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Expert has applied his mechanical engineering background to provide innovative mechanically sound solutions to difficult engineering problems. He understands the need to design for manufacturability (DFM) and design for assembly (DFA) and implements cost effective designs into each project. He has selected proper material and manufacturing methods depending on the use and annual production volume of each component. Expert has over 5 years of FEA training using ANSYS to solve difficult engineering problems and to prove designs meet structural and thermal limits. He is associated with Quality Tool, a sheet metal and machining contract manufacturer and has the ability to product quick-turn prototypes, prototypes within 1-2 weeks, to prove concepts and to keep the development cycle moving forward.
Typical design projects involve data network storage providers; including 1U-8U rack-mount servers. Custom designs will take into consideration all components including power supply (PSU), motherboards, PCI boards, fans, batteries, interface panels, interface latches, bezels, rack-mounting kit, and any other specialty components supplied by customer. Designs will consider innovative solutions for ease of manufacturability and assembly.


Bezel designs for custom data network storage/server providers; plastic, metal embossed and engraved. Bezels can be customizable and swapable to fit a generic platform for OEM suppliers.

Innovations for data network server/storage applications and for almost any electronic enclosure.
Fasteren-less components for data network server/ storage applications including:
-Fastener-less fans
-Fastener-less PCI/PCB
-Fastener-less covers that pass EMC testing at high-frequency

Low-friction rail kits with no-ball bearings.
Gasket-less covers that pass EMC testing at high-frequency.
Hot-swappable and blind pluggable modules.
Integral Rivets
Custom latch designs


Medical device design for Guidant, Boston Scientific, Medtronic, Cardiosonix, and Luminetx. Projects include custom products for use in manufacturing to new product development for large volume manufacturing.

One project includes a Patient Management System that automatically gathers data from an implanted pacemakers and defibrillators and sends it through the phone line to the patients doctor. This project involved designing, prototyping, and manufacturing the sheet metal structure to hold the electronics and power supply. The product was easy to manufacture and easy to assemble and fit it all into the specifications provided by the customer.


Example of a success data network storage project where the product was designed by outside Industrial Design Firm. The sheet metal and bezel was finalized through the conceptual design (no prototypes were made). The customer tried to manufacturer the product but all manufacturers offered a 'no-quote' due to its complexity.

This project was handed-off to Expert and with the help of Quality Tool, he modified the design to cut down on costs and preserved unique industrial design. The product was redesigned for manufacturability and thus made the product manufacturable.

The project was a success and the customers new product release date stayed on-time.

The VeinViewer by Luminetx uses a combination of near-infrared light and patented technologies to image vascular structures, allowing healthcare professionals to clearly see accessible veins (or lack thereof) in real time, directly on the surface of the skin. Expert was tasked to reduce the cost of production. The product was designed by an industrial design house that did not have an expertise in sheet metal manufacturing. Expert's design and manufacturing engineers were able to modify the sheet metal base structure to reduce costs significantly. The assembly and base pan are pictured. The base pan was redesigned to reduce over 60% in welds and reduced the number of total parts in half. With the reduction of parts, less part numbers are needed in inventory, the chance for assembly error was eliminated, and the time to assemble was reduced in-half.
The Latitude Patient Management System automatically gathers data from your implanted pacemakers and defibrillators and sends it through the phone line to your doctor. Expert was approached by Boston Scientific to design and prototype the sheet metal structure to hold the electronics and power supply. Our engineers worked directly with the design team at Boston Scientific to model a product that is easy to manufacture and easy to assemble and fit it all into the specifications within the industrial design.
Quantix/OR is designed to enable vascular and cardiovascular surgeons to obtain volume blood flow readings in various targeted blood vessels within seconds. The system consists of an angle-independent ultrasound probe and digital numerical displays of blood flow rate. The surgeon obtains immediate, real-time and quantitative reading while focused on the target vessel. Expert was approached to design and manufacture an enclosure to house the electronics and to design a front bezel that was easy to assemble and easy for the user to operate.
This project consists of a QLogic custom network server to be adaptable for expansion of additional components with additional heat requirements. The design allowed for two fan locations to help dissipate the heat for an extreme case. The goal was to use only one fan location, thus reducing cost and complexity of assembly. Expert ran a thermal fluid-flow analysis to determine the areas of concern. This analysis identified one area that exceeded temperature specifications. Airflow diverters were added to distribute the temperature evenly throughout the enclosure. The analysis was modeled again in ANSYS and proven to meet all temperature requirements. This project reduced total design time, allowed for fewer components, and quicker assembly.