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.

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Expert Details

Plastics, Injection Molding, Injection Mold Design, Injection Mold Building, and Plastics Part Design

ID: 731068 Wisconsin, USA

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He possesses extensive expertise in high-speed, high-cavitation, runnerless and unscrewing injection molding of plastics and plastics part design.

Engineered, specified and designed mold with radial parting line opening and ejection for ceramic injection molding of jet engine blades, allowing for semi automatic machine operation vs old hand operating method. Reduced scrap from over 40% to less than 0.2%.
Resolved flash issue on 16 cavity collapsible core molds for European manufacture of soft drink plastic closures.
Identified leakage issues on cooking oil tamper evident closure and implemented plan to modify plug seal component on 32 cavity runnerless injection mold.
As member of a task force for improving productivity on Motorola cell phone made recommendations on improving cooling of mold cavities, cores and side actions resulting in reduced cycle time while improving component appearance.
Designed new injection shot end utilizing stepper motors, which were then retrofit to 34 existing machines, to preciously meter material to insure a full shot without flash for a component used in the lost wax process and ceramic injection molding process.


Year Degree Subject Institution
Year: 1964 Degree: Bachelor of Science Subject: Industrial Education Institution: University of Wisconsin - Stout

Work History

Years Employer Title Department
Years: 1995 to Present Employer: Undisclosed Title: President, Owner-Operator Department: Consulting
Via this eponymous firm, Expert provides expert witness, management, marketing and technical consulting services to the industry. He specializes in injection molding, plastic part design, mold design, mold building and processing of plastics.
Years Employer Title Department
Years: 1991 to 1994 Employer: Seaquist Closures Title: Director of Engineering Department: Engineering
Expert directed activities of this 10-person group in the quotation, specifying, placement and productionizing of over $7,500,000 worth of high-speed unscrewing injection molds and automatic assembly equipment for a 40-machine dispensing closure manufacturing company.
Years Employer Title Department
Years: 1983 to 1991 Employer: D-M-E Company Title: Manager of Engineering Department: Engineering
Expert managed the activities of this 10-person engineering group responsible for the design and maintenance of documentation for a $150,000,000 marketer of basic mold products sold worldwide. He generated sales and technical application data and provided support to sales and technical service on all company products. He interfaced with counsel on all technical, intellectual property and product matters.
Years Employer Title Department
Years: 1979 to 1982 Employer: North American Systems - Mr. Coffee Title: Manage of Tool Engineering and Model Shop Department: Engineering
Expert interfaced with design engineering and advised on best practices, placed and put new molds into production. He provided all technical services to outside molders and evaluated new potential vendors.
Years Employer Title Department
Years: 1972 to 1979 Employer: Lake Center Industries - Gale Products Division Title: Staff Tool Engineer Department: Management Staff
Expert interfaced with customers and design engineering on best plastic part design and material selection. He surveyed supplies of molds and molding and quoted all plastic-related parts and tooling. He also placed, followed, sampled and established process conditions on all new molds for the 30-machine inside molding operation and outside suppliers alike.
Years Employer Title Department
Years: 1966 to 1972 Employer: Square D Company Title: Industrial and Tool Engineer, Supervisor of Tool and Manufactuing Engineering Department: Manufacturing Engineering
Expert performed industrial engineering activities, time and motion studies, and application of standards. He established routing operations also. He quoted, place and sample new injection, compression and transfer molds and handled engineering changes and repair. He managed the activities of up to 12 manufacturing and tool engineers in a 2,500-person fabrication and assembly operation. He also managed the staff in planning, allocating and purchasing equipment and executing a plant relocation plan.

International Experience

Years Country / Region Summary
Years: 1997 to 2005 Country / Region: Europe Summary: Technical consulting, interfaced with users and lecturing on the use of AMPCO SA's materials in molds through out Western Europe

Career Accomplishments

Associations / Societies
Society of Plastics Engineers (SPE), Senior Member since 1970
SPE, named Honored Service Member
SPE, Member of the Board of Directors of the Mold Making and Mold Design Division, Chairman
SPE, Member of the Board of Directors of the I.T, Quarnstrom Foundation, Chairman
SPE, Member of the Board of Directors of the Milwaukee Section, Secretary
Society of Manufacturing Engineers, PMMA-PTMD Plastic Mold Committee, Chairman
Member Tri-State University Plastics Technology Advisory Board and Focus Team
Appointed Member of the Plastics Pioneers Association
Awards / Recognition
Named Honor Service Member by the Society of Plastics Engineers
Name Mold Designer of the year by the Mold Making and Mold Design Division of the Society of Plastics Engineers
Name Distinguished Alumnus by the University of Wisconsin - Stout
Received the Society of Plastics Engineers PRIDE award for Division Excellence while chairman
Publications and Patents Summary
Wrote the Mold Making and Mold Materials Chapter for the Society of Plastics Industry Handbook.
Authored the Mold Design Chapter, SPE - Plastics Technician Toolbox
Wrote Mold Maintenance Chapter, SPE- Plastics Technician Toolbox
Developed the Collapsible Cores Chapter, SPE- Plastics Technician Toolbox
Developed and co-authored the series on Copper Alloys within Mold Design Guidelines – CDA
Authored the Modern Mold & Tooling, Guia para el diseno de moldes, Nueve series patrocianadas por la, Cooper Development Association, Instituto Technologico de Plastico, A.C. Mexico
Contributing Editor, Modern Mold and Tooling, Modern Plastics and Modern Plastics International Magazines (six years)
Developed the English version of the Injection Mold Design Tutorial CD
Developed and had translated the Spanish version of the Injection Mold Design Tutorial CD
Generated the Fundamentals of Injection Mold Design, CD Tutorial for Motorola University
Over 90 technical papers and articles authored or co-authored and published
Design Patent awarded for Unitary Hot Sprue Bushing

Additional Experience

Expert Witness Experience
Expert has written 13 Expert Witness reports. He has been deposed 8 times and has testified in Bench and Jury Trial. He has worked on cases involving patents, trade secrets, trade dress, contract disputes and injury as related to plastics, molding and/or tooling.

Examples of retainers and experience available upon request.
Training / Seminars
Delivered the SPE Mold Design and Mold Building Seminar
Presented the SME and Fundamentals of Mold Design
Lectured at Honda for Akron Polymer Training Center, Injection Mold Design
Presented seven papers at SPE's ANTEC's and RETEC's
Presented Seminars on Design, Molding and Mold Building for Intel, Siemens, Eaton, and Motorola
Vendor Selection
Search, identified, surveyed and qualified mold builders and molders for Johnson & Johnson Intrusive Inter-vascular device for 48,000,000 annual production requirement
Researched, surveyed and rated mold builders for Tier One supplier to Toyota and Honda
Identified, visited and rated potential suppliers for electronic enclosures for Dow Chemical
Conductive exhaustive search for tooling supplies for Tier One Automotive Supplier
Marketing Experience
Conducted search, identified, surveyed and visited potential suppliers for Dow Chemical Corporation
Researched tooling market and identified potential customers for alloys used in tooling and molding for the Copper Development Association
Other Relevant Experience
Staffed and wrote the "Ask the Expert" section for the Injection Molding Division of the Society of Plastics Engineers.

Fields of Expertise

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