My résumé

Remtec, Inc. Norwood MA – 2016 through present.
Senior Process Development Engineer

Saint-Gobain Ceramics and Plastics 2008 through 2016
Northboro Research and Development Center, Northborough, MA
Research Engineer
Skunkworks innovation program: new product development
• Transformed a blue-skies research program into a solutions-driven early stage product development program supporting business groups within the corporation.
• Redesigned program to mitigate financial risk of new product development.
• Managed $250k yearly budget to develop products in analytical methods, abrasives, novel ceramic and polymer processes, building materials, and process modeling.
• Evaluated technical and business merit of proposals, assembled multidisciplinary development teams, and provided technical guidance and brainstorming as needed.
• Led the program resulting in two commercialized products, two new analytical techniques, and follow-on spending of 5X initial project investment.
Ceramic Processing
• Developed a new method of producing abrasive grain. Designed and fabricated prototype process equipment and secondary process equipment.
• Characterized sources of variability to justify redesign of an abrasive grain pilot line.
• Designed, fabricated, and verified performance of redesigned machine components.
Product troubleshooting
• Determined cause of defect formation in a commercial polypropylene injection molded product responsible for >$1MM warranty claims.
• Developed and ran on-site manufacturing designed experiment, analyzed DOE response.

Technic Inc 2003 to 2008
Woonsocket, RI
Manager, Specialty Materials
• Managed inventory and production of precipitated precious metal powders and flake used in microelectronics, medical, dental, and military applications. .
• Expanded production and product capability of wet chemical processes.
• Trained as an internal auditor, ISO 9001:2000. Trained in Lean Six Sigma methodology.

Ferro Electronic Materials (formerly Degussa Electronic Materials) 1999 to 2003
South Plainfield, NJ
Application Engineer, Ceramic Materials
Primary dielectric technical representative to the multilayer ceramic capacitor (MLCC) industry.
• Developed process parameters for new dielectric compositions. Worked with US, Asian, and European customers to qualify new products in commercial applications.
• Partnered with sales staff as technical specialist to address customer concerns with existing products, introduce and integrate new products.
Determined root cause of customer process and device failures; presented findings and process solutions to customers.
• Solved pilot-scale tape casting problems at Ferro Netherlands R&D. Instituted substrate, binder systems and process parameters to allow automatic production of MLCCs.

SRI International (formerly David Sarnoff Research Center) 1995 to 1999
Princeton, NJ
Associate Member of Technical Staff
Key member of a multidisciplinary program to develop a multilayer microfluidic device for combinatorial chemistry drug discovery.
Technical contributions led to two patents, award of stock options, and two Sarnoff Technical Achievement Awards.
Microfluidic device development
• Played a key role in microfluidic device development from concept through functional commercial prototype.
• Developed procedures to yield defect-free glass substrates for 3-D microfluidic structures.
• Identified source of incoming raw material flaws. Developed procedures that decreased raw material costs, increased quality, and decreased process cycle time in multi-step device fabrication process.
• Co-developed novel methods to make glass-to-glass anodic bonds without glass degradation.
• Developed gold inks and procedures that achieved specification of >99% hermetic and conductive vias in glass substrates.
• Developed electroplating procedures to form precision bumped electrode tips that were the basis of the microfluidic pumping system.
Hybrid microelectronics packaging
• Developed process methods to produce low temperature co-fired ceramics on metal (LTCC-M).
• Technology is the basis of Sarnoff spin-off company Lamina Ceramics.
• Developed novel method to eliminate firing distortion of multi-cavity LTCC-M substrates, allowing top-level thick film circuit metallization without post-firing processing.

Elan Technology 1993 to 1995
Belleville, NJ (now located in Midway, GA)
Ceramic Engineer
Developed Elan’s ceramic materials capability. Position required extensive knowledge of ceramic compositions, process methods, and testing.
• Provided customer technical support in area of glass-to-metal and ceramic-to-metal sealing for microelectronic packaging.
• Developed compositions and procedures to produce alumina, zirconia, and steatite ceramics.
• Developed isostatic and uniaxial dry pressing parameters, including tooling, binder, and lubricant selection.
• Developed custom ceramic products in response to customer requests.
• Ran custom spray drying operations for customers.

Microcel Technology 1990 to 1993
Edison, NJ
Senior Development Engineer
Key member of a startup venture to commercialize hollow ceramic spheres with applications in energy-absorbing composites, catalysis, and non-fibrous refractories.
• Established guidelines for new manufacturing operation, evaluated ceramic sphere production systems to ensure safe operation.
• Led marketing program to introduce energy-absorbing syntactic foam composites to major suppliers in the US and English automotive industry, composed marketing literature. Product was qualified and instituted in select vehicles by Ford and BMW.

General Electric, Astro-Space Division 1987 to 1990
Valley Forge, PA
Ceramic Engineer
Key team member in the development of high-power thermoelectric devices for space power applications (SP-100 program). Position required extensive knowledge of high temperature chemistry, thin film deposition; and ceramic, metal, and semiconductor process methods.
• Analyzed process-related failures of complex thermoelectric devices. Recommended process changes based on failure analysis.
• Fabricated and tested device bonds, including refractory metal to sapphire diffusion bond, and brazes joining glass, ceramic, metal, and semiconductor components.
• Designed mechanical tests, test fixtures and procedures to determine device integrity.
• Presented project updates to GE management and Government contract representatives.

VIZ Manufacturing Company 1985 to 1987
Philadelphia, PA
Sensor Engineer
• Managed production of temperature, pressure, and humidity sensors for meteorological and military applications.
• Improved temperature sensor inspection & test procedures, resulting in savings of $80k/year..
• Additional duties included evaluation and troubleshooting of water-activated battery process, electroplating operations, surface-mount and through-hole circuitry, circuit board manufacture, injection molding, and screen-printing operations.