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 Expert  723669

Expert in Ceramic & Composite Materials Development, Processing and Commercialization


Available for your Consulting and Expert Witness Needs

New York (NY)
USA
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
He has a comprehensive ceramic component manufacturing experience. This encompasses everything from ceramic materials and process development, production scale up and running of a production operation, as well as marketing and sales, excelling in all areas. He has worked in materials processing and industrial scale up for over 25 years with engineering, operations and program management for the past 20 years.
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ceramic component manufacturing

He has worked extensively and consulted in markets focused on corrosion/erosion environments. An example of this was the work he did as a consultant with also applied at DuPont Corporation where he was a contract consultant managing several parallel multi-group programs in the chemical processing industry. These programs focused on solving technical processing material problems, addressing production yields and new marketing product requests associated with high temperature Chlorine and Fluorine reactor environments. He developed new chemically resistant refractory compositions and tested them out in coordinated lab and production units. He then worked with several vendor suppliers to commercialize and scale up these materials and design them into the current process reactors. This work successfully extended the "uptime" of these specialty process reactors and contributed to second generation reactor designs.
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ceramic corrosion

He is experienced in working and designing dryers and drying technology as it applies of ceramic materials & components including:

1) Conventional drying 2) Micowave and RF drying 3) Humidity drying 4) Chemical drying 5) Freeze drying 6) Batch drying 7) Spray drying

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ceramic drying technology

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ceramics drying

With a PhD in Ceramic Engineering from Rutgers and 25 years of industrial experience, he has a comprehensive ceramic materials and processing background,with strong applications focus. He is a proven innovator with extensive technical and business management experience in established as well as entrepreneurial environments, both domestic and international. This encompasses everything from materials and process development, program initiation, contract authorship, production scale up and running of a production operation, as well as marketing and sales, excelling in all areas. He has worked in ceramic materials processing and industrial scale up for over 25 years with engineering, operations and program management for the past 20 years.
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ceramic engineering

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ceramic material

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ceramic material selection

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ceramic processing

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ceramic technology

He has extensive knowledge and experience in erosion theory, testing and material design optimized for erosive environments. Much of my work focused on ceramic for hard rock mining and minerals processing, for which he wrote a chapter in an ASM handbook.

Erosion testing expertise include: 1) Dry erosion (sand blast) 2) Slurry erosion 3) Contact abration 4) Friction measurement 5) Surface finish measurement 6) Hardness testing

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ceramic erosion

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ceramic wear testing

With expertise in ceramic sintering, glass, fiberglass, glass bonding and glazing, he has worked on and has experience with a wide range of glass and glaze systems, developing glaze and glass bonding technology for a variety of material systems. These range from pottery glazes on whiteware bodies, to glass to metal seals, to glass bonding of SiC materials.
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ceramic glazing

With a PhD in Ceramic Engineering from Rutgers and 25 years of industrial experience, he has a comprehensive ceramic materials and processing background,with strong applications focus, especially in heat treatents and firing technology and equipment design. He has designed heat treating ovens and kilns with electric, gas and oil heat sources with atmosphere as well as vacuum and inductive capabilities. He has worked with, designed, procured, built and installed kilns with a wide variey of designs and needs. He has worked closely with most of the leading kiln suppliers and design houses for this kind of equipment.
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ceramic material heat treatment

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kiln

He has been involved in commercializing new ceramic material and processing technology for over 25 years. He is a proven innovator with extensive technical and business management experience in established as well as entrepreneurial environments, both domestic and international. This encompasses everything from materials and process development, program initiation, contract authorship, production scale up and running of a production operation, as well as marketing and sales, excelling in all areas. He has worked in ceramic materials processing and industrial scale up for over 25 years with engineering, operations and program management for the past 20 years. These are all key aspects to commercialization of technology.
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commercialization

With a PhD in Ceramic Engineering from Rutgers and 25 years of R&D as well as industrial experience, he has a comprehensive ceramic & composites materials and processing background,with strong applications focus. This includes a good understanding ot composite materials, processing and their limitations.
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composite material selection

His scale up, process development engineering and operational management experience was demonstrated at Alanx Products, a 30 person SiC ceramic and polymer composite manufacturing company focused on the wear and corrosion market. Alanx was a joint venture spin off from Lanxide Corp where he had worked to develop the technology. He worked to establish this JV and became its technical and operational leader.

