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 Expert  725078

Expert in Industrial Design, Product Development, Rapid Model Making, Inventions, Prototypes, Expert Witness

Available for your Consulting and Expert Witness Needs

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

Summary of Expertise: Listed with other top experts in: 
Expert has been creating innovative new consumer product designs, as well as commercial, industrial, medical, toys and fitness products for over 35 years as both an Industrial Design Professional and a Creative Design Director. He has hands-on knowledge of the design process and has excellent skills in ideation, invention, and innovation. He has assigned over 35 patents to various clients' royalty free. Plastic product development and multi-material solutions are always translated into rapid product development and rapid prototyping functional models.

consumer product design

As CEO of an independent Industrial Design Consulting firm for over 30 years Expert has developed the Design Process into a unique new product development approach that provides cutting edge new award winning product design solutions.

design process

Ideation is an integral part of new product development. Expert's design process is to create as many innovative new patentable features as possible so the client will have 20 years of exclusive utilization and profitability. Utility patents are the key to a long-term product-life-cycle that can remain profitable for 20, 30 or more years. A 10-year product review procedure insures that the new product design remains competitive and in some instances can use the redesign process to upgrade the product and add new patentable features to extend the product life cycle protection to 25 or 30 years.



redesign process

Expert took the initiative during his professional education in Industrial Design to obtain three different basic design philosophies. He attended The Institute of Design at IIT (Illinois Institute of Technology), The Art Institute of Chicago, and Pratt Institute in Brooklyn, NY. By combining the Bauhaus, Technical and Fine Arts approaches he has multiple disciplines to draw from depending on the client's market segment and industry. From high profile consumer electronic products to capital equipment and industrial machine enclosures the design process is targeted directly to each specific industry.

industrial design

Innovation is the ability to work within a tight set of specifications for a new product design and provide improved functional or aesthetic variations to improve the appearance or user-ability of given design assignment.

Innovation is also useful when trying to circumvent competitive Patent Claims. This includes reverse engineering a competitive product and the analysis of the component relationships, assembly sequence and use of different materials.



New Consumer Product Development is a design process that requires an analysis and field study of related product categories, market segments and emerging technologies that can be combined and used to create totally new products. Expert has used fuzzy front-end focus group market research sessions to create new consumer products out of the needs and desires of the respondents that identify both problems and opportunities in a give product category. A case study is available that demonstrates this procedure.

new consumer product development

New Product Design, New Product Development and Product Design are somewhat interchangeable terms for the tasks, goals and objectives of a given design assignment. The term "New" implies a product that has a different function or operation than competitive products in the same market segment.

Expert has experience leading creative group work sessions to generate hundreds of new ideas for a specific category that is either “material and process” driven or “product category” driven. He has structured an NPD program that provides 6 new products per year in two-month increments. Physical rapid prototyping models or mockups are created within each 60-day time frame.


new product design

Combining two related products into a new product design is one of many methods that can be utilized. Or separating a multi-function product into a cost reduced single function product may provide increased sales with a lower piece part cost. New Product Development, New Product Design, & Product Design are interchangeable terms for the goals and objectives of a specific design assignment.

Expert specializes in structuring programs and writing proposals for New Product Design Programs. He has a team of Industrial Designers and Model Makers that can take on large new product design development programs for any industry or product category.


new product development

Expert has over 40 years of Plastic Product Development experience. As a practicing Industrial Designer he pioneered the use of polypropylene "Living Hinge" technology by designing a one piece plastic sponge mop that had four living hinges molded into one piece part. Expert utilizes the various plastic resin suppliers to assist with the specification of the appropriate resin that can be reinforced with fiberglas talk or air assisted to provide thick structural parts with no sink marks or surface blemishes.

plastic product development

Product Design is the Industrial Design discipline that is comprehensive in nature. Designing an entire product from the inside out involves understanding the electro-mechanical or functional aspects of a product. Expert interfaces with mechanical engineers and electronic engineers that many times provide the internal mechanisms, components, transformers, PCBs, power supplies, etc. that make up a complete product. A written proposal will be prepared to integrate all the disciplines required to product virtually any product in any category, including large scale capital equipment, industrial machines and equipment that can be 20 or 30 feet long and 12 to 15 feet high, all the way down to, but not including nano size products. Product design scale is not an issue.

product design

With the emergence of Stereolithography 20 years ago and 2D and 3D CAD the process of CAID “Computer Aided Industrial Design” and Rapid Product Development procedures have accelerated to “light speed” compared to drafting on vellum with a T-square and triangle.

