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

Failure Analysis, Product Design, Industrial Machinery, Appliances, Heaters and Patents

ID: 730321 Maine, USA

Request Expert

Expert has engineered, built and patented many types of automated industrial machines. These systems range from machines to make Compact Discs and DVD’s to machinery for making plastic cutlery, to other devices for automated assembly and processing of parts. He has 19 issued and pending patents covering a range of products and technologies.

Following is a partial list of industrial machines engineered and developed by Expert:

• Machines for producing compact discs (CD’s) and DVD’s. This includes all mechanical design, electrical design and control software development. Many of these systems are installed worldwide and continue to manufacture product today.
• Automated metalizing machines for making metalized plastic cutlery. These machines produce plastic spoons, forks and knives look like metal. Multiple systems have been built and are currently operating on both coasts.
• Automated industrial metalizer machines for applying metal coatings to 3-dimensional plastic parts such as lipstick and mascara packages and other types of three dimensional parts.
• An automated metalizer for coating men’s shaver packaging with a chrome coating.
• An in-line metalizer system which implements Expert’s Thick Layer Deposition process. This system deposits thick metal coatings on mobile phones and other similar parts for EMI/RFI protection.
• A patented process for manufacturing DVD’s with high yields and high quality.
• A patented metalizer design for depositing aluminum coatings on CD’s at a high rate of speed.

From his years of experience in hybrid electrical and mechanical engineering environments such as Bell Labs, GTE, Chapman Corp and others, as well as from his broad graduate education at Stanford and the University of New Hampshire, Expert is an expert in the design and use of electric heaters, electric motors both in their design and use in products such as appliances. He holds a patent for use of a PTC (barium titanate) style heater to actuate an insecticide dispensing device developed for SC Johnson's Raid and Glade divisions and has designed for use in appliances of various types and for automotive use. He has extensive experience, and patents, in the design of static elimination systems for industrial use.

Common in all aspects of Expert's career has been the need to design equipment that is safe to operate and maintain and compliant to applicable industry standards. For automated machinery this means developing a design for safe use from the start.

Properly implemented, machines designed for safe use are more convenient and economical to use. Operator access and maintenance functions are optimized and maintenance procedures are more straightforward. Anticipating and designing around safety issues early in the process reduces cost and risk as effective, low-cost solutions can be identified and implemented. Expert is familiar with designing for both U.S. and international markets, including Europe. He is familiar with applicable standards relating to guarding, lockout
tagout, and the proper design of operator and maintenance manuals.

Vacuum metalizing processes are at the core of every integrated vacuum metalizing machine. Machines engineered, built and delivered by Expert and his team contained one or more magnetrons for sputtering
metal onto plastic parts at very high rates. They are fully computer controlled and designed to operate in difficult, high-throughput, factory environments where reliable operation and ease of use of these complex systems is critical.

Expert has patented a unique sputtering process to deposit very thick metal coatings (generally copper) onto plastic substrates for mobile telephones and aerospace applications, with 100 micron thickness capability and no thermal part damage. His patented Thick Layer process has been approved for use on the Joint Strike Fighter program.

Expert has extensive experience in sputtering of aluminum and aluminum alloys, copper, stainless steels, chrome gold, and other metals and alloys. He is recognized as an innovator in bringing vacuum metalizing processes into general manufacturing use, having accomplished this with optical discs, plastic cutlery, plastic
packaging, aerospace products and other applications.

Manufacturing and Process Development in Massachusetts - In this time and performance critical project, Expert identified and solved a major production problem impeding high volume manufacturing of packaging for a new high-visibility men's shaver product. Production delays with package manufacturing were threatening the on-time holiday launch of the product. Patent Infringement Case in California - This case related to a claimed infringement of a patented highly complex electrical connector system for military use. In this case Expert worked closely with counsel, evaluated patent claims, made an assessment of the designs and provided an opinion on infringement. Provided a detailed report of conclusions.Personal Injury Case in Pennsylvania - Expert analyzed a component failure which resulted in the injury of a worker while moving large I-beams at a shipyard. Deliverables were as follows: review of depositions, practices, procedures and industry standards. Analysis of failed components. Provided a detailed report of conclusions.Intellectual Property Protection Case in California - This case related to the alleged piracy of compact discs by California-based CD manufacturer. Expert assessed characteristic manufacturing features on the product and provided opinion on the likelihood of actual piracy. Provided a detailed report of conclusions.Product Liability Case in Illinois - In this case Expert reviewed the design and operation of a large steel door press to determine the cause of its frequent and costly failures and made recommendations on corrective actions. Provided a detailed report of conclusions.