While with Alanx, he obtained international business and marketing experience that included negotiating and overseeing the establishment of two international joint venture companies, one German and a second Japanese. He transferred technology and trained design, production and marketing teams from those countries. With these teams, he designed and marketed product at new foreign customer bases and created manufacturing plant layouts for future scale up efforts.

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joint venture

He has been involved in new material, processing and product devlepment my whole career.

His process & materials development and program management experience includes my work at Lanxide Corporation, a start up entrepreneurial company that developed and marketed new patented SiC ceramic, polymer and metal material composite systems. Process development, equipment design and efficient manufacturing were key to making this technology viable. This work involved development, scale up and salesmanship of SiC materials based technologies, establishing new market interests and accounting for spent funds. Lanxide spawned six joint venture entities as well as numerous national and international licensees, many of which he played a part in establishing and maintaining.

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new product development management


Show Secondary and Basic Areas of Expertise
Localities:
Expert may consult nationally and internationally, and is also local to the following cities: New York, New York;  Yonkers, New York;  Newark, New Jersey;  Jersey City, New Jersey;  Paterson, New Jersey;  Elizabeth, New Jersey;  Bridgeport, Connecticut;  New Haven, Connecticut;  Stamford, Connecticut;  and Philadelphia, Pennsylvania.

Often requested
with this expert:

Process Engineering and Chemistry of Inorganic Chemicals
Industrial Minerals, Glass Raw Materials,Glass Sand
Extractive-Metallurgy, Hydro-Metallurgy, Pyro-Metallurgy,...
Thermal and Fluid Systems Engineering Design, Analysis,...

Education:
Year   Degree   Subject   Institution  
1983   PhD   Ceramic Engineering   Rutgers College of Engineering  
1982   MS   Ceramic Engineering   Rutgers College of Engineering  
1978   BS   Chemistry   Rutgers College  

Work History:
Years   Employer   Title   Responsibilities

2005 to 2006

 

Starfire Systems

 

Program Manager

 

Program management and business development in aerospace, semiconductor and industrial applications utilizing preceramic polymer for high temperature ceramic & polymer matrix composites. Responsibilities & technical successes include: - Management of $5.5 million aerospace & DoD programs - Awarded 3 Phase 1 SBIR programs, 1 more pending - Development of improved ultra-high temperature composites for TPS applications - Development & marketing of flame resistant coatings for fiberglass fabrics - Identification of business opportunities and marketing to customers & investors

2004 to 2005

 

M Cubed Technologies

 

Director of Product Development

 

Technical development, scale up and marketing of new ceramic-metal composite technologies for use in multiple markets including:semiconductor, armor, wear, thermal management and precision structures - Successfully transferred technology from parent factory for prototype facility in CT - Established new markets & customers in semiconductor, thermal management & wear - Developed metal brazing & glass bonding technology for large MI components - Designed & created company brochures & web site for enhanced marketing

1996 to 2004

 

Pratt & Whitney

 

Technology Manager

 

Development of polymer & ceramic composite materials & coating systems used in military & commercial applications. Coordination of composite materials strategic planning activities for turbine engine related programs. - Designed & implemented 30% cost reduction on F119 coatings - Authored a PRDA 7 proposal on high temperature polymer resin development - Managed special development programs in coatings & composite materials - Established blade repair programs for Ti and Ni Integrally Bladed Rotors (IBR) - Established funding & managed IBR low cost fabrication technologies - Spearheaded programs for high temp DRA Aluminum & ?Ti composites - Established programs for improved abradable rub seal for military engine fans

1995 to 1996

 

Dupont Corporation

 

Engineering Consultant

 

Improved corrosion resistant and refractory materials of construction used in TiO2 white pigment production and fluoropolymer technology. - Set up lab tests that simulated reactor environments for comparative erosion/corrosion testing of ceramic and metallic materials - Established vendor alliances for co-development of new materials - Implemented in-plant tests of new refractory materials - Developed new proprietary corrosion resistant refractory compositions Patents pending. Licensed the technology for these new materials

1988 to 1995

 

Alanx Products, Inc.

