Carbon Fiber and Thermoplastic Composites Manufacturing Expert

Technical Consultant #2034

Composites and thermoplastic composites processing.
New molding technology and development in the carbon fiber manufacture industry.
Development of self-heating composite tools utilizing carbon nanotube dispersions.
Low cost carbon tooling through recycled carbon fiber.
Compose comparative materials properties studies changes in fiber architecture and process.
Market new fiber materials that were improved to elevate impact properties.
Vacuum Assisted Resin Transfer Molding, VARTM, using polyurethane materials.
New applications development for market in recycled carbon fiber for veils hiding fiber read-through in the marine craft industry.
Provide marketing reports for companies entering into the composite markets promoting new form factors.

Undisclosed Company, Principal, 2011 - Present

Composite research and development in the carbon fiber and carbon nanotube material industry.
Develop new molding techniques for manufacturing carbon fiber parts with a high fiber volume fraction and a single sided tool using a silicone bag.
Create self-heated composite tools using carbon nanotube dispersions.
Develop low cost carbon tooling using recycled carbon fiber from Boeing off-fall.
Wrote study on comparative materials properties based on changes in fiber architecture and process to help sell new fiber material for improved impact properties.
Research and development for Vacuum Assisted Resin Transfer Molding, VARTM, using polyurethane materials.
Development of new applications to market recycled carbon fiber for veils that hiding fiber read-through for marine customers.
Compose marketing reports for carbon nanotube clients, attempting to enter composites markets with several new form factors.

Plasan Carbon Composites, Bennington; VT, 2008 - 2011

Automotive research and development in the carbon materials manufacturing.
Developed new manufacturing training program to reduce scrap and re-work from over 26% down to 2%.
Wrote study on evaluation of Non-destructive testing technologies.
Research and development for vacuum bag and autoclave manufacturing processes to reduce rework.
Development of new low-cost RTM process, (Resin Transfer Molding) for Corvette roof inner structure.
Design of new pre-forming tools using anaerobic binder, with 2-min. cycle time.
Set up materials lab with DMA, Rheometer, DSC, Instron Tensile test equipment, Dynatup Impact test, digital microscopy, and white light inferometry for surface analysis.
Developed low cost testing method for surface finish, and mechanical property.
Proposed and ran preliminary tests for new out-of-autoclave manufacturing process, patent pending. This manufacturing process led to a new plant being built with new non- autoclave bladder presses for over a $30 million contract with GM.

Nanocyl, S.A., Rockland, MA, Marketing, 2005 - 2008

Established development of the North American Market for carbon nanotube additives industry.
The company went from making no sales in the U.S. to more than $2 million annually.
Development of new dispersion techniques, and thermoplastic and thermoset composite materials which were later used by several customers.
Developed new markets for CNTs through customer technical support for research and development.
Three patents granted to Nanocyl, based on projects started.

Hyperion Catalysis, Inc., Cambridge; MA, Development Specialist, 2001 - 2005

Automotive market strategy for development of new applications for carbon nanotubes at U.S. OEMs.
Composed procedures, processes and strategies defining this market which is still used today by their sales staff.
Development of new thermoplastic composite applications for ESD properties of fuel pumps used in GM's Epsilon platform, using POM resin by BASF, and fuel pumps by Bosch.
Established a thermoset research program (epoxy) with Tier 1, and Tier 2 suppliers.
Participating member of SAE workgroup on electrostatics in fuel system components.

DaimlerChrysler, Rochester Hills; MI, Composite Manufacturing Engineer, 1999 - 2001

Responsibilities and focus to structural composite vehicle research.
Project management of show car (ESX3) design of closure systems.
Responsible for design of doors, hinge mechanisms, window lifts and intrusion protection.
Performed research in composite manufacturing processes and materials for lightweight structure.
Project management of special programs such as the ACC (Automotive Composites Consortium) on Focal Project 3, the all-composite body-in-white.
Chairman of the Processing Committee for ACC.
Leading research on low cost pre-forming, zoned pressure molding, cyclics, thermoplastic sandwich composites, gyrotron curing, E-beam, and other technologies.

Fraunhofer, U.S.A., Boston; MA, Internship,1998 - 1999

As a Rapid Prototyping Research Project Manager, performed research in rapid prototyping technology, including SLA, SLS, and FDM as well as the new Z-corp, LOM and other new equipment.
Developed manufacturing techniques for carbon composite materials using a thermoplastic matrix.

Daewoo Worthing Technical Centre, West Sussex, UK, Internship, 1997 - 1997

For the Advance Materials and Processes Research Department, performed experiments in robotic vacuum casting.
Experiments performed to investigate: Mold longevity, relative quality of materials, dimensional stability, of various silicones.
Managed a product development project from CAD design to sterolithography and prototype production.

Solectria Corporation, Wilmington MA, Fabricator, 1994 - 1995

Contracted to help the electric vehicle company meet a deadline to build a complete prototype vehicle for a car show (from composite to prototype).
Welding and fabrication of large industrial oven.
Composite (carbon fiber pre-preg) body-tub building, chassis assembly.
Paint preparation, wiring. Implementation of closure designs.
Fabricated crash-test vehicle parts.
"Sunrise," the vehicle name, held the world record for distance range for a four-passenger electric vehicle, 375 miles, (recently broken), and passed all crash tests, without any metallic frame structure.

Vantage Motorsports, Founder and Manager, Boston, MA, 1988 - 1996

Serviced clients in the composite prototype industry.
Oversaw daily operations while supervising a full time team.
Executed major projects that included the prototyping of an all-composite sports car body using high-temperature epoxy tooling, pre-preg, and honeycomb-cored sandwich materials.
Designed a cost-effective all-composite sports car chassis for a company in the UK; consulted on manufacturing feasibility for Consulier, Mazda, and others.

Credentials

Technical Careers Institute: One-year course with focus on modules in engine rebuild, transmission rebuild, MIG and gas welding, tune-up, brakes, and suspension.
Tools: CAD - CATIA (surfacing), Pro Engineer - Creo 2., 3-D solid modeling, Word, Excel, Powerpoint, Project & MS. Applications, QuickBooks.

Academic and Professional Affiliations

Publications

MBA Boston University, Graduate Schools of Management, Boston, MA
M.S. Manufacturing Engineering (dual degree, MBA program) Northeastern University, Boston, MA
B.S. Business Administration - New Venture Management, Northeastern University, Boston, MA