Year Degree Subject Institution
Year: 1981 Degree: Post Graduate Coursework Subject: Servo Systems and Signal Processing Institution: University of New Hampshire
Year: 1980 Degree: MS Subject: Mechanical Engineering Institution: Stanford University
Year: 1979 Degree: BS Subject: Mechanical Engineering Institution: Northeastern University
Year: 1974 Degree: non-degree Subject: Machine Tool Technology Institution: Central Maine Vocational Technical College

Work History

Years Employer Title Department
Years: 2000 to Present Employer: Undisclosed Title: East Coast Manager Department:
Expert provides engineering consulting relating to patents, intellectual property, product design, heaters, appliances, electric motors, process automation, failure analysis, safety and product remediation.
Years Employer Title Department
Years: 1998 to Present Employer: Undisclosed Title: President Department:
Expert provides engineering consulting and product development work relating to patents, intellectual property, product design, heaters, appliances, electric motors, process automation, failure analysis, safety and product remediation.
Years Employer Title Department
Years: 2009 to 2011 Employer: Marca Coating Technologies, LLC Title: Director, Sales and Innovation Department:
At Marca, he led product development and sales efforts for an innovative new automated coating and metallizing product for decorating 3-dimensional plastic components such as cosmetic packaging. Through he successfully sold three initial systems to large European manufacturer of cosmetic packaging.
Years Employer Title Department
Years: 2001 to 2009 Employer: D2 Inline Solutions, LLC Title: President Department:
D2 Inline Solutions was a small engineering company and an early spin-off of D2 Systems. Expert led the development of various production machines for coating and metallizing men's shaver packaging, mobile telephones, metalized plastic cutlery and 3D plastic parts.
Years Employer Title Department
Years: 1991 to 1998 Employer: First Light Technology Title: Director of Engineering Department: Engineering
At First Light Expert led the development of innovative processes and production equipment for producing CD's, CD-R's and DVD's. As a start-up, he grew the engineering organization from a handful of staff to many tens of people as well as developed the associated support infrastructure. This machinery was engineered to be small and integrate with injection molding such that molded discs were metallized, coated and printed within less than a minute after molding. Expert developed patented DVD manufacturing technology that revolutionized the DVD production process.
Years Employer Title Department
Years: 1985 to 1991 Employer: Chapman Corp. Title: Vice President of Engineering Department: Engineering
At Chapman, Expert developed instrumentation, bench-top ionizers and other static elimination products for controlling static electricity in equipment and in the workplace. Many of these products are still manufactured today.
Years Employer Title Department
Years: 1982 to 1985 Employer: GTE Products Corporation Title: Senior Engineer Department: Engineering
Expert designed various types of semiconductor-based heater products for consumer, commercial and industrial applications.
Years Employer Title Department
Years: 1979 to 1982 Employer: Bell Telephone Laboratories Title: Member of Technical Staff Department:
In this position Expert was a development team member with responsibility for the magnetic head on a new type of data cartridge-based tape recording system for data storage applications.

Government Experience

Years Agency Role Description
Years: 2011 to Present Agency: Army Role: Research and Development Description: Expert was a co-developer of a photovoltaic textile technology for the US Army.

International Experience

Years Country / Region Summary
Years: 2008 to 2008 Country / Region: Europe Summary: Expert met with clients in France and Italy to introduce his company's new in-line metalizer product.
Years: 2009 to 2009 Country / Region: Mexico Summary: Expert's new prototype machine, a high speed metallizing machine for 3D parts, was installed in Mexico for testing. Expert led the debug effort.
Years: 2008 to 2008 Country / Region: China Summary: Expert was hired to determine the root cause of poor yields at a large mobile phone package production facility in Guangzhou China.
Years: 2003 to 2003 Country / Region: Finland Summary: Met with a Finnish customer to kick off the development of a new type of metalizer for applying EMI/RFI shielding coatings to mobile phone shells.
Years: 1997 to 1997 Country / Region: Japan Summary: In this visit to Japan, Expert and a staff member worked with a Japanese partner to develop a new type of compact disc metalizer.

