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 Expert  711797

Expert in Product Design and Manufacturing, Materials, Fastening and Joining, Consumer Product and Safety

Available for your Consulting and Expert Witness Needs

Minnesota (MN)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness

Summary of Expertise:

Listed with other top experts in: 

Expert is the contact for an applied research and development engineering office. Production has included well over 200 individual product models of various shapes, sizes, and functions. These projects have ranged from outdoor, lawn/garden, snow, off-road vehicle, and golf course equipment, as well as medical, food equipment, and handicap devices. His experience includes work in consumer and business product, plastic and aluminum part design, finite element analysis (FEA), solid modeling, computer simulation and animation, failure analysis, safety, and cost reduction. He is also knowledgeable of UL, CSA, TUV/GS, and NSF standards. He is available for technical management consulting.

Expert is experienced with hardware production organization and troubleshooting, equipment justification, return on investment analysis, life testing, and packaging. The process equipment he is familiar with includes envelope machines, special production machinery, PC board assembly analysis, production software, and computer simulation. His computer modeling skills regarding mathematical, mechanical, and electrical concepts are particularly exceptional. Efforts have included elevator components, geared transmissions, complete mechanical-electrical motor driven products, systems, and many points between. Over the past 30 years, his clients have included start-up companies to large corporations such as Black & Decker, Toro, Andersen Corp, Gould, Turck, Honeywell, 3M, IBM, Seimens, Stratasys, Polaris, Rimage, Allen Bradley, General Motors, and the U.S. Government.

The biomedical design experience of this office includes ECG connectors, enteral delivery system, ethylene oxide sterilizer safety review, hospital food delivery system, fused deposition modeling (used for elbow, knee joint duplication, etc.), wheel chairs, walkers, patient assist devices, ultrasound support and positioning devices, and passive motion exercise devices.

His initial experience was heavily involved in the consumer product area. This has included almost all of Toro's consumer product areas--in this case, as originator of numerous concepts in snow, riding lawn mowers, lawn vacuums, and yard lights. Safety was (and is) the number one issue in consumer product design. In fact, expert believes design experience is the absolute "crown jewel" of legitimate product safety experience.


new consumer product development


new product development


product design


design for manufacturability


product manufacturing


biomedical engineering


consumer product safety


consumer product

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Minneapolis, Minnesota;  Saint Paul, Minnesota;  Rochester, Minnesota;  Burnsville, Minnesota;  Saint Cloud, Minnesota;  Eden Prairie, Minnesota;  Minnetonka, Minnesota;  and Eau Claire, Wisconsin.

Year   Degree   Subject   Institution  
1965   B.M.E. (5-year Program)   Mechanical-Industrial Engineering   University of Minnesota  
1961     Physics, Pre-Engineering   St. Olaf College  
1975     Electronics & Related Equipment   Devry Institute  

Work History:
Years   Employer   Department   Title   Responsibilities

1975 to


(Expert's Firm)






He provides design and consulting for a wide variety of hardware products and equipment. One of his strongest suits is in mathematical modeling of equipment accompanied by appropriate graphics to explain and clarify. Efforts have included much original design plus troubleshooting of various design or production problems. He has some limited familiarity with computer controlled machining for manufacturing and has programmed in G-Code. He is licensed to practice as a Professional Engineer in several states.

1979 to 1981


Food Engineering Corporation


Engineering and Assembly


Director of Engineering


He was responsible for most of the company's technical operations (Engineering and Assembly). This included about half the 100-person-company's people. Equipment designs included pellet and flake dryers, conveyors (vibratory and otherwise), and other food processing, stainless steel, type equipment. A good bit of the work required professional certification, which he was able to provide due to professional licensure.

1973 to 1976


Black & Decker, Inc.


Outdoor Appliance Engineering


Group Leader


Expert was responsible for the majority of outdoor appliances with the exception of lawn mowers. Since leaving B&D as an employee, he has performed work for them on a consulting basis. This work has included hedge trimmers, string trimmers, and an original design and prototype build of a bench grinder.

1965 to 1973


The Toro Company


Consumer Division


Senior Design Engineer


Expert worked on research and development in all areas of consumer products. He was the project engineer for Toro's original line of large two-stage snowthrowers. He was also the originator of Toro's "Power Curve" snowthrower configuration, the bagging system that allows the operator to dump grass without getting off the lawn tractor, their original lawn vacuum, plus a number of other items still in the Toro system.

1962 to 1965


Lincoln Dairy Plant Suppliers, Inc .




Technical Assistant


He assisted company engineers while he was a student at the University of Minnesota.

