Engineer Injection Molding

Jerry Lu

*** ******** **. **, ***** Rapids, MI **546

616-***-****, *********@*****.***

SUMMARY

A Six Sigma certificated engineer/scientist looking for a position that can best utilize broad experiences in product and process development, innovative and incentive ways to execute projects effectively.

Polymer Materials & Process: Various Polymer Materials (Plastics, Elastomers, TPE), Adhesives (Thermal and UV Curable, Hot Melt, PSA etc), Structure/Property, Polymer Chemistry and Polymerization, Polymer Compounding & Mixing, Coating, Extrusion/Co-Extrusion, Reactive Extrusion, Molding, Lamination & Packaging etc.

Material Characterization: Rheology, Thermal Analysis, FTIR, Electron & Optical Microscopy, etc.

Statistical & Six Sigma: Lean and Design for Six Sigma, DOE, SPC, R&R, Process Capability Analysis etc.

Project Management: Plan, Budget and Execute Projects; Lead, Coordinate Cross Functional Groups and Vendors, Customers Service and Tech Support.

Production Equipment: single and twin-screw extruders (screw design, configurations for extrusion, mixing, reaction, venting etc.) continuous compounders, batch mixer, injection molding, multi-manifold cast die, feedblock die, reactor, roll, Coaters (hot-melt, rollers, knife on roll, Gravure and Mayer Rod etc).

Lab Instrument: DMA, DSC, TGA, TMA, GPC, SEM, FTIR, Tensile, Hysteresis, Shear & Extensional Rheometers, HPLC.

PROFESSIONAL EXPERIENCES

FIRST SOLAR Inc, Perrysburg, OH 2011–Present

Development Engineer

Conduct evaluation, selection and qualification of packaging films, adhesives, coatings, cables used in photovoltaic module.

Conduct studies on failure mechanisms of materials. Successfully found root causes of sealing and encapsulating material failures.

Saved millions of dollar worth of raw materials from scrapping by conducting comprehensive investigations of material properties and processes.

Established and managing the lab of polymer characterizations including rheology (shear and elongation rheometers), thermal (DSC, DMA, TMA, TGA), structure (GPC, FTIR). Hands on instrument operation, analyzing and interpreting the data to provide key information for business decision.

In house expert of thermal, RT and UV polymer curing systems.

Provide leadership for applying new technology and conducting engineering development; plan, coordinate, and execute projects.

Lead method development for evaluation of long term stability and reliability of PV module including the mechanical properties and electronic performances under moisture, thermal, UV, chemicals impacts.

Lead improvement projects, assessing the risk associated with the new materials, process and equipment changes.

NOVEN PHARMACEUTICALS Inc, Miami, FL 2007–2011

Senior Research Engineer

Successfully completed pre-formulation & product development of several new transdermal drug delivery systems.

Lead new technology innovations and implementations for alternative drug delivery systems.

Coordinate development of new adhesives for exploring new technologies applicable in new product development.

Conduct process development from lab to pilot and production scales for new product transfer.

Leader of polymer structure/property/process relationship studies to evaluate and characterize raw materials (silicone, acrylic, polyurethanes and biodegradable etc.) and new products for optimizing formulation and process and improve the end-use properties of finished products.

Conducted DOE, process capability analysis for process development and scale up for multiple key projects, significantly reduced development time and cost for the company.

Helped marketing/business development by screening transdermal drug candidates with modeling API skin permeability.

Conduct drug/polymer solubility and compatibility study for new drug delivery systems.

Coordinate process design/scale-up, implement and validate technology transfer of new products and processes to commercialization.

Conduct Design for Six Sigma (DFSS) and Lean methodologies for improving project executions and significantly impact the business.

CORIUM INTERNATIONAL LLC, Grand Rapids, MI 2004–2007

Project Engineer/Senior Process/Product Development Engineer

Established/validated overall process flow and design criteria for coating/extrusion and lamination of new medicated products.

Completed transfer from concept/feasibility phase to a pilot line mode and ultimately to commercial scale production for hydrophilic polymers based medicated product. Saved the project from abandonment by resolving significant challenges from product properties and process difficulties.

Completed all stages of product development from prototype to preclinical and clinical studies for a PSA based topical anesthetic patch. Rescued the project from discarding by optimizing formulation and modifying properties of excipients.

Provided scientific leadership and technical expertise to the material selection for drug delivery systems, optimized process development on coating, extrusion and injection molding processes of variety drug delivery platforms.

Designed new screw configurations for compounding heat and shear sensitive API and excipients.

Lead cross-functional team for investigation of product quality issues.

Worked with engineering and manufacturing for selection, evaluate and validate process/equipments.

GYRICON LLC, Ann Arbor, Michigan 2003–2004

A subsidiary of Xerox, developing a reusable display material electronically writeable and erasable.

Development Engineer

Designed and implemented new coating process to enable electronic media production to be carried out efficiently and led successful completion of assigned goals.

Provided expertise to contribute to the material development including adhesives (Epoxy, Urethane and Acrylic, thermal and UV curable etc manufacturing, and analysis of polymer based electronic media.

Conducted defining and troubleshooting product defects, reduced production cost and significantly improved the product quality.

TREDEGAR FILM PRODUCTS, Terre Haute, Indiana 1999–2003

Product Development Engineer

Developed and commercialized breathable and cloth-like film/non-woven laminate with high moisture vapor transmission rate (HMVTR) for diaper back sheets that resulted in multimillions revenue.

Developed and commercialized co-extrusion multi-layer elastomeric films for hygiene application using elastic copolymers, resulted in a new business of several million in annual revenue.

Conducted Rheology studies in materials evaluation and selection to eliminate or reduce processing issues such as die lip buildup, molten curtain breaks, and draw resonance, etc., resulted in faster commercialization and a significant reduction of development cost.

Improved layer distribution uniformity of co-extruded elastic films by optimizing process and innovative die design, significantly improved product quality and reduced product returns.

Optimized screw design for compounding shear and heat sensitive TPE blends, resulted in better control of melt temperature and higher quality product.

Applied Six Sigma methodologies in new product design and process optimization that helped company to reduce development and production cost.

Proactively engaged with customers and vendors for meeting customer needs and improving product quality and reducing cost.

COLLEGE OF POLYMER SCIENCE & ENGINEERING 1996–1999

University of Akron, Akron, Ohio

Researched extrusion, injection molding, rheological properties of Thermoplastic Vulcanizate (TPV), styrene block copolymer, polyester, polyurethane Thermoplastic Elastomer (TPE).

SHANGHAI UNITED COMPANY OF CHEMICAL TECHNOLOGY, Shanghai, China

Product/Project Engineer, Center of Technical Development

Developed multiple coating methods (roll, knife, rod and extrusion etc.) for various web coating process (film, foil, paper, fiber matrix etc.), successfully transited the development plans to manufacturing. In house specialist on coating defects.

Led development and commercialization of epoxy acrylate and urethane acrylate UV curable oligomers, coatings, and inks, creating high profit margin.

Developed and led production of polyurethane elastomer and polyurethane composites materials.

Developed emulsion co-polymerization of tetrafluoroethylene propylene (TFEP elastomer), successfully led scale up for commercial production.

EDUCATION

Master of Science in Polymer Engineering

University of Akron, Akron, OH

Bachelor of Science in Chemical Engineering

East China University of Science & Technology, Shanghai, China

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