 

Technical & Operations Manager

 

Oversaw all areas of production, facilities, safety, and quality implementation. Directed all technical development and engineering. - Increased capacity to handle 4 times the volume - Reduced costs by over 50% - Converted process and equipment from electric to gas power - Improved ergonomics and product flow through plant layout redesign - Incorporated computer based scheduling in production - Significantly improved on-time deliveries - Decreased number of days in manufacturing cycle by over 2.5x - Transferred and scaled up ceramic, metal, and polymer matrix composite technologies from lab to production scale operation for market driven abrasion resistant products and applications. - Directed three R&D development and production support teams - Designed layout of production, office, and lab facilities - Designed and purchased all lab and production process equipment - Hired and trained personnel for production, technical, and office staffs - Authored and instituted QC, SPC, and SOP procedures - Developed and commercialized ceramic filled polymer composites - Designed ceramic composite lined process slurry pumps and hydrocycones

1985 to 1988

 

Lanxide Corporation

 

Senior Research Engineer

 

Engineered microstructural and fabrication process control of new ceramic and metal matrix composite technologies. - Pioneered new fabrication techniques for net-shaped preforms utilizing ceramic and metal powders in aqueous and non-aqueous systems - Designed and patented ballistic resistant armor systems (DARPA) - Formed and led multi-group process and materials task force for process development and company wide problem solving - Developed composites with improved corrosion/erosion resistance for industrial products division - Awarded 10 key material and process patents

1983 to 1985

 

Arwood Corporation

 

Research Ceramic Engineer

 

Process development and production support for investment (lost wax) casting of ferrous and non-ferrous alloys. - Developed injection molded non-ferrous ceramic core leachable in water. Awarded several patents for this product - Improved on ceramic shell high temperature permeability and strength - Spearheaded program for reclamation of ceramic materials - Developed rheological controls on ceramic slurries - Improved plaster based solid mold investment mixes

2006 to 2013

 

Ceramaterials

 

President

 

CeraMaterials markets highest quality & lowest priced graphite insulation, ceramic insulation, CFC's, graphite foil, moly & tungsten products, machined graphite, ceramics and all furnace related products.

CeraMaterials™ is a customer focused consulting and sales representative company providing technically based solutions and services with engineered ceramic, metals and polymer materials and processing. Our goal is to aid the research, development and commercialization of products for industrial customers through contract research, educational consulting, strategic material & partnership brokering, proposal writing and industrial processing.


Career Accomplishments:
Associations/Societies

American Ceramic Society American Society of Materials


Publications:
Publications and Patents Summary

Over 20 published articles, 15 patents, and over 50 presentations at scientific and trade conferences.

Selected Publications and Publishers  
 - ASM Engineering Materials Handbook  
 - U.S. Patent and Trademark Office  

Government Experience:
Years  
2005 to 2006  

Consulting Services:
Selected Consulting Examples:
  • Successful product development with electrical porcelain company to help them diversify into high volume profitable market areas, expanding their business and utilizing existing unit operations, labor and floor space.
  • Product & process development with start up company utilizing their processing know-how into new material, satifying existing market pull for rapid successful commercialization.
  • Process and product scale up from a lab operation to production for technology developed at a university lab.
Recent Client Requests:
  • Expert in ceramic formulation for consulting on ceramic bead product development.
  • Ceramic systems expert for consulting on Tungsten/Iron shielding.
  • Ceramic engineer expert witness for consulting on Ceramic Propp.
  • Expert for consulting on ceramic tubes for rotary calciner process.
  • Expert in two stage sintering nano ceramics for consulting on transparent mgal2o4 by slip casting & sintering.
  • Expert in castings for consulting on OFHC copper and in magnesium alloys or a phosphate bonded mold.
  • Expert in slip casting for consulting on slip casting methods and procedures.
  • Steel boiler expert for consulting on cupola liner structure failures.
  • Expert needed for consulting on lamination of films into glazing.
  • Expert in automotive exhaust sensor for consulting on sensor package that can withstand exhaust temperatures.
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:
Materials 1) Advanced engineered materials with emphasis on ceramics & composite materials 2) Ceramic matrix composite fabrication, interface coatings & processing 3) Preceramic polymer & PIP (Polymer Infiltration & Pyrolysis) processing 4) Traditional (sintered) & melt infiltrated ceramics 5) Metals casting (ferrous and non-ferrous), ceramic cores & molds 6) High temperature polymers (polyimids) 7) Refractories (ultrahigh temperature & TPS materials) 8) Wear products (erosion/corrosion resistance materials) 9) Radar signature control materials & additives

Processing & Services 1) Materials characterization & development 2) Process development, documentation and training 3) Processing equipment design, specification, sourcing and installation (new or used) 4) Shape making capabilties (slip casting, pressing, injection molding, FRP, etc.) 5) Brainstorming materials, product, process and marketing ideas or changes 6) Cost reduction studies and implementation 7) Process scale up & commercialization 8) Safety review procedures for lab & production settings

Recent Litigation Client Requests:
  • Expert for consulting on Declaration Needed for Patent Prosecution Matter.
  • Material science expert testimony for consulting on armor plating and chemical composition of same.
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.

