Intellex Acquires Expert by Big Village

We're thrilled to announce that Intellex has acquired Expert by Big Village, effective March 22, 2024. This strategic move enhances our capabilities and strengthens our commitment to delivering exceptional solutions to our customers.

Stay tuned for more updates on how this acquisition will benefit our clients and experts.

For inquiries or more information, please contact us at


Expert Details

Applied Rubber Technology, Design of Experiments, and Training in Both

ID: 722479 North Carolina, USA

Request Expert

The primary rubber-forming process he works in is molding, including compression, transfer, and injection methods. His experience with molded products is broad, including automotive weather strip, milking inflations, various types of vibration mounts, seals, diaphragms, aerospace components, vehicle tracks, and myriad others. His over 30 years in the industry took him from very low- to very high-volume products, single cavity to multicavity molds, standard and exotic polymers, and lab presses to giant rotary injection presses. His involvement is often from process development to process optimization for molding operations, often using design of experiments methods for maximum efficiency.

Expert's original function in the rubber industry was as a compounder and process engineer, and that expertise remains a major part of his practice. Several of his publications are centered on compounding work. Balancing multiple rubber properties to an optimum for a given function is one of the more interesting challenges in the field and has become a specialty for him. Also, compounding for dynamic properties (resilience, damping, and fatigue life) has become a significant area for him. However, he also focuses on achieving desired final compound properties with efficient processing characteristics, which is also of key importance to good business.

He notes that there are well over 20 families of elastomeric polymers, and he has worked with most of them over many years in the industry. Writing chapters and complete textbooks for the rubber industry, as well as giving courses in rubber technology for the ACS Rubber Division, required him to stay in touch with a much broader group of the polymer families than is common, which is a great help in any kind of selection process for elastomeric materials. His expertise in rubber technology in general has caused him to be sought out as an expert witness in several major lawsuits involving rubber products.

As a manager, consultant, writer, and frequent trainer of engineers and chemists in rubber technology, expert has polished his presentation skills and increased his background knowledge of the overall field extensively. He has provided training to numerous companies and organizations (Clemson University, the University of Wisconsin, Worcester Polytech, and others) as well as to various subgroups of the American Chemical Society. This includes both basics of the technology, as well as applied methodology (compounding, etc.) and hands-on training using equipment (including, but not limited to, mills and mixers).

Starting in the 1980s he received training in statistics and statistical methods, and he subsequently branched out into statistical process control. From there he proceeded into design of experiments (DOE), which has become a major specialty for him, including publishing a book on the topic and providing advanced training in the subject for companies and organizations. The application of statistical methods to tabulating, organizing, and doing detailed analyses of many kinds of data naturally followed from all this, and has also become a major facet of the services he supplies to clients. These methods combine very well to serve numerical optimization purposes. He teaches design of experiments methods regularly for corporations and institutions, at several levels, and has served as a beta tester for development of specialized software for DOE users.

Starting with original training in a Du Pont rubber laboratory in 1965, he has expanded on his experience in all common and many less-common modes of rubber material and rubber product testing. He has also been involved with development of specialized tests for particular properties (such as engineering properties) and purposes, with an emphasis on rubber bond testing; he has several publications on the latter topic. He has managed rubber laboratories and works frequently with many rubber labs, both corporate and commercial. He is very familiar with the body of ASTM test methods for rubber and has written extensively on the topic of rubber testing.

His long experience with advanced rubber products for which bonding is a critical property began with rubber-fabric bonding and progressed into crash-critical rubber bearings for helicopters in 1976. Subsequent employment as a manager of one of the founding companies for rubber adhesives led to immersion in this methodology, and he has presented some of the most detailed technical papers available on this topic. He also instructs on this subject for the University of Wisconsin.

Expert investigated and optimized the production of PTFE composites by designed experiments. He developed special rubber compounds for milking applications, acceptable to the German health office. He optimized a rubber compound for a superabrasive application involving food preparation. He maximized flex/abrasion life for snowmobile tread compounds. Expert helped set up and provide training for technology transfer from a U.S. plant to Shanghai.


Year Degree Subject Institution
Year: 1965 Degree: M.S. Subject: Organic/Polymer Chemistry Institution: Holy Cross College
Year: 1964 Degree: B.S. Subject: Chemistry Institution: Holy Cross College

