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Advanced Materials and Composite Engineering Development Consultant

Technical Consultant #2448


Expertise

  • Advanced materials technologies.
  • Produce radiation shielding and counter weights through the science in spun molybdenum crucibles for sapphire crystal growth and tungsten heavy alloys penetrators.
  • Identify products to maximize potential marketing value in the plate, sheet, foil, rod, wire, and fabricated components for customers in multiple industries.
  • Large-scale production of sapphire for watch faces and optical windows.
  • Government contracting; contract negotiations, reporting, technical marketing, and management of patent application processes.
  • Develop corrosion resistant aircraft parts for military use.
  • Increase composite yields through implementing procedures to identify and prevent defects during material fabrication.

Experience

Undisclosed Company, Senior Materials Engineer, 2013 - 2017

  • Directed the spun molybdenum crucibles for sapphire crystal growth and tungsten heavy alloys for penetrators, radiation shielding and counter weights.
  • Brought on in a largely self-managed role. Identify product areas that have the greatest unrealized potential (company offers a wide range of product forms, including plate, sheet, foil, rod, wire, and fabricated components for customers in multiple industries).
  • Oversaw molybdenum spun crucible development as part of major project with Apple - GTAT involving large-scale production of sapphire (used in watch faces and optical windows).
  • On Site at customer's facility to resolve production issues.
  • Demonstrated in-depth understanding of customer needs. Grew project over 15-month period, with crucibles generating $26 million annually.
  • Paved the way to capture 65% of company's heat exchanger business ($2 million) by identifying and resolving issue with brazing temperature.
  • Eliminated prior $250,000 in monthly expenditures by conducting detailed analysis and evaluation that led to corrected anneal cycles and halted costly flood of scrap.
  • Facilitated $1.8 million in annual profit increase by pinpointing and fixing issue with incorrectly processed product, achieving $150,000 in monthly Material Usage Variance (MUV) savings.
  • Implemented alloy system already available from competitors, with initial applications of medical devices valued at $6 million and defense valued at $20 million.

Chesapeake Composites, New Castle, DE, Director of Technology, 1992 - 2013

  • Founded and directed technical aspects of the company.
  • Held full technical responsibility for the company.
  • Prepared technology road maps, forecasts, and market differentiation strategies.
  • Conducted in-depth analysis of existing operations and research of markets, products, and processes.
  • Directed government contracting efforts that included contract negotiations and reporting, technical marketing, and management of the patent application process.
  • Captured 50% of bids and proposals for multiple contracts from the NSF and DoE, with contracts ranging from $50,000 to over $1.5 million.
  • Awarded U.S. and international patents for Oxide Dispersion Strengthened (ODS) alloy process and form of matter technology; developed aluminum alternate for a beryllium optic component.
  • Fostered partnership with Federal-Mogul (Europe) to develop crown inserts for next-generation TDI passenger car diesel engines.

Lanxide, Newark, DE, Senior Materials Scientist, 1989 - 1992

  • Defined new product needs for start-up company and led team in creating stronger composites and more economical processes. Increased yield of thick cross-section components by 25% through implementing procedures to identify and prevent defects during material fabrication.

Honeywell International, Morristown, NJ, Group Leader, 1983 - 1988

  • Established a multi-year project with Lawrence Livermore Laboratory to scale-up the diameter of Yttria - Alumina garnet (YAG) single crystals used for laser optics.
  • Reduced alloy development time 50% by establishing an automated mechanical testing system.
  • Initiated projects with the U.S. Navy to develop corrosion resistant air to air missile wings and the U.S. Air Force to develop a laser-based air to air missile guidance system.

Honors & Publications


Academic and Professional Affiliations

  • The Science, Technology and Research Institute (STRIDE)

Publications

  • Author and Co-Author of publications in peer reviewed journals, international proceedings and conferences.

Patents

  • U.S. and International patents for Oxide Dispersion Strengthened (ODS)

Education

  • Ph.D. Material Science Engineering, University of Cambridge, Cambridge, United Kingdom
  • B.S. Ceramic Science, Rutgers University, Dept. of Engineering, New Brunswick, NJ
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