Advanced Materials and Composite Engineering Development Consultant

Technical Consultant #2448

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.

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.

Academic and Professional Affiliations

Publications

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

Patents

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