Work History

Years Employer Title Department
Years: 1990 to Present Employer: Undisclosed Title: Technical Consulting Services Department: Consulting
Expert has a sole proprietorship serving the rubber industry and clients of the rubber industry.
Years Employer Title Department
Years: 1988 to 1990 Employer: Barry Controls Title: Director of Materials & Process Technology Department: Material Processing
He had broad responsibilities for a multi-plant company serving the commercial and aerospace industries with engineered rubber products.
Years Employer Title Department
Years: 1984 to 1988 Employer: Lord Corporation Title: Manager of Materials & Process, Aerospace Products Division Department: Material Engineering
Expert had broad responsibilities for a multi-plant company serving the commercial and aerospace industries with engineered rubber products.
Years Employer Title Department
Years: 1981 to 1984 Employer: Rogers Corporation Title: Manager of New Product Development/Engineering Manager Department: Produ
He worked in the engineering department of the plant in both development and manufacture of specialty engineered rubber products.
Years Employer Title Department
Years: 1976 to 1981 Employer: Airex Rubber Title: Technical Director Department: Custom Molding
He was responsible for all technical aspects of a small custom molding firm serving aerospace industries.
Years Employer Title Department
Years: 1975 to 1976 Employer: DeLaval Separator Title: General Manager, Rubber Plant Department: Rubber Plant
He operated a 50-man rubber manufacturing facility.
Years Employer Title Department
Years: 1974 to 1976 Employer: Sikorsky Aircraft Title: Materials Engineer Department: Materials
Expert was responsible for all matters relating to rubber components of helicopters.
Years Employer Title Department
Years: 1969 to 1975 Employer: B F Goodrich Title: Process Engineer Department: Compounding
He worked in compounding, process development, troubleshooting, and manufacturing support in a large rubber manufacturing plant.

International Experience

Years Country / Region Summary
Years: 1981 to 1981 Country / Region: Singapore Summary: He worked on a consulting job to set up and start running a mixing and molding plant.
Years: 1992 to 1992 Country / Region: France Summary: He was on a consulting assignment to troubleshoot silicone compounding and processing for missile mounts.
Years: 1988 to 1990 Country / Region: England Summary: Expert coordinated technical development work between U.K. and Boston plants.
Years: 1996 to 1996 Country / Region: Singapore Summary: He provided training in molding technology as part of a government-sponsored educational program.
Years: 2000 to 2000 Country / Region: Canada Summary: Expert worked on a project to troubleshoot carbon black dispersion problems.

Career Accomplishments

Associations / Societies
Expert is a member of the Rubber Division of the American Chemical Society, plus several regional subgroups.
Publications and Patents Summary
He has over 20 publications and has made contributions to five technical books, and has edited and/or written three technical books (two on rubber technology and one on the design of experiments).

Additional Experience

Expert Witness Experience
Expert has been an expert witness in about 12 different cases, three of which went to deposition/trial in federal courts.
Training / Seminars
He has given training sessions in design of experiments, basic rubber technology, engineering with rubber, and statistical process control.
Vendor Selection
He is well-versed in vendor selection.

Language Skills

Language Proficiency
German Expert has retained basic conversational and reading skills in German.

Fields of Expertise

compression molding, molding, rubber molding, rubber vulcanization, elastomer compounding, rubber compounding, rubber formulation, applied rubber technology, elastomer selection, natural rubber, PEBAX, rubber selection, elastomer training, analysis of experiments, central composite design, design of experiments, Latin square, numerical analysis, numerical optimization, response surface methodology, statistical design of experiments, compression set, durometer, rubber durometer, rubber hardness, rubber hardness testing, rubber physical property, rubber tensile strength, rubber testing, elastomer bonding, rubber adhesion, rubber bonding, rubber design, design technology, medical polymer molding, medical polymer selection, analysis of variance, elastomer blend, polymer fatigue, electrically conductive rubber, rubber antioxidant, rubber handling, rubber latex, flame-retardant rubber, tackify, curing agent, high-temperature rubber, silicone compounding, ozone cracking, ozone degradation, particulate rubber, rubber insulation, surface bloom, liquid silicone rubber injection molding, liquid silicone rubber, rubber injection molding, rubber curing, silane coupling agent, vibration isolator, rubber additive, synthetic latex, rubber degradation, glass transition, rubber masterbatch, masterbatch, rubber filler, pelletized rubber, crumb synthetic rubber, injection compression molding, rubber oxidation, capillary rheometer, silicone sponge rubber, rubber component, rubber fatigue, rubber failure analysis, rubber product manufacturing, high-voltage rubber compound, process capability study, process design variation reduction, product design variation reduction, rubber friction, evolutionary operation, polymer application, rubber processing equipment, rubber product, rubber bearing, rubber extrusion, statistical computer software, viscoelastic material mechanical property, polymer science, adhesive selection, Taguchi method experimental design, energy-efficient rubber processing, computer spreadsheet, rubber torsion spring, vulcanizing, rubber product manufacturing facility, mixture experiment, hard rubber, sponge rubber, carbon black, polymer blend, chlorosulfonated polyethylene, synthetic rubber, styrene-butadiene rubber, viscosity, tensile strength, statistics, statistical process control, simplex method, silicone rubber, rubber spring, rubber seal, rubber impact testing, rubber hose, rubber gasket, rubber adhesive, room-temperature vulcanizing rubber, process optimization, polyisoprene, nitrile rubber, natural polymer, injection molding, elastomer processing, rubber processing, creep, butyl rubber, adhesive testing

Request Expert

Dev Tool:

Request: expert/applied-rubber-technology-design-of-experiments-and-training-in-both
Matched Rewrite Rule: expert/([^/]+)(?:/([0-9]+))?/?$
Matched Rewrite Query: experts=applied-rubber-technology-design-of-experiments-and-training-in-both&page=
Loaded Template: single-experts.php