Sr. Materials/Product Engineer

CHENGTAO LI

**********@*****.***

***** ***** ***** ****: 248-***-****

Novi, Michigan 48374 Cellular: 248-***-****

CAREER SUMMARY

Market-driven Senior Materials Engineer/Scientist with unique background combining project management and development engineering with polymer materials and mechanical expertise. Adept at taking projects from concept design through manufacturing. Strong background in product development and numerical optimization. Extensive knowledge and hands-on experience in material formulation and polymer processing with an emphasis on multiple cutting-edge functionality integration technologies. Consistently obtain high performance through leadership and team work, follow through on commitment, clearly organize and conclude projects and report outs.

AREAS OF EXPERTISE

Research & Development Product / Process Development Mechanical CAD/CAE/FEA

Quality Control / Improvement Analytical Problem Solving Part & Mold Design, Numerical Analysis

Customer / Supplier Relations Materials Characterization Test Method Development / Validation

Six Sigma/ DOE / FMEA/PPAP Processing-Structure-Property Unigraphics, AutoCAD, MoldFlow

PROFESSIONAL EXPERIENCE

INTEVA PRODUCTS, LLC ( formerly Delphi Interior ), Vandalia, OH 2009-Present

An engineering, manufacturing and supply powerhouse to global customers for automotive interiors and closures, as well as no-automotive value-based products.

Materials/Product Engineer

Manage materials engineering activities on all injection molding and slush cast technologies. Responsible for bringing to market Inteva's in-house TPE/TPO material technology and supporting production programs using commercially available grades, such as PVC's, TPO’s, TPE's and TPU's, developing process and design guidelines to achieve a high quality product, and supporting problem solving and cost savings initiatives.

• Indentified and selected cost-effective filled/unfilled polymer/plastics materials (TPE/TPV/TPO/TPU, PVC, PC/ABS, PP, PC/ASA, PET/PBT, Nylon, POM….), foam, adhesive, grease/lubricant that meet customer/OEM specifications; Provided technical support/guidance to PDT’s and quote team from material selection, bill of materials (BOM), VA/VE improvement activities, prototype trials and processing DOE, to MSDS and CMAP coordination, ADVP&R plans, COA and PPAP review & approval, until production lunch.

• Led in-housing compounding development of interior TPO/TPE formulations that meet OEM spec with low-cost advantage, benchmarking with competitive materials, testing, analyzing, and validating material property and performance, issuing material specifications.

• Provided problem solving expertise for plastics material application utilizing Six-Sigma methodology that assists PDT’s and production plants to identify root cause and trouble-shoot problems; Tested and analyzed samples using FTIR, TGA, DMA, DSC, microscopy, mechanical (tensile, flexural, impact), MFR, etc., providing testing reports and findings.

• Led and participated in continuous improvement activities on molding plastics that can bring cost savings and green footprint on environment, testing and validating reground and reprocessed materials, selecting and validating replacement or alternative materials for production programs.

• Developed and completed and 15+ material specifications for injection molding plastics/compounds, and regrind/reprocessed polymer blends for production programs.

CARDINAL INTELLECTUAL PROPERTY, Evanston, IL 2008-2009

A global leader in patent research selected by the US Patent and Trademark Office ( USPTO ).

Patent Search Analyst / Research Professional

Conduct Patent Cooperation Treaty ( PCT) searches and analysis. Prepare the preliminary PCT opinions. Specialize in the subject categories of polymer, chemical and mechanical engineering.

EXATEC LLC ( subsidiary of SABIC Innovative Plastics, formerly GE Plastics ), Wixom, MI 2003-2008

A technology global center for automotive plastics window systems development and demonstration.

Material Scientist, Molding Technology Leader

Lead the development, formulation, compounding, and testing of new glazing resins, and delivered high level cross-functional CTQ to customers. Lead the development of new test methods that controlled and improved optical molding and coating cost performance. Lead the development of new process / product for automotive glazing system to integrate new functionalities. Develop and transfer specifications and processes to Licensees and Tiers.

• Developed a quantitative mold-in stress measurement method for optical plastic windows.

o Implemented such a system for visual inspection and quality control, as well as customer demonstration.

• Led development of functional resin grades for automotive glazing, developed and validated processes for each new polymer compounding (including filled/unfilled blend/composite).

• Collaborated with leading technology companies combining and integrating the best available technologies and the most advanced components into Exatec glazing system that created a competitive advantage for polycarbonate ( PC ) glazing.

o Opened up and developed injection-compression process for large optical glazing that reduced stress, birefringence and optical distortion.

• Led team that designed, specified, tested, installed, and commissioned the most complicated and advanced two-component large glazing machine Engel 2500 COMBI M ( $2MM ) for prototyping and business development.

• Led team that designed and delivered a complex state-of-the-art backlite stack mold

( $1MM ) & vacuum forming tool, and secured advance large rear windows for OEMs / Tiers.