Career Accomplishments:

Expert is a past officer and (remains a) member of the Minnesota chapters of the National Society of Professional Engineers and the American Consulting Engineers Council and their local Minnesota chapters. He is also a member of the Minnesota Reliability Consortium (MRC). He is presently a member of the University of Minnesota's Institute of Technology Alumni Association and is a past member of its Board of Directors.


He is a Registered Professional Engineer in several states.

Professional Appointments

Expert has chaired a number of operating committees and is a past member of the Board of Directors of both the National Society of Professional Engineers and the American Consulting Engineers Council. He is presently a member of the Board of Directors for the University of Minnesota Institute of Technology Alumni Association.


Expert is a past recipient of Minnesota's Seven Wonders of Engineering Award and two U.S. Small Business Innovation Research Grants. He is the sole recipient of the President's Award from the Minnesota Consulting Engineers Council. He received the Minnesota Governor's Star Award for Handicapped Equipment Design. Expert was selected as sole recipient of the University of Minnesota Duluth's Engineering Appreciation Award for Service to the College of Science and Engineering. He was the sole recipient of the Minnesota Consulting Engineer's Council's President's Award for active contribution to the group's goals. A No.1 with Consumer Reports has been awarded to four different product lines he has been responsible for. One snow thrower, a riding lawn mower, a hedge trimmer, and most recently, a yard blower-vacuum, This past summer, a high speed blower by Toro that is constructed around his original compound fan design was awarded No. One with Consumer Reports.

Publications and Patents Summary

Expert is the credited inventor for 24 U.S. patents and two patents pending. He is also the author and contributor to two articles for Machine Design magazine concerning use of the Weibull distribution as a tool for product reliability calculation.

Selected Publications and Publishers  
 - Machine Design  

Government Experience:
Years   Agency   Role   Description
1986 to 1989   United States Bureau of Health & Human Services     Expert conducted two separate research, design, and study grants for the U.S. Department of Health and Human Services. This included a study of over fifty residences around the Twin Cities metropolitan area regarding elderly people's ability to safely move around their homes. Subsequently, this involved the design of equipment to assist these folks to safely climb or descend stairways.
1980 to 1990   United States Bureau of Mines   Consultant Design   He has designed and fabricated three variations of coal auger heads. This included design of three extremely high capacity gear heads (25,000 ft-lbs capacity). Testing was performed by Bureau of Mines individuals. Other smaller analysis projects were performed for them throughout the 80's until the USBM Twin Cities office was closed.

Consulting Services:
Selected Consulting Examples:
  • ENVELOPE FORMING MACHINE Designed an envelope forming machine to replace an existing, but very old, machine. The object was to duplicate the function of the existing unit but at approximately twice the speed. In addition, the setup for each individual envelope size took about 4-6 hours. By making the width of the carrier track adjustable with a hand crank, he was able to cut setup to about 20 minutes per size. Also, the output per unit time was about two times the original unit's.
  • AUTOMOTIVE HEATER Thermodynamic (heat transfer) investigation and analysis of the effect of restrictions in water flow to various automotive heaters for various input water and air conditions. Formal report.
  • RESEARCH ON TORO'S SNOW PUP SINGLE STAGE SNOW THROWER (Asst. Project Engineer) Work included experimentation with various paddle/rotor materials and options Final configuration including rubber paddles and means for attaching to rotor evolved from this work.
  • MINNOW DISPENSING SYSTEM Review of design for a coin operated minnow dispensing system. Major problem was the minnows did not seem to last as long as they should. Identified a problem with the material in one of the components the minnows were exposed to. Also recommended improved aeration system. Part list and cost estimates were also constructed.
  • ENGINE GENERATOR Complete engineering and industrial design for enclosed 4000 watt, 110 volt engine/generator set including styling, prototype construction, cooling air flow, ducting, etc. Included UL investigation. Unit designed for inclusion into mobile homes and similar vehicles.
Recent Client Requests:
  • Expert in product safety for consulting on product safety audit.
  • Expert for consulting on hand tool market and threaded fastener removal.
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
Expert has provided expert testimony for both product liability and patent litigation issues.
Recent Litigation Client Requests:
  • Lawn mower safety expert needed for consulting regarding a Honda HRX217HXA lawnmower.
  • Snow thrower expert for consulting on a personal injury case.
  • Mechanical engineering expert for consulting on invalidity of a patent.
Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:

He has worked with training seminars for reliability calculation issues. He has also presented multiple seminars for junior high school through college students to talk to them about engineering as a career.

Supplier and Vendor Location and Selection

Vendor selection has always been an integral part of the design work for Expert's office.

Other Skills and Services

Expert has been primarily responsible for two product lines that have achieved "No. 1" with Consumer Reports, and has been a major contributor to two others. Quite recently, August 2007, Toro's main line of leaf blowers was chosen No.1 with Consumer Reports. Its double-sided fan design was originally conducted by him.


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