specific definition.
  • Structured a 312-row BOM including 199 purchasable or COTS lines.
  • Established CTQs, first-article and test matrices, supplier questionnaires, quotation templates, and deviation tracking.

Outputs

  • Architecture record
  • Variant requirements
  • BOM strategy
  • CTQ and inspection definitions
  • Supplier RFQ controls

What this record proves

The publication-cleared record supports architecture, sourcing, CTQ, inspection, and quotation readiness. The program was not fabrication-release-ready; final native CAD, released drawings, toleranced interfaces, CAD-derived BOM reconciliation, and validation closure remain.

Active architecture + prototype development

Thermal Consumer Product Architecture

A consumer thermal product required repeated architecture and CAD revision to reconcile a master shell, liner, thermal cartridge, top interface, containment, sealing, condensation, assembly, service, and user interaction.

SRCAn anonymized derivative of the archived revision record; native product geometry and client files remain private.

My role

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

Engineering actions

  • Developed the shell, liner, thermal-cartridge, and top-interface assembly.
  • Reworked sealing, containment, condensation paths, assembly order, access, and service.
  • Maintained native SolidWorks parts, assemblies, configurations, and eight archived revisions.
  • Prepared stage-appropriate definition for prototype and patent-support decisions.

Outputs

  • Native SolidWorks parts and assembly
  • Alternate configurations
  • Eight-revision development sequence
  • Prototype and patent-support definition

What this record proves

The source record supports eight revisions and this architecture work. Measured cooling duration, food-contact certification, leak or condensation testing, a validated production process, and a completed commercial product are not claimed.

Ended · editable CAD delivered

Complex Geometry Reconstruction and Design-Intent CAD

Supplied scan and mesh data had holes, edge noise, and continuity defects that prevented controlled editing.

SRCA publication-safe derivative of the verified reconstruction record. Native model geometry and client-specific source data remain private.

My role

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

Engineering actions

  • Separated measured evidence from inferred design intent and fit-critical interfaces.
  • Used loft, sweep, and filled surfaces to bridge gaps and restore continuous geometry.
  • Recovered datums, interface logic, and editable feature relationships rather than making a format conversion.
  • Delivered native SolidWorks geometry and neutral STEP data.

Outputs

  • Input and repair plan
  • Reconstructed surfaces
  • Editable SolidWorks model
  • Neutral STEP data

What this record proves

The source record confirms a native SolidWorks part, supporting model imagery, and neutral STEP output. The public derivative does not identify the client or product, expose proprietary geometry, advertise standalone scan acquisition, or claim production validation.

Independent design studies

Selected Product and CAD Studies

Independent SolidWorks studies covering a luxury NFC medical-ID bracelet and bespoke packaging, Mercedes-Benz CLS 63 AMG exhaust tips, Porsche HVAC ducts, and a custom Toyota Supra hood. They demonstrate CAD and visualization work; they do not claim fabrication, validation, tooling, commercial release, or affiliation with the named vehicle manufacturers.

SolidWorks render of a sculpted luxury medical-ID bracelet with a concealed NFC information interface and hinged closure.
Luxury NFC medical-ID bracelet developed as a discreet personal-information wearable with a precision metal form and integrated closure and interface details.
SolidWorks render of bespoke black presentation packaging for a luxury bracelet, with patterned side panels and a circular top interface.
Bespoke presentation and protective packaging designed around the luxury NFC medical-ID bracelet, with controlled presentation, protection, and access.

INDEPENDENT DESIGN STUDY | LUXURY WEARABLE + PACKAGING

Luxury NFC Medical-ID Bracelet and Bespoke Presentation Packaging

Developed a fashion-led medical-identification bracelet concept that discreetly integrates an NFC-enabled personal-information interface into a sculpted wearable form. The paired SolidWorks study extends the same design language into bespoke presentation and protective packaging, connecting wearable architecture, closure details, protective structure, and a deliberate unboxing and storage experience.

