Expert Details

Expert in Product Design and Manufacturing - related product/system defects, also Intellectual Property

Expert ID: 729917 United Kingdom

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Expert has over 40 years' experience in Product Design and Engineering covering a broad range of product categories, also has some 20 years experience as an Expert Witness involved in, amongst other fields, faulty design and manufacture, product failure, intellectual property, contractual disputes and personal injury. Over recent years he has been commissioned to investigate the causes of accidents at home and at work, recreational accidents, accidents resulting from some cosmetic treatments etc where these relate to faulty or defective products/equipment resulting from design/manufacturing defects, inadequate instructions etc etc.

During his professional experience he has developed a knowledge and understanding of most materials and associated manufacturing disciplines. The majority of his design and development work has been innovative by nature, involving either a new product concept or a significant departure in terms of material or process application. In many cases the innovative design has led to the formation of a new company or new division within an existing client firm and has typically involved patent or other forms of I.P. protection.

Expert has extensive experience of analyzing, testing and establishing likely causes of product failures and/or resulting injuries in many different fields such as automotive, numerous categories of consumer goods and certain items of equipment.

Klix (Mars Foods) - design of range of innovative in-cup hot/cold beverage vending machines, also development of Flavia sachet fresh brew coffee brewing system now extensively used in US, Canada, Japan, China, Germany, France and Ireland plus the KDesign of award-winning modular Trajan Photographic Staging system, subsequently exported to USA, Australia, Austria etc.Design of numerous hand tools for Stanley Tools, Sheffield, England: planes, drills, scrapers, vices etc.Design and development of wall-mounted payphone and trolley plus other telephones for British Telecom Design of ticket machines, luggage conveyors etc for London Transport.


Year Degree Subject Institution
Year: 1966 Degree: BA Hons Subject: Industrial Design (Engineering) Institution: University of Central England (Birmingham)

Work History

Years Employer Title Department Responsibilities
Years: 1982 to Present Employer: Undisclosed Title: Managing Director Department: (Undisclosed) Responsibilities: Malcolm Expert is and has been responsible for many challenging, ground breaking and varied product design commissions for national and international clients and for embedding inclusive design principles and criteria within the design process.
Years: 1997 to 2004 Employer: (Undisclosed) Title: Co-ordinator for Design Practice Department: Industrial Design Engineering Responsibilities: He has been responsible for all aspects of professional practice, student placements, design and technology lecture series and content, administrative requirements of course, student visits to industry, crits, examination criteria, tutorial records, reporting, timetabling/grouping, departmental review, new student application process, web-site design, exhibitions etc
Years: 1996 to 1997 Employer: (Undisclosed) Title: Head of Department Department: Industrial Design Responsibilities: Responsible for all aspects of Departmental and associated Faculty operation and organisation, staff supervision, tutoring, administration, programme management. application procedures, tutoring, examinations, student crits etc.
Years: 1966 to 1982 Employer: (Undisclosed) Title: Director Department: N/A Responsibilities: New business generation, new project management, research and development, electronic development, undertaking personal project with associated client liaison, financial management of projects and client portfolios etc.

Government Experience

Years Agency Role Description
Years: 1984 to 1985 Agency: Ministry of Defence Role: Design Consultant Description: Design of Aircrew Oxygen Mask Physical Support system.
Years: 1982 to 1990 Agency: Department for Trade & Industry Role: Approved DesignEngineering Consultancy Description: Projects undertaken for user companies, both fully and partly funded, under DTI Design and Enterprise Initiatives (originally the Funded Consultancy Scheme).

International Experience

Years Country / Region Summary
Years: 1978 to 1979 Country / Region: Holland Summary: Design of range of clocks for Philips, Eindhoven.
Years: 1972 to 1974 Country / Region: Ireland Summary: Design of range of cast iron products including pans, cookers, fires, oil-fired room heaters, cookware etctc.
Years: 1980 to 1982 Country / Region: France Summary: Bus and Train-based Ticket Machine Feasibility Study Project carried out for Syndicate of Passenger Transport executives.
Years: 2004 to 2005 Country / Region: US£ Summary: Commissioned as expert witness examining and reporting on motor crash/roll over fatality in Morocco

Career Accomplishments

Associations / Societies
MBAE (Member of British Academy of Experts) for approx 15 years.

Expert (tier 1) Association of Personal Injury Lawyers
Licenses / Certifications
Fellow, Chartered Society of Designers(FSCD).
Professional Appointments
Subect Reviewer (Quality Assurance Agency) for various UK Universities and compilation of Overview Reports.
Awards / Recognition
British Design Award, (Undisclosed), Trajan Photographic Staging.
Medical / Professional
Various design/development and expert witness reports and projects for manufacturers, also personal injury matters involving the UK/NHS etc
Publications and Patents Summary
Numerous UK and International Patents.

Additional Experience

Expert Witness Experience
Over 25 years' experience as an expert witness including provision of detailed reports, giving evidence and being cross examined in High Court and Patent Court, London, also provincial courts across the UK. Involvement also with firm of US Attornies in connection with fatality in Morocco following 4 x 4 SUV roll-over incident requiring provision of detailed expert report and examination of numerous depositions.
Training / Seminars
Single Joint Expert training, London, England.
Vendor Selection
Extensive knowledge of supplier network as associated with manufacture of new products and consumer goods.
Marketing Experience
Extensive knowledge of wide range of product areas and associated manufacturing expertises.
Other Relevant Experience
Product investigation and testing to establish nature of product failure.

Language Skills

Language Proficiency

Fields of Expertise

component design, consumer product design, design engineering, design for manufacturability, design for manufacture and assembly, engineering design, 3D design, castings, computer design, consumer product ergonomics, design for assembly, electronic equipment design, high volume, low cost product assembly, high volume, low cost product design, industrial design, manufacturing, metal component design, metal component fabrication, plastic component design, plastic part, plastic product design, product design, snap-fit, wood product design for manufacturability, accident, accident analysis, accident causation, incident investigation, investigation, occupational injury, personal accident injury, industrial accident investigation, plastics research and development, European manufacturing, consumer focus group, plastic product development, tamper-evident closure, case temperature, engineering specification, composite material testing, consumer product packaging, bayonet coupling, composite material design for manufacturability, product reliability improvement, ski injury, electronic display instrument design, plastics industry, product testing, wood physical property, living hinge, electronic-product design for manufacturability, aluminum product design, automotive engineering design review, electronic product, machinery-related accident, electrical accident, industrial accident, motor vehicle accident, automotive accident, engineering design productivity, hinge, electrical engineering, patent law, burn injury, polymer, nondestructive testing, human factors engineering, accident investigation

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