Expert was an early adapter to the new CAD technologies that emerged in the 70's, 80's and 90's. CAID and Rapid Prototyping are the cutting edge technologies of the 21st century that combined with the Internet have revolutionized the Industrial Design Profession. Solidworks 2D and 3D software are a primary tool to provide innovative product design and rapid model making.


rapid product development

Rapid Prototyping and Model Making have recently expanded into the utilization of a variety of plastic, urethane, elastomer, nylon, ABS and other resins that can be simulated in the rapid prototyping arena. Now rapid prototyping can provide models in metal but the technology is very new and not as cost effective as SLA and SLS rapid models are in plastic resin materials. CNC machining in 3 to 5 axis mills is capable of making metal models as long as they are not too complex. Expert is following these technologies for use with current rapid prototyping projects currently being provided and can provide up to date methods that are available, rapid and cost effective.

rapid prototyping

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;  Peoria, Illinois;  Joliet, Illinois;  South Bend, Indiana;  Gary, Indiana;  Milwaukee, Wisconsin;  and Madison, Wisconsin.

Often requested
with this expert:

Mechanical Engineering Design and Prototype Development
Product Development, Failure Analysis, Finite Element...
Industrial Design / High Volume Consumer Electronics...
Plastic Packaging Technology, Molding, Creating New...

Year   Degree   Subject   Institution  
1961   BID   Industrial Design, Package Design   Pratt Institute  
1956   UnderGrad Studies   Industrial Design   Institute of Design, IIT  
1957   UnderGrad Studies   Product Design, Sculpture   Art Institute of Chicago  

Work History:
Years   Employer   Department   Title   Responsibilities

1972 to


(Undisclosed Consulting Company)


Industrial Design




He purchased the company in 1975 from 1947 founders who retired. He is the principal and owner with one partner who will be retired in 2008.

1965 to 1972


CCA - Container Corporation of America


Industrial Design / Product & Package Design


VP / ID Department


He pioneered a new industrial design department within the CCA Design & Market Research Laboratory, serving all 5 divisions~ Plastics, Folding Carton, Display, Corrugated & Solid Fiber (tubes)

1962 to 1965


US Army


Signal Corp


Captain / Design Engineering Group


He served in Viet Nam and created a design & construction group to provide signal corp security buildings, teletype communications furniture, consoles and interior & exterior security systems, towers, a modular concrete bunker system and perimeter security systems.

1960 to 1962


CDI ~ Creative Designs International


Industrial Design & Prototype Departments


Director / Department Manager


He established an Industrial Design department for a Bronx, NY Commercial Interior Design Firm that designed and built Shopping Malls, Stores & Retail Shops. He started department while attending Pratt Institute while majoring in Industrial Design.

Career Accomplishments:

Who's Who in the Midwest, Biographical profile, International Society of General Semantics, Member IDSA Industrial Designers Society of America, Member and Officer


Pratt Institute, BID - Industrial Design IDSA - Industrial Designers Society of America

Professional Appointments

IDSA Chicago Chapter Chairman, 4 years IDSA District Vice President - 1994 - 1995, 2 years IDSA National Executive, Board of Directors Member Jury Member - Industrial Design Annual Awards


ID Review, Excellence of Design - O-Cedar Sponge Mop The Chicago Athenaeum, Good Design Award, Thermos ID Excellence Awards, Bronze, Lincs Lighting System The Chicago Athenaeum, Good Design Award, Table

Medical/Professional Internships

44 Years of Professional Practice in Industrial Design

Publications and Patents Summary

He has 35 Utility Patents - USPTO 2 Publications 1 Internet Blog - 1 million dollar ideas

Government Experience:
Years   Agency   Role   Description
1962 to 1970   US Army, Signal Corp   Design Specialists   He was assigned special duties in Viet Nam regarding security, Top Secret defensive devices and physical security systems.

