Expert Details

Expert in Composites Materials (Applications, Processing, Manufacturing), Solid Mechanics, Material Science and Mechanical Testing

Expert ID: 738085 North Carolina, USA

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Expert in composites fabrication techniques and equipment including vacuum infusion, resin transfer molding, compression molding of SMC/BMC, pultrusion, filament winding, casting, spray-up and hand lay-up. Applied knowledge of thermoset polymer resin chemistry including resin synthesis, formulation and compounding for fiber reinforced plastics.

Expert in mechanics of materials, material science and static-and-dynamic mechanical and testing of materials utilizing relevant ASTM, ISO, UL, ANSI and MIL-SPEC test methods. Skilled use of universal test equipment and software and for mechanical testing. Experience designing laboratory test equipment and retrofitting full-scale composite production equipment.

Skills:
• Complex Problem Solving
• Product and Process Troubleshooting
• Personnel Manager
• Project/Product Manager
• Mechanical & Analytical Testing
• Design Engineering
• CAD & 3D Solid Modeling
• Closed Form Analysis
• FEA & Simulation
• Mechanical, Thermal, Fluid, Basic Electrical
• Programming & Software
• Capital Expense Projects
• Team Building & Mentoring
• Safety Conscious

Education

Year Degree Subject Institution
Year: 1998 Degree: PhD Subject: Mechanical Engineering Institution: North Carolina State University
Year: 1993 Degree: MS Subject: Civil Engineering Institution: Colorado State University
Year: 1990 Degree: BS Subject: Mechanical Engineering Institution: University of Colorado

Work History

Years Employer Title Department
Years: 2019 to 2022 Employer: Cornerstone Building Brands Title: Direct of R&D and Testing Department: Foundation Labs - Insight Center
Responsibilities:
The Expert was responsible for managing Foundation Lab’s R&D operations for Residential-Building New-Product-Development and managing the mechanical and analytical testing laboratory. He was responsible for advanced testing, simulation, prototyping, quality assurance & quality control testing for scale-up and product launch, continuous laboratory improvement, cost reduction and safety.

• Reported to CBB’s Innovation Officer for Residential and Commercial Building Products.
• 6 direct reports and 6 indirect reports.
• Managed Foundation Lab’s mechanical and analytical testing laboratory.
• Managed Foundation Lab’s R&D operations (added responsibility).
• Reduced CBB testing expenditures by optimizing internal and 3rd party testing and leveraging testing resources throughout CBB with an annual $1MM+ in cost avoidance. Grew Foundation Lab’s testing capabilities by identifying test equipment, methods, procedures and best practices that support continuous laboratory improvement. Developed internal test methods.
• Supported new product development and CBB business units with advanced testing, simulation and prototyping. Supported scale-up and product launch with quality assurance and quality control testing. Recommend test equipment and methods to support transition of product quality from development to production.
• Identified and led specific Foundation Labs Residential R&D projects and supported additional R&D and testing efforts in CBB’s Residential and Commercial business units. Investigated new technologies including products, materials, equipment and processes that supported NPD. Reviewed 3rd party and start-up technologies.
• Troubleshot material and process issues with new & existing products. Provide material, process and testing
recommendations to facilitate product development, cost reduction and assist with the resolution of quality, warranty or field issues.
• Developed safety programs with 3rd party aid and supported laboratory safety through training, use of standard operating procedures, proper equipment and identification and implementation of best practices.
• Utilized continuous-belt forming manufacturing processes with thermoset polymer systems and extrusion process with thermoplastic systems.
• Employed SCRUM agile methodology for NPD.
Years Employer Title Department
Years: 1994 to 2019 Employer: Reichhold Chemicals Title: Senior Mechanical Engineer Department: Composites
Responsibilities:
The Expert was a Technical Service Representative providing product, process and engineering support to large scale composite manufacturers including Wind Energy (Blade & Nacelle), Commercial and Residential Construction, Automotive & Marine. He supported existing and new product development with his expertise in vacuum infusion, resin transfer molding, compression molding of SMC/BMC, pultrusion, filament winding, casting, spray-up and hand lay-up and his applied knowledge of thermoset polymer resin chemistry (including resin synthesis, formulating and compounding for fiber reinforced plastics). The expert managed a state-of-the-art ISO 9001 mechanical testing laboratory performing static & dynamic mechanical & material testing using relevant ASTM, ISO, UL, ANSI and Mil-Spec test methods. He also designed laboratory equipment and retrofit full-scale composite production equipment.

