Duane K. Emerson

*** **** ***** *****, ********* Hills, MI 48309 actk34@r.postjobfree.com 248-***-****

Technical engineer with broad experience in all facets of plastics engineering, interacting with customers & suppliers, and building strong business relationships; capable of leading a team or contributing as an individual. Analytical with highly effective presentation and computer skills; self-motivated, excels at problem solving and working in a high-pace environment. Very safety-conscious with high ethical standards; advocates continuous improvement in all aspects of work..

Expertise

Building customer relationships and generating new business development

Rheological, physical, and mechanical properties of neat and fiber reinforced thermoplastic materials

Rheological, physical, and mechanical properties of fiber reinforced thermoset materials (polyesters, epoxies, polyurethane, and polyimides)

Continuous fiber (carbon, glass) reinforced composites; thermoplastic and thermoset matrices

Plastics processing (injection molding, extrusion, blow molding, ATP, suction blow molding, RTP, rotational molding, others)

Insert molding and 2-shot molding (plastic-over- metal, plastic-over-plastic)

Tool design and construction [for inj. molding, blow molding, composite structures, others]

New application development / plastic part design / metal-to-plastic conversion

Material characterization and failure analysis via thermal analysis methods

Program management and technical processes (e.g. DFMEA, PFMEA, DVP&R, APQP, DOE, Product benchmarking)

Motorola Six Sigma trained

Developing strong customer / client relationships

Computer literate with MS-Office, MS-Project, MoldFlow interpretation / analysis

Valid passport and DOD clearance

Professional Experience

Ticona Engineering Polymers 2001-2015

Ticona is the plastics division of Celanese Corporation, a $7.2 billion chemicals company

Program Development Engineer

Started as Sr. Process Development Engineer to characterize COC, POM, PPS, LCP, and Polyester materials for alternative processing technologies (blow, rotational, and extrusion); hands-on technical and customer support from part design through tool build and developing plastic processes for manufacturability; developing new processing technologies for Ticona polymer portfolio (hard/soft 2-shot molding, in-mold coatings, molded-in circuitry for electronic apps; in-mold decorating for rotational molded tanks). Current responsibilities involve program management and new application development with Commercial Vehicle customers (Daimler Trucks, Kenworth, Volvo), HATCI and Tesla Motors; also process and product development with UD-composites with automotive OEMs and industrial based clients.

Developed LFT-HDPE material solution for Class8 truck customer to solve customer issue w/cold-temp impact failures; Re-captured 3MM lbs business through technical innovation and customer service; Characterized and developed alternative processing guidelines for POM, PPS, LFT engineered materials; Developed molding process and validated POM grades to CARB and EPA standards for fuel tank market; Developed in-mold coating process for injection molding, supporting Chrysler CCV program.

Trico Products 1996-2001

Trico Products is a global supplier of windshield wiper systems to the transportation and marine industries.

Materials Research & Development Manager

Managed 8 employees, 4 laboratories for the research, development and validation of new materials and processes, to advance windshield wiper technology; developed internal procedures and tools for compressing product development cycle time and system validation; accelerated life-cycle testing, material test methods, global standardization of rubber compounds and extrusion processing technology; maintaining QS9000 laboratory certification and VDA compliance; acting technical liaison with OEMs.

Developed and validated synthetic and natural rubber materials and processes for OEM applications in EU; Developed test equipment for characterizing rubber-to-glass friction dynamics; Developed global procedures for material testing and processing specifications; Team leader for establishing compound development and extrusion operations in Wales, UK.

Ingersoll Rand Company 1990-1996

IR is a global, diversified industrial company, headquartered in Dublin, IR.

Senior Staff Polymer Engineer

Championed plastic innovation and metal-to-plastic conversions throughout all I-R divisions; developed training modules and conducted courses in plastic materials, plastic part design, tooling & processing; supported new product development with reviews and recommendations regarding material selection, design feasibility, FMEAs, testing, quality criteria, vendor/supplier qualification process, and auditing; also conducted failure analysis of components.

Managed multiple design and development programs for plastic industrial components including 2-shot (hard/soft) hand tools from Aro and Power Tool divisions and door hardware components for Schlage and LCN door hardware divisions; Managed tool design, processing, and testing of polymer rotors for screw compressor application; managed design team for plastic pump housings and impellers for Industrial Pump division; Hands-on development of RTM process of composite impellers for auxiliary seawater pump (SeaWolf submarine); established QC procedures with DSC to characterize / quantify cure rates for thermoset polyester composite impeller; initiated 7 patent disclosures, awarded 2 patents.

Motorola Government Electronics Group, Tactical Electronics Div. 1984-1990

Motorola GEG was sold to Lockheed-Martin in 1992.

Senior Plastics Engineer

Responsible for supporting GEG engineers with internal programs developing electronic assemblies for various military ordinance applications with feasibility and recommendations on the design, production, and testing of plastic electro-mechanical components; conducting design reviews for part consolidation, developing polymer compounds for dynamic-loading applications; developing tools and processes for over-molding electronic components with thermoplastic materials; supplying prototype quantities for design validation and testing; documenting job estimates per DOD and FAR procedures; department coordinator for DCAS audits of GEG molding lab.

Developed tooling specifications and approved supplier list for tool build sources in the metro-Phoenix area; Was primary support engineer for providing plastic part design, development and supply of prototype components for Army artillery XM762 fuse, 40mm grenade fuse, and WASPM Land Mine program; Air Force sub-assembly components for FMU-140 fuse, Phoenix and HARM missile programs.

Davidson Rubber Company 1973 – 1984

D-R was a Tier 2 automotive supplier of exterior and interior body components, primarily front and rear fascias and also instrument panels.

Project Engineer, Automotive Exterior Components.

Responsible for client development at the engineering level with the Big3 OEMs, for the design and build of prototype and/or production tools for large automotive exterior parts; included the managing of all program timing - release drawings, tool build schedule, impact of engineering changes, proofing tools, 1st Article approvals, color matching, demo parts, PPAP approval, managing multiple tool build programs and budgets involving several million dollars; hands-on supervising of tool start-ups at the production plant..

Managed front and rear fascia programs for: 1980 Chrysler LS Front, 1981 Chrysler K Car Front, 1983 Ford Thunderbird Rear, 1984 Oldsmobile Cutlass Front, 1985 Ford Mustang Rear; Every program involved liaison with OEM engineers, SQA, and Styling Studio personnel to resolve issues, incorporate engineering changes, and complete PPAP certification; Also responsible for in-plant trials, tooling modification where necessary (or required), ancillary equipment design and build thru outside suppliers, packaging design approval, etc.

Education

New Hampshire Technical Institute 1970-1972, A.S.M.E.

University of New Hampshire 1973-1974

References Provided Upon Request

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