Career Accomplishments

Associations / Societies
Licenses / Certifications
Professional Appointments
-Northeastern University Industrial Advisory Board

-Past President, Windham Educational Foundation
Awards / Recognition
Tau Beta Pi, Phi Kappa Phi, Pi Tau Sigma; Summa Cum Laude Graduate; Cooperative Education Award; Sears B. Condit Award
Publications and Patents Summary
Expert holds 19 U.S. and international patents and applications.

Additional Experience

Expert Witness Experience
As an engineering practitioner with solid depth and breadth in engineering methods, Expert excels at conveying complex engineering principles to both technical and non-technical audiences alike. His experience as a presenter at technical conferences, as a teacher of engineers, and as a sales person to non-technical customers, has taught him to adjust his message and approach to convey his desired message. As the primary inventor of many technologies, he has been deposed and testified on machine safety and intellectual property cases.

Specific cases:
2010, California - Workplace accident - safety interlock and machine design analysis
2010, California - Workplace accident - Safety interlock and machine design analysis
2012, California - Workplace accident - Injury from fluid piping failure
2007, California - Compact disc piracy case, deposed and report produced
2007, Massachusetts - Intellectual property/Patent/ Business valuation
2002, California - Intellectual property/Patent infringement analysis
2002, Pennsylvania - Workplace accident - review of depositions, practices, procedures and standards; analysis of components; report produced
2002, Pennsylvania, Workplace accident - review of depositions and practices; testified at hearing; report produced
2001, Illinois - Large hydraulic steel door press failure - Forensic analysis of machine; consulting on redesign effort; report produced.
Training / Seminars
Expert prepared, organized and taught review classes to prepare candidates for the PE Exam review classes. These classes were held at the University of Southern Maine.
Vendor Selection
Throughout his 30-year career, Expert has outsourced both engineering services and multiple products and processes when additional or unique skills were required.
Marketing Experience
Expert has been an innovator in the design of electric heaters, heater products, small appliances. He has been a leader in the plastic part coating, metalizing and decorating industry for 20 years. His primary focus and skill is in identifying high cost, high labor content processes, quantifying and categorizing major cost drivers, and in developing new and innovative industrial processes and equipment. Expert's efforts have resulted in the successful launch of various high-volume consumer and technology-based products for manufacturing in both North America and Europe.
Other Relevant Experience
-Public speaking, publication and technical authorship.
-Mentoring of high school students.
-Member of Northeastern University Industrial Advisory Board.

Language Skills

Language Proficiency
French French was Expert's primary language in his early years. This has been a significant advantage to him in working with his former clients from France.

Fields of Expertise

machinery, industrial machine design, electric-resistance heater, household appliance, design engineering, machine failure analysis, machine safety, vacuum metallizing, assembly, mechanical machine, advanced process control, automation engineering, heat transfer technology, patent application, heat transfer equipment design, heat flux, automation technology, automated machinery, electrostatic charge, automation control, assembly automation, assembly equipment, industrial sensor, automatic handling equipment, chromium sputtering, copper sputtering, aluminum sputtering, gold sputtering, United States patent, automated painting, automation, thick-film metallizing, automation system, industrial automation, mechanical design automation, aluminum deposition, process monitoring, electric machine, metallizing composite material, electric stepper motor design, direct-current motor heat loss, heat loss, heat shield, design-for-quality, heat transfer experimentation, engineering design, engineering design automation, convection heating, household appliance liability, convection heating system, electronic equipment heat convection, electronic equipment heat conduction, electrical equipment heat transfer, computer design engineering, machine guard, gas-liquid heat transfer, machine design review, design review, automated equipment development, assembly machine design, fault analysis, control equipment, engineering drawing management, design for manufacturability, design for assembly, heat sink, new product development, computer-aided design, electric motor design, design for manufacture and assembly, engineering design standardization, engineering design productivity, conveyor design, automated machine design, energy-efficient heater, energy-efficient heating device, barium titanate heating element, heat flow, process automation, air heater, automatic control, patent, machine element, static electricity, static, metallizing, leak detection, heat, heat transfer, heat radiation, heat convection, heat conduction, forced convection, failure analysis, factory automation, electrostatic discharge control, electric heat, conveyor, convection heat exchanger, control system, manufacturing automation, assembly machine

Request Expert

Dev Tool:

Request: expert/failure-analysis-product-design-industrial-machinery-appliances-heaters-and-patents
Matched Rewrite Rule: expert/([^/]+)(?:/([0-9]+))?/?$
Matched Rewrite Query: experts=failure-analysis-product-design-industrial-machinery-appliances-heaters-and-patents&page=
Loaded Template: single-experts.php