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Mechanical engineer with over 30 years of hands-on experience developing products for mass production. Career focus on integrating technology and innovative design to create products that enrich the human experience. Passionate about technology, and its effects on people and the planet. Proven track record of creating commercially successful products in a diverse number of industries. 


Creative, forward thinking problem solver with a thorough knowledge of engineering processes.  Seasoned troubleshooter, skilled in analytical and intuitive approaches. 

Well versed in design methods, committed to collaboration. Sensitive to all aspects of product aesthetics, including social, psychological, and cultural impacts.   

Highly skilled at interpreting complex product requirements and developing design concepts into fully engineered products, from prototype stage through production release. 

Adept at understanding end-user needs; balancing trade-offs between performance, cost, and feel.

Technical expert in colors, materials, and finishes, with expertise in color matching, color tolerances, appearance requirements, appearance evaluation methods, acceptance criteria. 

Industry recognized Subject Matter Expert in plastic part design and material selection for injection molding. 

CAD Software: Solidworks (10,000+ hrs), Pro/ENGINEER (8,500+ hrs)  

Work Style

Versatile team player; equally effective as team lead, staff member, or individual contributor.  Flexible social style; high emotional intelligence. Described by a former manager as  “the ultimate collaborator.”    


Social Profiles: 

  • Myers-Briggs: ENTP
  • HBDI:  2,2,1,1+
  • MIR:  Driving-Expressive

Select Projects

Work History


Founder / Chief Engineer

Art of Mass Production

Founder of consulting company providing services in plastics technology to select clients in the wireless, medical, and consumer products industries. Primary focus on guiding product concepts into full-scale production. 

  • Primary consultant for all technical projects
  • Sourced and hired personnel (technical, marketing, administrative)
  • Developed training programs in plastic material selection 
  • Responsible for company branding, marketing, and business development

Partial Client List:  Lytx, Cisco Consumer Products Division, Underwater Kinetics, Tandem Diabetes Care, Encap Technologies, Watershot.

Notable Project:  Development of the iDive housing for the iPad, the world's first fully functional touch screen device for underwater use. 

  • Featured in Apple 2014 SuperBowl Commercial "What's Your Verse?"
  • Winner 2015 IAPD Plastics Design Competition


Consulting Mechanical Engineer

Quartus Engineering / PDG Hightower

Mechanical engineering of parts and sub-assemblies for the wireless and consumer electronic industries. Responsible for fit, form, and function of user interaction components. Key projects:     

  • Nokia 6265 - first slide-style CDMA phone
  • Nokia 6255 - all-in-one clamshell style phone
  • Low cost accessories for Hewlett-Packard Deskjet printers


Staff Engineer

Motorola Personal Communications Sector

Member of Appearance Technology Center: investigated new materials, finishes, and decorative processes and facilitated their use in personal communications products.

  • Primary responsibility for metal and metallic finishes, including in-mold decorating, plastics plating, aluminum anodizing, and PVD.
  • Spearheaded development of anodized color and texture palette on replaceable aluminum housings for V series phones.  
  • Coordinated training for Motorola design team that developed the Razr phone series, the world's best selling clamshell phone.   


Contract / Project Engineer

various assignments

Mechanical engineering of plastic parts and components, prototyping, testing, vendor liaison, manufacturing support. 

  • Key Assignments:  Eli Lilly / IDEO Product Development, Nellcor Puritan Bennett, Skil-Bosch Power Tool Company, Whirlpool Corp. 
  • Member of new product development team for SRAM Corporation, a bicycle component manufacturer. Responsible for design integrity and manufacturability of shifters, derailleurs, and braking systems.


Adjunct Faculty

Institute of Design, Illinois Institute of Technology

Taught undergraduate course in Manufacturing Methods. 


Senior Design Specialist

DuPont Engineering Polymers

Provided design support and technical assistance to major DuPont customers as a value added service of global Sales and Development Groups. Customer base included key OEM sales accounts along with development projects at targeted major manufacturers.