Consulting Services:
Selected Consulting Examples:
  • Professional Design Consulting - Commercial Products to:McDonnell Douglas, Signode, Dow Chemical, AT&T, Borg Warner, Westinghouse. SERVICES: Industrial Design, New Product Development, Design for Cost Reduction, Re-Design existing products, create new patented products.
  • Professional Design Consulting - Consumer Products to:3M Company, Sears, Wilson Sporting Goods Fitness Equipment, Square D, Sunbeam, Drackett O-Cedar Co., SERVICES: Industrial Design, New Product Development, Design for Cost Reduction, Re-Design existing products, create new patented products.
  • Professional Design Consulting - Package Design to:CCA - Container Corp of America, McDonald's Corp, Vidal Sasson, Ethyl Corp, Silgan Plastic Bottles, Reynolds Metals, Kraft Foods, Kimberly Clark, Continental Can. SERVICES: Package Design, Bottle Design, Dispensers, Food Packaging, New Product Development, Design for Cost Reduction, Re-Design existing products, create new patented products.
  • Professional Design Consulting - Medical, Diagnostic & Scientific Products to: Abbott Labs, Packard Instrument, Argone Natl Labs, Searle, Omron, Bristol-Myers, Zimmer Medical / Surgery Instruments, SERVICES: Industrial Design, New Product Development, Design for Cost Reduction, Re-Design existing products, create new patented products.
  • Professional Design Consulting - Capital Goods, Industrial Machines, Commercial Equipment - to: AEC Corp, IMCO, Ingersol, Signode, Interlake. SERVICES: Enclosure Specialists to improve the safety, ergonomics, aesthetics, user interface, control panel readability, create a Corporate Identity with a unique look or appearance to a line of commercial machines or equipment. Brand identification, corporate colors, name plates and logotype name plates. ie, Design Excellence.
Recent Client Requests:
  • Expert for consulting on How to make a living hinge work.
  • Living hinge expert for consulting on Living Hinge.
  • Expert in Hearing aid for Pets.
  • Expert in intota for consulting on coffee cup warmer.
  • Living hinge design expert for consulting on a plastic living hinge design with a snap-fit for a consumer product.
  • ANSI expert for consulting.
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:
He has served as an Expert Witness for a number of law offices and trial cases for either plaintiff or defendant, depending on the law firm's client case assignment. Subjects include product design patent infringement, package design safety for hazardous material, bottle design infringement, Nursery school molestation and store fixture safety construction.
Recent Litigation Client Requests:
  • Expert for consulting on retail cash recycling machines.
  • Design expert for consulting on playpen patent infringement case.
  • Expert for consulting on Viking Oven Door Hinge Failure.
  • Expert witness "product design" for consulting on expert witness for Industrial Design/Consumer Product Patent.
  • Expert in package design to consulting on steel rack design for overseas shipping.
  • Packaging design engineer expert for consulting on Patent Infringement Litigation - shipping container construction and design.
  • Expert in the garment industry wholesalers litigation case.
  • Bottle Design experts for patent and utility design
  • Expert for consulting on Faucet design.
  • Medical packaging expert for consulting on bottle design and sterility.
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.

International Experience:
Years   Country / Region   Summary
2006 to 2007   Taiwan, ROC   He worked with Injection & Metal forming plants to produce patented hot coffee drink containers for U.S. market & International market.
2005 to 2006   South Korea   He worked with electronic PC board and paging technology manufacturer and a separate injection molder to produce a desk top consumer electronic device to display ad messages directly into homes and offices.
2005 to   Thailand   He provided CAD database files and designs to both a stainless steel metal former and plastic injection molder for the production of a consumer kitchen product for mass production. Coordinated component interface and proper fit and function for the product.
2006 to   Belgium, EU Europe   He is coordinating the design & demonstration of a high speed stainless steel door enclosure prototype to be produced in the USA and a potential application in the EU market place in the future.
2007 to   Alberta, Canada   Product Design coordination and prototype development for the design of a commercial food processing appliance. Focus group sessions in Minn. and manufacturing off shore to be coordinated for mass production.

Market Research:
Projects and programs for both re-design of existing products or new products are subject to an extensive competitive field study, Internet survey, exploratory market research, pre-design focus groups, and the creation of competitive, unique cutting edge concepts, the application of emerging new technologies and "invention" providing patentable features for client that are assigned to client royalty free upon payment of standard design consulting fees. Expert has assigned more than 35 utility patents over the last 44 years of practice.

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:

For eighteen years, Expert has been involved with the public schools, conducting a series of on-going educational lectures, classroom sessions and career day seminar/exhibits with the FBLA (Future Business Leaders of America) in DuPage County, IL. He has consulted pro-bono with the high school vocational center in DuPage county to critique and recommend improvements in vocational courses so they would relate more closely to career opportunities and to encourage college bound students to continue their education in design related college curriculums such as Industrial Design, Graphic Design, Package Design, Interior Design, Fashion Design, Environmental Design, Urban Planning and Architecture.

Supplier and Vendor Location and Selection

New Product design programs include piece part production 2D and 3D CAD database files, BOM ~ Bill Of Materials and an RFQs ~ Requests For Quotations. Vendors for OEM components, Fabricators (multi-materials - plastic, metal, wood, composites) Toolmakers for injection, compression, extrusion, stamping, progressive die, blow, rotational, thermo, etc. are sourced both domestically and off shore. Assembly, fabrication, packaging, palletizing and sea container sizing are an integral part of design development programs on an as-needed basis.

Other Skills and Services

He has developed new products or innovations that have provided a complete paradigm shift in a specific market segment such as lighting and lighting fixtures, a new product segment in consumer product packaging and other innovations in commercial, scientific and medical - analytical systems.


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