• Designed, setup and managed a state-of-the-art ISO 9001 accredited mechanical testing laboratory with 4 direct reports. Performed static and dynamic testing using ASTM and ISO methods and provided analysis and
interpretation of test results. Also performed UL, ANSI, MIL-SPEC & custom testing. Skilled use of universal test
equipment, software and methods for mechanical testing.
• Technical service representative serving large scale composite manufacturers including Wind Energy (Blade &
Nacelle), Commercial and Residential Construction, Automotive & Marine. Customer focused product and process development, trials, scale-up and manufacturing support.
• Product, process and engineering technical support to Polynt / Reichhold’s technical staff, manufacturing facilities (R&D, pilot plant, scale up, production) and customers.
• Demonstrated knowledge of composites fabrication techniques and equipment for vacuum infusion, RTM,
compression molding of SMC/BMC, pultrusion, filament winding, casting (static & rotational), spray-up and hand lay-up. Skilled use of laboratory and composites production equipment.
• Applied knowledge of polymer resin chemistry including thermoset polymer resin synthesis, resin formulating and compounding for fiber reinforced plastics and safety & chemical hygiene (PPE, SDS).
• Planning and execution of capital expense projects such as equipment retrofit, equipment design, selection and purchase of laboratory and test equipment.
• Custom equipment design and equipment retrofit with selection and installation of controllers, sensors, actuators, data acquisition systems and custom software development for operating and monitoring molding processes, monitoring in-process polymer synthesis reactions, measurement of real-time cure shrinkage and determination of resin gel & cure properties.

Career Accomplishments

Associations / Societies
Tau Beta Pi – National Engineering Honor Society
Pi Tau Sigma – International Mechanical Engineering Honor Society
Licenses / Certifications
E.I.T.
Awards / Recognition
ACMA/CAMX - Awarded best paper in testing and materials categories including "The Effect of Fracture Toughening a Thermoset Resin on the Fracture Toughness of a Fiber-Reinforced Laminate” and “Impact Properties of Polyester Resins”.
Publications and Patents Summary
Industry Publications:
• 11 publications (Composites and Advanced Materials Expo, American Composite Manufactures Association & the Society of the Plastics Industry).

Research Publications
• 3 publications (Journal of Applied Mechanics, Journal of Solids and Structures and Journal of Intelligent Material Systems and Structures)

Additional Experience

Vendor Selection
Extensive experience identifying and working with material and equipment vendors.
Other Relevant Experience
Quick study with software, programming languages, mechatronics, processes and equipment.

• CNC machining using WinCNC, Cut2DPro and 3D SLA printing (Formlabs PreForm).

Software:
▪ Windows, Mac & UNIX OS. MS Office, Visual Basic, Visual C++, CAD (Solid Works, AutoCAD / Inventor), FEA (Ansys, Solid Works, Inventor), Data Acquisition (LabView), MATLAB and FORTRAN.
▪ SAP for production BOMs, costing, scheduling, ordering and material management.
▪ Frontline for MOC and LMS operations.
▪ Confluence for global technical collaboration.
▪ Minitab for design of experiments.
• Analytical methods – understanding of the basic operation and results of NMR, GC/MS, FTIR, GPC, DMA, TMA, TGA, DSC & Rheometer

Fields of Expertise

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