• Developed film and metal insert molding process as a new manufacturing path and cost-effective approach for PC glazing that resulted in multiple innovations that integrated new functionalities ( defroster, antenna, solar control, decoration ) into windows and eliminated very expensive 3D printing.

o The patent-pending technology was in testing for a GM commercial program.

• Led team that developed, demonstrated, and integrated electro-luminescence into PC glazing system, resulting in the introduction of a new functional product ( Exatec®900el ) and solution for Exatec.

o Developed and qualified electro-luminescence ink compatible with plasma enhanced chemical vapor deposition ( PECVD ) coating and silicone hard/wet coating process.

o Designed and validated electro-luminescence for large optical PC glazing.

• Initiated and organized live showcases of Exatec technology with vendors in K-2004 and NPE 2006, supporting glazing marketing and increasing the extent of Exatec’s influence and commitment to the best possible glazing solution.

• Completed molding process and glazing resin Blue Book and FMEA for industrialization of Exatec®900 coating system that provided technical guidance and transferred specification to Licensees and customers.

INSTITUTE OF POLYMER ENGINEERING, The University of Akron, Akron, OH 1998-2002

Research Assistant

Participated, presided in various R & D projects.

• Conducted compression molding, co-injection molding, gas-assisted injection molding, resin transfer and reaction injection molding, compounding for research. Studied various materials including PP, PE, Nylons, PS, PC, Polyester, Vinyl, EPDM, SBR, PU, TPE, TPO…

• Implemented numerical simulation ( FEA / CFD ) for flow and thermal stress analysis, crystallization and microstructure development, and residual birefringence prediction.

• Developed mathematical methodologies and novel physical models for multi-component molding, the numerical analysis was compared with and validated by experimental results.

o The FEA/CAE model was applied to two-component transfer and compression molding of rubber compounds at Lord Corporation to predict the interface penetration and encapsulation phenomena.

• Developed resin formulation, and performed materials characterizations on polymer physical, thermal, rheological, optical, structural, morphological, and mechanical properties.

• Used statistical methods in the design of experiments ( DOE ) and data analysis to optimize processes, interpreted data from analytical equipment and on-line measurement.

INSTITUTE OF PLASTIC PROCESSING & MACHINERY 1995-1998

South China University of Technology

Research Associate

Participated, presided in various R & D projects including reaction injection molding of BMC

with fiber/glass reinforced polymer ( FRP ), foam extrusion, material formulation and compounding, twin-screw co-extrusion of nanoparticle and FRP composite, screw specification, design and testing.

EDUCATION

PhD, Polymer Engineering, the University of Akron, Akron, OH

MS, Mechanical Engineering ( CAD/CAE ), Dalian University of Technology, Dalian, China

BS, Mechanical Engineering, Dalian University of Technology, Dalian, China

Company Sponsored Training: Six Sigma Green Belt (GE Global Research Center)

MEMBERSHIPS / AFFILIATIONS

Society of Plastic Engineers 2000-present

Society of Automotive Engineers 2003-present

American Chemical Society 2006-present

HONORS AND PUBLICATIONS

Management Awards, Exatec/Sabic Innovative Plastics 2003-2007

TICONA Award, The University of Akron 2002

Fellowship, Lord Corporation 2000-2002

Outstanding Women Students, The University of Akron 2001, 2002

Book Scholarship, Women in Higher Education, The University of Akron 2001, 2002

Research Assistantship, The University of Akron 1998-2002

PATENT APPLICATIONS:

1. US20060209551A1, “Light Emissive plastic glazing”, Robert Schwenke, Wilfried Hedderich, Chengtao Li, Christophe Lefaux, Ken Foster

2. US7,681,364, “Decorated two component window assembly and method of manufacture”, Billy Bui, Thomas Cutcher, Eric v.d. Meulen, Chengtao Li

3. US20060204746A1, “Plastic panels with uniform weathering characteristics”, Chengtao Li, Jonathan Sagent, Steve Gasworth, Meng Chen

4. US20070286966A1, “Method of depositing an abrasion-resistant layer onto an electroluminescent plastic window”, Meng Chen, Chengtao Li

5. US20070286995A1, “Polycarbonate glazing system having solar reflecting properties”, Chengtao Li, Wilfried Hedderich

6. US20080028697A1, “Window defroster assembly with light control”, Chengtao Li, Keith Weiss, Wilfried Hedderich, Rebecca Northey

7. US20080160298A1, “Polycarbonate glazing system and method for making the same”, Chengtao Li, Keith Weiss

8. US20080187725A1, “Functional layers for polycarbonate glazing”, Sunitha Grandhee, Chengtao Li, Keith Weiss, Eric v.d. Meulen

9. US20080085415A1, “A decorated plastic glazing assembly via a film insert molding process”, Chengtao Li, Sunitha Grandhee, Keith Weiss

10. US20080157416A1, “Method of producing a low haze plastic glazing”, Barry Hoult, Harold Mukamal, Chengtao Li, Keith Weiss

11. US20080265459A1, “In-mold coating (IMC) for plastic glazing”, Steve Gasworth, Chengtao Li, Suniha Grandhee

12. US20080274652A1, “Electrical terminals for film insert and two shot molded plastic windows”, Chengtao Li, Juan Velasquez, Keith Weiss, Todd Adkins, Yana Shvartsman

PAPERS

1. Chengtao Li, “Thermal expansion behavior and dimensional stability of bonded polycarbonate panels”, Accepted, SPE ANTEC Papers, 2010.

