The design and production of a prototype cost-effective, energy-efficient, and portable jaw crusher for small-scale rock crushing addresses critical challenges in artisanal and small-scale mining (ASM). Conventional jaw crushers, while effective for industrial applications, are often expensive, energy-intensive, and immobile for ASM operations. This study presents a mechanically optimised single-toggle jaw crusher designed for accessibility, efficiency, and portability. Key innovations include a modular frame constructed from reinforced mild steel, reversible manganese steel jaw plates for extended wear life, and a dynamically balanced flywheel to reduce energy fluctuations. Finite Element Analysis (FEA) validated structural integrity under operational loads, with safety factors exceeding 1.3 for all critical components. Performance testing on granite, quartz, and iron ore demonstrated a crushing efficiency of 85% and energy consumption ranging from 1.67–5.00 kWh/ton, with quartz processing achieving the highest efficiency – 0.167 kWh/ton due to optimal breakage characteristics. Throughput varied from 400–1,200kg/hr, while reduction ratios of 7:1 to 10:1 were achieved. Comparative cost analysis revealed a 50–60% reduction in capital costs versus imported mini jaw crushers and 30–40% lower energy consumption than hammer mills. The crusher’s compact design (