Printing tool Download PDF


Mechanical Engineer with 30+ years of hands-on experience developing products for mass production. My career has focused on integrating materials and innovative design to create products that enrich the human experience. I help companies bridge the gap between "what if" and "wow." 


  • Published author and industry recognized Subject Matter Expert on plastic materials, including their effective use, re-use, and environmental impact. 

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

  • 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. Sensitive to all aspects of product aesthetics, including social, psychological, and cultural impacts.  

  • Seasoned troubleshooter, skilled in analytical and intuitive approaches, with a proven track record of commercial success. 

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 to select clients in the wireless, medical, and consumer products industries. Primary focus has been on guiding new product concepts into production using injection molding. 

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

Partial Client List:  SRAM Corporation, Axess Americas, Cisco Consumer Products, Daimler North America, Otter Products, Tandem Diabetes Care.

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 TV 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  parts and sub-systems  affecting user interaction.

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.
  • Provided technical support to Motorola design team in development of colors and finishes for the V60 and Razr phone series.  


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, SRAM Corporation.  


Faculty Member

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

“Take A Look at This: Using Visual Comparison to Evaluate and Control Appearance.”  2019 Annual Technical Conference, Society of Plastics Engineers. March 18, 2019. Detroit, MI. 

"If Lady Gaga was a diabetic, what would her insulin pump look like?"  2018 Medical Device & Manufacturing Expo, UBM. Feb 7, 2018. Anaheim, CA.  ( keynote presentation )

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

Plastic 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 )

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

Select Publications

"A plastics engineer gets personal with plastics recycling." Lead article in the Newsfeed for Plastics TodayNovember 1, 2019. Part 1 of an eight-part series documenting my personal experiences with recycling PE film, and the quest for sustainability.

"Plastics and extreme hurricanes: Houston, we have a problem." Lead article in the Newsfeed for Plastics Today, September 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.

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

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

“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, for Professional and Scholarly Excellence. 

 Currently in the permanent collection of over 450  libraries in 20 different countries. 

"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.