JeffForge develops functional parts by starting with the problem, constraints, and interfaces first. The portfolio is organized around six different engineering problem types, with room for multiple case studies in each category as the work grows.

Replacement & Repair Parts

Recreate a part that is broken, unavailable, or no longer supported.

Reverse engineering, critical dimensions, pivots and interfaces, print-aware redesign, fit, tolerance, and reinforcement where the original part is vulnerable.

Fusion CAD development model of a replacement washing machine door handle with ribs, pivot supports, and latch geometry

Washing Machine Door Handle Reconstruction

A broken appliance handle reverse-engineered from reference geometry, inferred measurements, and functional interfaces rather than copying an existing STL.

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Mounts & Brackets

Add a stable mounting solution when standard hardware does not fit.

Mounting geometry, screw locations, stiffness, access, spatial constraints, and practical installation or removal.

Technical placeholder for the JeffForge adjustable doorbell mount case study; CAD and prototype imagery will be added as testing progresses

Adjustable Doorbell Mount for Uneven Walls

A custom mounting system designed around an irregular wall surface, with adjustable support points, a sliding attachment interface, and a serviceable release mechanism.

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Adapters & Connectors

Connect two useful things that were never designed to fit together.

Interface measurement, inside/outside diameters, transitions, insertion fit, retention, taper, and tolerance.

Enclosures & Holders

Build mechanical structure around electronics and real component geometry.

PCB mounting, connector cutouts, LEDs, buttons, cable exits, standoffs, lids, wall thickness, and assembly.

Organizers & Storage

Turn a recurring workspace problem into a modular system.

Standardized dimensions, reusable interfaces, multi-part fit, expandability, workspace ergonomics, and system-level design.

Working prototype of the JeffForge modular vertical electronics storage system

Modular Electronics Storage System

A freestanding, expandable vertical organizer with removable and stackable bins for components, connectors, tools, and other workbench essentials.

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Prototypes & Custom Mechanisms

Turn an idea into a small mechanism that moves, locks, slides, or grips.

Motion, hinges, sliders, latches, flexures, springs, clearances, multi-part interaction, and iterative prototyping.