  • Developed a child safety mechanism for use in disposable lighters
  • Charter Member, DuPont Center for Creativity and Excellence
  • Nicknamed Design Wizard by colleagues



Bachelor of Science in Engineering

University of Michigan, Ann Arbor, MI

Major:  Aerospace Engineering,  magna cum laude  

Professional Activities

Plastics Industry Contributions

  • Member, Society of Plastics Engineers,  2012-Present
  • Board of Directors, SPE Product Design and Development Division, 2014-2016
  • Contributor to SPE newsletters and publications; guest columnist for Plastics Today
  • Published author, moderator of the blog site 


Professional Engineer Certifications

  • State of Illinois - License Number 062-049331
  • State of Delaware - Registration Number 8253

Select Presentations

Plastic Material Selection for Wearable Devices.”  2017 Medical Plastics & Compounding Conference, Compounding Solutions, Dec 5, 2017. San Jose, CA.  ( keynote presentation )

“Thermoplastic Material Selection for Performance, Cost, and Feel.”  Cyclitech 2016 Conference, Society of Plastics Engineers / JEC Group, Dec 6-7, 2016. Newport Beach, CA.  ( keynote presentation )

“An Engineer’s Perspective on Performance Plastics.”  IAPD 60th Annual Convention, International Association of Plastics Distribution, October 4-7, 2016. Phoenix, AZ. ( breakout session

“Visions in Plastic: How designers incorporate plastics into their work.” Design in Plastics 2016, Society of Plastics Engineers, Rhode Island School of Design, Providence, RI.  ( panel discussion )

“Growth Opportunities in Patient Compliance – Improving Medication Adherence with New Engagement Solutions.”  MEDevice Conference, San Diego. Sep 1-2, 2015.  ( panel discussion )

“Plastic Material Selection.”  Western Plastics Trade Fair, Society of Plastics Engineers, Southern California chapter. August 2015. ( keynote presentation )

“Designing with Plastics.” Plastics University, Annual Technical Conference, Society of Plastics Engineers, March 2015. ( breakout session )

Select Publications

"Plastics and extreme hurricanes: Houston, we have a problem."  Lead article in the Newsfeed for Plastics TodaySeptember 19, 2017.

"Material Considerations for Wearable Devices." Plastics Engineering magazine, February 2017.

"Plastic Material Selection For Medical Wearables: Key Material Families."  Summary article in Med Device Online magazine, final entry under guest column "Talking About Plastics,” December 5, 2016.

"True Confessions: A plastics engineer explains why we don't need no stinkin' bag bans."  Lead article in the Newsfeed for Plastics Today,  November 18, 2016.

"True Confessions: A plastics engineer explains why he despises property data sheets."  Lead article in the Newsfeed for Plastics Today,  August 13, 2016.

“True Confessions: An engineer explains why he will never buy a 3D printer.”  Lead article in the Newsfeed for Plastics Today,  May 24, 2016.

“Plastic Material Selection: The four performance killers.”  Lead article in the Newsfeed for Plastics Today,  October 1, 2015 (reprinted in the March 2106 print edition).

"Thermoplastic Material Selection: A Practical Guide." Elsevier, Oxford, England. May 2015. 324 pages, hardcover.

Nominated for a 2016 PROSE Award. [1]

 Currently in the permanent collection of over 120 libraries in 20 different countries. [2]

[1] Presented by the Association of American Publishers, the Awards for Professional and Scholarly Excellence (PROSE) recognize works of great merit that add groundbreaking knowledge to the arts, humanities and sciences. 

[2] As reported on Dec 31, 2106, by WorldCat, the world’s largest network of library content and services. 

"Eine Methodik zur technischen Bewertung von Kunststoffen” GAK Gummi Fasern Kunststoffe, April 2015.  (reprint and translation of SPE paper)

“Material Selection Based on Feel.”  Proceedings from the Annual Technical Conference, Society of Plastics Engineers, April 2014.

“Material Selection Based on Cost.”  Proceedings from the Annual Technical Conference, Society of Plastics Engineers, April 2014.

“Life Cycle Design Guidance Manual.” U.S. Environmental Protection Agency, 1993.  (contributor)

“Inside Injection Molded Parts.”  Materials Engineering, August 1992.

“Designing Better Thermoplastic Parts.”  Progettista Industriale, July/August 1991.  (reprinted from Machine Design)

“Designing Better Thermoplastic Parts.”  Machine Design, February 1991.

“Big, Baad, and Beautiful.”  Modern Woodworking, November 1990.  (reprint of SPI paper)

“Engineering Resins: Breaking the Rules.”  Plastics Engineering, May 1990.  (editorial contribution)

“Big, Baad, and Beautiful: Advances in the Use of Engineering Plastics in the Office Furniture Industry”  Proceedings from Structural Plastics ‘90 Conference, April 1990.

“Finding New Parts for Plastics.”  Mechanical Engineering, August 1989.