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 Expert  715993

Expert in Plastic Molded Gear Design, Inspection, and Manufacturing

Available for your Consulting and Expert Witness Needs

Wisconsin (WI)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
PLASTIC AND POWDER METAL GEARS; HELICAL GEAR. The core of the expert's professional work has been in the design, testing, inspection, molding, and material selection for plastic and pressed metal gears. This includes mold cavity design, vendor selection, and quality control. He works primarily with spur and worm gears, but also designs and produces helical and bevel gears and splines. He can provide complete technical support of powder metal gearing from design through production, as well as plastic gearing.

GENERAL GEAR DESIGN. A significant portion of his career has been in high reduction fine-pitch gear systems, including compound gears, worm drives, planetaries, and harmonic drives. His design focus includes low-cost, high-power, efficiency, low-noise, and high-accuracy gears.

MOLD CAVITIES; COMPUTER NUMERICAL CONTROL (CNC) AND WIRE ELECTRON DISCHARGE MACHINING (EDM) CUTTING PATHS. He develops efficient tool and wire cutting paths using successive arc approximations of polynomial curves. These curves can be anything from involutes and trochoids to a specialized cam shape or digitized curve. He also can mathematically generate arc approximations accurate to .000020 inches.

PLASTIC GEAR INSPECTION; GEAR ERROR; GEAR FAILURE ANALYSIS. A fundamental part of the expert's service is providing specific inspection of plastic gears for shrinkage, involute form, warpage, eccentricity, and accuracy. He also provides specialized master gears for roll testing against plastic, and can do the roll testing himself at his own facility. Currently, his company has exclusive capability to directly measure shrinkage and related errors in plastic gears. The company also has a scanning coordinate measuring machine.

PLASTIC GEAR DESIGN. A significant portion of his work involves plastic gears and transmissions. He designs, tests, and inspects transmissions and components for functionally related requirements such as low noise, high power, low cost, high tolerance, and rotational accuracy. From design through production tooling, he supervises and directs the development of plastic gear. He has all the necessary inspection equipment to analyze plastic and steel gears and gear mold cavities.

COMPUTER-AIDED GEAR DESIGN, INSPECTION, AND TESTING. He has developed a new software approach to gear design that he uses in his own designs. The software he designed controls his scanning profilometer. He designs and builds PC-controlled data acquisition test equipment for customer's applications.

PLASTIC GEARS FOR ABUSIVE ENVIRONMENTS. He offers a fundamental designing of transmissions expected to survive environmentally harsh conditions. He is familiar with the materials, geometry, and tolerances essential to withstand harsh design requirements.

GEAR GRINDING AND DRESSING. He has developed curve-fitting algorithms to guide NC grinders and wire EDMs in cutting gears and cams.

GEAR ROLL TESTING. His company designs unique master gears specifically to inspect gears for plastic gear roll testing. They own roll testing equipment and will perform these tests for clients and customers.

GEAR INSPECTION. He owns a gear roll tester and some master gears as well as precision profile scanning involute inspection equipment. He routinely inspects plastic gears for both form and shrinkage.


abusive environment plastic gear


annular gear


computer numeric controlled wire electrical-discharge machining


computer numerically controlled machine


computer-aided design and manufacturing


coordinate measuring machine


crossed helical gear design


eccentric gear


gear application


gear design


gear drive


gear error


gear failure analysis


gear grinding


gear inspection


gear machining


gear manufacturing method


gear wear


gearing arrangement


helical gear


helical gear design


injection mold design


injection molded plastic


mold cavity design


molded component


planetary gear


plastic gear design


plastic molding


powdered metal gear design


precision gear manufacturing


rack and pinion


reduction gear


ring gear


spur gear design


step-up gear


transmission gear


wire electrical-discharge machining


worm gear design


internal gear


involute gear tooth

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;  Duluth, Minnesota;  Burnsville, Minnesota;  Saint Cloud, Minnesota;  Eden Prairie, Minnesota;  Minnetonka, Minnesota;  and Eau Claire, Wisconsin.

Often requested
with this expert:

Gear Design & Analysis
High Performance Gear Design
Gear Dynamics, Gear Noise
Permanent Magnet Motors, Generators, Devices and Materials

Year   Degree   Subject   Institution  
1979   MS   Mechanical Engineering   Michigan Technological University  
1975   BS   Mechanical Engineering   University of Kansas  

Work History:
Years   Employer   Title   Responsibilities

1991 to






Expert supervises and controls the design, inspection, and molding of precison plastic gears

1989 to 1991


UFE, Inc.


Plastic Gear Design Specialist


1984 to 1988



Contract Plastics Design Engineer


1983 to 1984


Teledyne Water Pik, Inc .



1982 to 1983


Ball Aerospace Corporation


Lead Project Engineer


1979 to 1982


Hewlett-Packard Corporation



Career Accomplishments:

Expert is a member of AGMA Plastics Gearing Committee, and a member of the Society of Plastics Engineers


Expert is a Registered Professional Engineer in Colorado.

Publications and Patents Summary

Expert has written numerous articles and technical papers on plastics gearing, molding, inspection, and design. He notes that many of these articles are available for download.

Selected Publications and Publishers  
 - AGMA Paper  
 - AGMA Technical Conference  
 - Power Transmission Design Magazine  
 - Society of Manufacturing Engineers  

Consulting Services:
Selected Consulting Examples:
  • Rainbird Corporation -Developed gear design and inspection methods for new plastic geared lawn sprinkler
  • Dura Automotive -Gave onsight seminar on design through production steps to a successful molded geared transmission
  • Keytronics -Gave a technical seminar on molded gearing. Reviewed current gear designs and inspection requirements and equipment in house.
  • Microsoft Corporation -Redesigned molded gears from a failed transmission and assisted start-up molding and trained off-shore inspectors with selected gear inspection equipment.
  • Hitachi -Designed, tooled, and developed first part samples for molded gears. Transferred molding technology to the customer. Trained personnel in proper inspection techniques.
Recent Client Requests:
  • Gear and noise expert
  • Expert in Plastic Gear failure analysis.
  • Gear expert for consulting on Rack and pinion system.
  • Expert in DC motor design engineer for consulting on dc motor and silent gear box.
  • Plastic gear expert for consulting on molded plastic crown and worm gear.
  • Expert in plastic gears for consulting on injection molded plastic worm gear problem.
  • Worm gear design expert for consulting on design of worm gear set.
  • Expert in fine pitch gear for consulting on fine pitch gear in a high reduction small gear box.
  • Expert in plastic gears for consulting on a plantation shutter stile for purposes of allowing the simultaneous up & down movement of louvers (slats).
  • Expert for consulting on Gear Dynamics; Gear Noise.
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 occasionally been called as an expert witness in molded gearing litigation. He has also assisted parties in the inspection of gears for legal review.
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.

Language Skills:
Foreign Language   Description
German   Minimal competency

Market Research:
Expert has helped develop numerous transmissions for production.

Click the green button above to contact Expert for a free initial screening call regarding your marketing research, industry research, and company research needs.  For research needs involving multiple experts or secondary research, a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:

Expert is available for giving seminars on precision molded gearing from design and tooling, through molding and inspection. He will review on-site capabilities and train gear personnel.

Supplier and Vendor Location and Selection

Expert has experience locating vendors of gear hobbing and precision inspection equipment.


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