2. Chengtao LI, “The effect of second shot material on warpage of molded and coated large two-component polycarbonate panels”, Accepted, SPE ANTEC Papers, 2010.

3. C. T. Li and A. I. Isayev, “Interface Evolution and Penetration Behavior during Two-component Transfer Molding. Part I: Modeling and Formulation”, Polym. Eng. Sci., 44, 4, 687-696, 2004.

4. C. T. Li, A. I. Isayev and R. L. Warley, “Interface Evolution and Penetration Behavior During Two-component Transfer Molding. Part II: Simulation and Experiment”, Polym. Eng. Sci., 44, 4, 697-713, 2004

5. C. T. Li and A. I. Isayev, “Primary and Secondary Gas Penetration during Gas-assisted Injection Molding. Part I: Formulation and Modeling”, Polym. Eng. Sci., 44, 5, 983-991, 2004.

6. C. T. Li, J. W. Shin, A. I. Isayev and H. S. Lee “Primary and Secondary Gas Penetration during Gas-assisted Injection Molding. Part II: Simulation and Experiment”, Polym. Eng. Sci., 44, 5, 992-1002, 2004.

7. C. T. Li, A. I. Isayev and R. L. Warley, “Simulation and Experimental Studies of Interface Development and Penetration in Multi-component Transfer Molding of Rubber Compounds”, Rubber Chem. Technol., 77, 5, 873-890, 2004.

8. G. D. Shyu, A. I. Isayev and C. T. Li, “Residual Thermal Birefringence in Freely Quenched Plates of Amorphous Polymers: Simulation and Experiment”, J. Polym. Sci., Phys. Ed., 41, 1850-1867, 2003.

9. C. T. Li and A. I. Isayev, “Interface Development and Encapsulation in Simultaneous Co-injection Molding of Disk: Part I: Two-dimensional Modeling and Formulation”, J. Appl. Polym. Sci., 88, 2300-2309, 2003.

10. C. T. Li, D. J. Lee and A. I. Isayev, “Interface Development and Encapsulation in Simultaneous Co-injection Molding of Disk. Part II: Two-dimensional Simulation and Experiment”, J. Appl. Polym. Sci., 88, 2310-2318, 2003.

11. G. D. Shyu, A. I. Isayev and C. T. Li, “Photoviscoelastic Behavior of Amorphous Polymers during Transition from the Glassy to Rubbery State”, J. Polym. Sci., Phys. Ed., 39, 2252-2262, 2001.

PRESENTATIONS:

1. Chengtao Li, “An assessment on optical quality of molded backlite compared to thermoformed backlite”, SPE ANTEC, Chicago, June 22, 2009

2. Chengtao Li, “Exatec® Polycarbonate Automotive Glazing Systems - Injection-Compression Molding for Larger PC Windows”, Plastic Technology Leading-Edge Molding Conference, Sept. 19-20, 2007

3. Chengtao Li, “Injection-Compression Molded Automotive Polycarbonate Glazing”, Molding 2007 Conference, Feb. 19-21, 2007

4. Bruce Benda, Chengtao Li, “New Choices and New Flexibility with Polycarbonate Glazing”, Above the Beltline Conference, Dec. 5, 2006

5. C. T. Li, J. W. Shin, A. I. Isayev and H. S. Lee, “Transit gas-melt interface and gas penetration during gas assisted injection molding: simulation and experiment” SPE ANTEC, 49, 414-418, Nashville, Tenn, May 8, 2003.

6. C. T. Li, A. I. Isayev and R. L. Warley, “Simulation and Experimental Studies of Interface Development and Penetration in Multi-component Transfer Molding of Rubber Compounds”, 162nd Technique Meeting of Rubber division, ACS, Pittsburgh, PA, Oct. 10, 2002.

7. C. T. Li, D. J. Lee and A. I. Isayev, “Interface and Encapsulation in Simultaneous Co-injection Molding of Disk: Two-dimensional Simulation and Experiment”, SPE ANTEC, 48, 465-469, San Francisco, CA, May 6, 2002.

8. C. T. Li and Y. C. Peng, “Modeling and Simulation on Flow in Plasticizing Unit of Injection Machine”, 5th Canton/HongKong Symposium on Application of Mechatronics, HongKong, June 12, 1998.

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