Market Research:
I have industry expertise & experience in the following areas: 1) Ceramics & ceramic composites 2) Wear and corrosion 3) Aerospace 4) Semiconductor 5) Chemical processing 6) Metal casting 7) Thermal Management 8) Armor 9) Refractories 10) Cement 11) Catalytic supports (automotive)

I have a comprehensive composites materials and processing background,with strong applications focus. I am a proven innovator with extensive technical and business management experience in established as well as entrepreneurial environments, both domestic and international. This encompasses everything from materials and process development, program initiation, contract authorship, production scale up and running of a production operation, as well as marketing and sales, excelling in all areas. I have worked in materials processing and industrial scale up for over 25 years with engineering, operations and program management for the past 20 years

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:
Supplier and Vendor Location and Selection

My process & materials development and program management experience includes my work at Lanxide Corporation, a start up entrepreneurial company that developed and marketed new patented SiC ceramic, polymer and metal material composite systems. Process development, equipment design and efficient manufacturing were key to making this technology viable. This work involved development, scale up and salesmanship of SiC materials based technologies, establishing new market interests and accounting for spent funds. Lanxide spawned six joint venture entities as well as numerous national and international licensees, many of which I played a part in establishing and maintaining.

My scale up, process development engineering and operational management experience was with Alanx Products, a 30 person SiC ceramic and polymer composite manufacturing company focused on the wear and corrosion market. Alanx was a spin off from Lanxide. In the technical and operations management roles, I was responsible for engineering scale up of the ceramic, metal and polymer matrix composite technologies into production, exceeding all technical, budget and production goals and objectives. I did this by optimizing the processing steps and establishing process control as well as product improvement through standardization and documentation of procedures. I concurrently cut costs of manufacturing in half, decreased the delivery times dramatically and increased overall plant capacity to over 4 times the volume with minimum of capital expenditure. I am responsible for a long list of innovations and improvements associated with this technology and equipment design. This includes converting the composite heat processing from electric to gas power, resulting in increased throughput, improved quality, and lower production costs. All materials were successfully commercialized into a profitable business within a 3-year window. I hired and mentored a team of engineers in all areas of production and marketing. We supported the marketing efforts by working closely with all customers, aligning the product and process capability with customer needs. This included numerous field visits to customer sites to fully understand their needs, with presentations and publications supporting the product and marketing effort.

While with Alanx, I obtained international business and marketing experience that included negotiating and overseeing the establishment of two international joint venture companies, one German and a second Japanese. I transferred technology and trained design, production and marketing teams from those countries. With these teams, I designed and marketed product at new foreign customer bases and created manufacturing plant layouts for future scale up efforts.

Other Skills and Services

My materials problem solving and project management expertise was also applied at DuPont Corporation where I was a contract consultant managing several parallel multi-group programs in the chemical processing industry. These programs focused on solving technical processing material problems, addressing production yields and new marketing product requests associated with high temperature Chlorine and Fluorine reactor environments. I developed new chemically resistant refractory compositions and tested them out in coordinated lab and production units. I then worked with several vendor suppliers to commercialize and scale up these materials and design them into the current process reactors. This work successfully extended the "uptime" of these specialty process reactors and contributed to second generation reactor designs.

My work with Pratt & Whitney focusing on project engineering, proposal solicitation, program management and materials development roles in the fabrication of military and commercial turbine engines. My track record in establishing, promoting and obtaining funding for new design and materials technologies at Pratt has been excellent. This includes authoring or co-authoring and winning numerous government and internally funded program proposals and contracts.

At M Cubed Technologies, I transferred, scaled up and improved SiC based melt infiltrated composite technology from one facility to a new pilot plant, while supporting the marketing group in establishing and growing new markets in semiconductor, thermal management and wear resistance. This included plant layout, design, purchase and installation of equipment, process documentation, cross training of employees and qualification of the commercial process. During this time, I made numerous presentations to customers and prospective clients.

The most recent position with Starfire Systems involved program management, process & materials development and funding establishment for new patented SiC preceramic and high temperature polymer materials.


 

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