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 Expert  722821

Expert in Materials Engineering for New Designs, Cost Reduction, and Yield Improvement

Available for your Consulting and Expert Witness Needs

Illinois (IL)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness

Summary of Expertise:

Listed with other top experts in: 

Expert's experience includes: 1) Working with mechanical and electrical engineers to help make decisions about the materials and processed used to manufacture a product. The decisions include consideration of cost, manufacturability, materials and components lot-to- lot variations, reliability, materials availability, and environmental restrictions. 2) Working with manufacturing and quality engineers on understanding the impact of materials, processes, and supplier quality on manufacturing yields. 3) Materials selection, characterization, and implementation for cost reduction and quality improvement. 4) Working with suppliers to help them understand the effects of their processes on the materials characteristics and quality of the final product. 5) Developing tests to evaluate the reliability of materials used to make a product.

design engineering


design for cost


electrical product design


electrical product development


electronic product development


engineering design


electronics design engineering


high volume, low cost product design


material design




material product development


new product development


product design

Expert has provided support to help designers understand in-house and supplier manufacturing and assembly capabilities. Examples include deciding which components could be masked off for a powdercoat process, the realistic plating tolerances for an electronic leadframe, and grain size tolerances for a steel making process.


design for manufacturability

Expert is experienced working with in-house manufacturing and suppliers to identify the key materials characteristics to monitor in order to evaluate component and assembly quality. He is also familiar with many of the analytical techniques used to evaluate materials characteristics. Some of the materials evaluations with which he is experienced are: grain size, composition, hardness, tensile behavior, layer thickness, viscosity, rheometry, microstructure, adhesion, and surface contamination. Some of the analytical techniques that he is familiar with include: optical microscopy, scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDS), x-ray fluorescence spectroscopy (XRF), atomic absorption (AA), atomic emission spectroscopy, differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), thermomechanical analysis (TMA), Fourier infrared spectroscopy (FTIR), and various high vacuum surface science techniques.

quality evaluation

Expert has worked as a process engineer and is familiar with statistical process control. As a design engineer he has experience writing specifications for materials and components.

quality standard

Expert has been involved in various cost reduction efforts involving materials or supplier changes. These include: aluminum component supplier change for $50,000 annual savings; elimination of Sn plating from a contact for $150,000 annual savings; switching solder paste suppliers for $500,000 annual savings; and changing sheet steel suppliers for $1,000,000 annual savings. All these changes involved understanding the characteristics, quality, and reliability of the new materials.

cost engineering

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Chicago, Illinois;  Rockford, Illinois;  Aurora, Illinois;  Naperville, Illinois;  Joliet, Illinois;  Elgin, Illinois;  South Bend, Indiana;  Gary, Indiana;  Milwaukee, Wisconsin;  and Madison, Wisconsin.

Year   Degree   Subject   Institution  
1991   Ph.D.   Materials Science and Engineering   Northwestern University  
1987   M.S.   Metallurgical Engineering   University of Illinois - Urbana  
1985   B.S.   Metallurgical Engineering   University of Illinois - Urbana  

Work History:
Years   Employer   Department   Title   Responsibilities

2004 to







1999 to 2004




Automotive Electronics


Principal Staff Engineer


Expert was responsible for materials selection, evaluation and implementation for: 1) new designs, 2) cost reduction, 3) quality improvement, and 4) manufacturing yield improvement.

1997 to 1999






Principal Staff Engineer


He was involved in the development of new processes for electronics manufacturing.

1991 to 1997




Semiconductor Products Sector


Process Engineer


Expert was a process engineer in an integrated circuit factory. He was responsible for cost reduction, yield improvement, cycle time reduction, development and implementation of new processes.

Career Accomplishments:

Expert is a member of ASM, IEEE, SMTA, and IMAPS.


He is a Registered P.E. in Illinois.

Professional Appointments

Expert was program chair for his local ASM chapter, and served on the Technical Book Committee for ASM International.

Publications and Patents Summary

He has five publications, and is working on a sixth. He has two patents.

Consulting Services:
Selected Consulting Examples:
  • Expert is working on a project to determine the feasibility of eliminating tin plating from the surface of a stainless steel part.
  • He worked on a project to determine the root cause of a steel cosmetic defect, add the information to the supplier material requirements, and help qualify a new supplier.
  • Expert worked on a project to characterize the effects of various metal fnishes on the adhesion of a sealant material to the surface.
  • He helped with a competitive analysis to understand the relationship between the components' performance, materials properties, and cost.
  • Expert worked on a project to understand the material and testing requirements to ensure final parts with good fatigue performance.
Recent Client Requests:
  • Quality improvement expert for consulting on CCA reduction project.
  • Expert in surface contamination found on/in syringe components.
  • Expert for consulting on on a new differential design project.
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:
Recent Litigation Client Requests:
  • circuit design expert for consulting on analog electronics reliability.
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.


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