Demonstrates
Product architecture · Luxury wearable architecture · NFC interface integration · Closure and enclosure detailing · Bespoke protective packaging · Coordinated product presentation
Stage
Independent luxury wearable and packaging concept
Matte SolidWorks render of a curved Porsche HVAC duct with compound surfaces and circular end interfaces.
Porsche HVAC duct geometry developed in SolidWorks to resolve constrained packaging, section transitions, and manufacturable form.

INDEPENDENT DESIGN STUDY | PORSCHE HVAC DEVELOPMENT

Porsche HVAC Duct Development

Developed a family of Porsche HVAC duct components with controlled round interfaces, low-profile routing, compound curvature, and smooth section transitions. The work demonstrates advanced surfacing, constrained flow-path packaging, and consistent interface development across multiple duct forms.

Demonstrates
Advanced surfacing · Section transitions · Constrained routing · Interface geometry · Finish visualization
Stage
Independent Porsche HVAC CAD and visualization study
View 2 supporting views
Matte SolidWorks render of a compact Porsche HVAC elbow duct with round openings at both ends.
Porsche HVAC elbow duct developed with smooth curvature and controlled round-end interfaces.
Side-view SolidWorks render of a low-profile Porsche HVAC transition duct with round openings at opposite ends.
Porsche HVAC transition duct developed around opposing interfaces and constrained routing geometry.
SolidWorks render of a paired set of black trapezoidal exhaust tips for a Mercedes-Benz CLS 63 AMG.
Paired trapezoidal exhaust tips designed in SolidWorks for a Mercedes-Benz CLS 63 AMG, with ribbed outlet detailing and rear pipe integration.

INDEPENDENT DESIGN STUDY | AUTOMOTIVE COMPONENT DEVELOPMENT

Mercedes-Benz CLS 63 AMG Trapezoidal Exhaust Tips

Designed a matched pair of trapezoidal exhaust tips for the Mercedes-Benz CLS 63 AMG. The SolidWorks models coordinate the visible outlet form, perimeter ribs, repeated geometry, rear pipe transitions, symmetry, and compact mounting interfaces as one automotive finishing system.

Demonstrates
Automotive component architecture · Styled rib and outlet detailing · Paired symmetry · Rear pipe transitions · Surface and finish development
Stage
Independent automotive component-design concept
View alternate view
Alternate SolidWorks render of black Mercedes-Benz CLS 63 AMG trapezoidal exhaust tips viewed from the front-left.
Alternate finish study of the Mercedes-Benz CLS 63 AMG exhaust-tip pair, emphasizing the molded ribs and rear mounting transitions.
SolidWorks render of a custom carbon-fiber Toyota Supra hood with broad compound curvature and a raised surface feature.
Custom Toyota Supra hood surface developed in SolidWorks; the carbon-fiber appearance is a finish visualization, not a fabrication claim.

INDEPENDENT DESIGN STUDY | AUTOMOTIVE SURFACE DEVELOPMENT

Custom Toyota Supra Hood Surface Development

Developed a custom Toyota Supra hood with broad compound curvature and localized feature definition, emphasizing highlight flow, surface continuity, form control, and carbon-fiber and high-gloss finish visualization.

Demonstrates
Large-surface continuity · Localized feature definition · Automotive form development · Carbon-fiber and high-gloss visualization
Stage
Independent automotive surface-development concept
View alternate view
Alternate glossy black SolidWorks visualization of a custom Toyota Supra hood with sculpted compound surfaces.
Alternate high-gloss visualization of the custom Toyota Supra hood, used to evaluate highlight flow and surface continuity.

Confidentiality + private portfolio

Technical specificity without compromising client trust.

Public records are limited to approved, anonymized descriptions and artifacts. Client identities, proprietary geometry, correspondence, pricing, supplier detail, native source files, and unreleased manufacturing information remain private.

Additional project examples, design artifacts, and confidential work samples are available during qualified employer or client discussions, subject to client permissions and confidentiality restrictions.

For employers

Review the additional work appropriate to a qualified role discussion.

Include the role, company, product context, and the mechanical decisions the hire would lead. Additional approved examples can be discussed privately.

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For product teams

Clarify the mechanical decision the product needs to close.

Include the product stage and a concise, non-confidential summary. I will respond directly.

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