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Expert has extensive experience with plastic molding processes and with injection molding in particular. He is often called upon to help clients with issues such as injection molding machine selection, injection mold lubrication, and in-mold labeling. He has been responsible for design feasibility, tooling maintenance, production standards, and quality control procedures for products such as computer components, automotive plastic parts, plastic medical devices, and plastic toys. He is familiar with runnerless and hot runner injection molding systems.

From his extensive experience with plastics processing, he has expertise in locating and correcting design errors in products or tooling that would cause product failure if not corrected. He has been responsible for specification of materials, design feasibility, failure analysis, and compliance to CPSA and FDA for a variety of molded plastic parts.

Based on a product's design and market needs, Expert through his teaching and consulting practice, has the expertise to choose the proper material-process combination for the most cost-effective method of production. His skill in this area is based on familiarity with material selection, part design, purchasing, marketing, and product definition. He is knowledgeable of preventative maintenance scheduling to assure process and product stability.

Expert has worked extensively on injection molding machines that use computer analysis to assure consistency of process, both open loop and close loop. He is familiar with finite element analysis for modeling the flow patterns, stress levels, gate locations, and cooling patterns of molds.

Expert has worked on several projects where electrically conductive elastomers (stainless steel wire impreg, graphite filled, etc.) were used for the certification of business equipment to comply to FCC EMI/RFI protocols. He has used electro-conductive paints, fillers in plastics, and conventional methods of plating over plastics and vacuum metallizing.

More than 75% of Expert's experience in industry has involved the selection, use, processing, and testing of parts made from engineering thermoplastics for specialty applications.

He has worked on several projects involving the manufacture of EPS parts, design of the parts, and the construction of packing materials through hot wire cutting or die cutting of EPS.

Expert has worked with fiber-reinforced plastics on many projects. He has consulted on the design of parts, construction of tools, design critiques, flow patterns of fiber in the parts, and the maintenance of tooling to assure proper quality parts.

Expert's work associated with load-bearing applications for plastics includes the design of snap locks, screws, bolts, thread design, nut retention, and material creep applications where the robustness of the applications was paramount.

In the area of plastic color, he has extensive experience with dry color, color concentrate, liquid color, as well as color match analysis applications. He has used dyes as colorants and as part of the sublimation transfer process.

Expert has studied plastic component failure for his work in project engineering, expert testimony, and component design. He has gained the ability to predict failure and design tests to show failure mode. The forensic analysis of failed parts is a major component of his experience. The thermal/chemical/mechanical degradation of polymers all effect the choice of materials and product design. He has had significant exposure to plastic failure analysis tests and techniques.


Expert has experience with the design and tooling and equipment as well as the processing and techniques of plastic die cutting.

Expert maintains that one of the most common failures in plastics processing involves improper drying of plastics. He is familiar with the equipment and the time-temperature relationship required for each plastic materials to gain the optimum properties of each resin. Instructing clients on proper drying techniques, maintenance of equipment, and how to program equipment and read the outputs has been a large portion of his consulting practice.

In his work with the electronics industry, Expert has gained extensive experience with stress free molding, the chemical etchant or electro-conductive paint primer step, and the control and application of the plating process.

Expert has been involved with several projects where embossing has been used as a post process decorating method. He has had extensive experience with the photo engraving of extrusion dies where embossed sheet stock has been the primary feed stock for thermoforming.

Expert has participated with the design, prototype testing, tooling, qualification of tooling, and ongoing production of plastic medical devices under the protocols of FDA Good Manufacturing Practices. He has been involved with the design critiques, tooling construction, tooling qualification, and testing of plastic valves for the medical industry.

Expert has setup, implemented, and supervised a painting facility at Hewlett Packard's Northern Colorado Plastics Technology Center. He consults on the applicability of painting, paint durability testing, and quality control methods.

Throughout his career, Expert has been active in designing tooling and setting up processes using hot-plate welding, spin welding, ultrasonic welding, RF sealing, and electro-magnetic bonding.

Expert teaches seminars, presented papers, and published articles on the proper construction of tooling. He has helped with tooling deliveries, critiques of mold designs, and tooling qualifications.

Expert is knowledgeable of all phases of spin welding, heat welding (hot gas, infra red, and laser), ultrasonic, and vibrational welding. He had managed the project at Ford Motor Company that developed the original design optimization for the ultrasonic weld bead. He has had extensive experience with designing and setting up equipment as well as the qualification and testing of processes of all phases of ultrasonic vibrational welding of both plastic-to-plastic welds (in both similar and dissimilar materials) and insertion welding.

Over the course of his career, Expert has summarized his knowledge of plastics inspection in two books that cover injection molding. He has set up inspection protocols and quality programs, taught seminars, and presented technical papers on this subject.

Expert has consulted on the design of plastic parts (particularly when they mate with dissimilar material) on the effect of thermal expansion and the design techniques required to compensate for this effect

Expert has participated in several projects where scrap plastic was used as the primary component of the end product. He has consulted with several companies as to the proper use (or reuse) of scrap plastic to avoid the disposal costs of purgings and regrind.

Having extensive experience with the design of vinyl parts, he has particular knowledge of vinyl ester resin. He has built tooling, set up precision processes and inspection protocols for vinyl products that were injection molded, thermoformed, and extruded.

Expert has been involved with projects where he has set up processes for applying decals, pad printing, silk screening, and hot stamping on plastic parts.

Expert has assisted in material selection, manufacturing processes, tooling specifications and on-site troubleshooting. Expert has evaluated businesses for sale or purchase as to their business worthiness. Expert teaches seminars on injection. Expert is available as an expert witness.