1992 - 2005 Vascor, Inc.
Pittsburgh, PA
R&D/Biomaterials engineer, Manufacturing Manager
During May 1992 Vascor
hired
me as a Biomaterials engineer to develop and scale-up proprietary
polyurethane elastomers suitable for an implantable heart assist
device. Vascor had
purchased polycarbonate polyurethane technology from another company
and
needed a product development engineer to help them implement the
technology.
My responsibilities included synthesis and characterization of
lab-scale
quantities of polyurethane. Synthesis was done in 1-liter reaction
vessels
under my supervision using a series of designed experiment protocols to
develop an optimum material formulation. The polyurethane elastomers
were
molded and tested for molecular weight, mechanical properties,
and fatigue
life. After 18 months of development I determined that the polyurethane
chemistry that Vascor licensed had insufficient fatigue properties for
human
implant
applications. I worked with a custom medical polyurethane supplier that
was able to modify one of their products to meet Vascor's needs. Within
6 months a satisfactory polyurethane elastomer was produced and
successfully
tested.
In May 1994, I was promoted
to Manufacturing Manager at Vascor. My new responsibilities included
design, fabrication, and assembly of prototype parts for the Ultracor
heart assist device. Many of these components were made with
implant-grade metals,
advanced composites, silicone rubbers, and polyurethane elastomers.
Most
of the polyurethane and silicone rubber components were made in-house
via
injection and compression molding or solution casting. Some of the more
demanding applications that I worked on included integrally textured
polyurethane
pump diaphragms, custom cannulae with improved blood flow
characteristics,
and polymeric heart valves. Several of my ideas were incorporated into
U.S. patents assigned to Vascor for new and novel blood pumps and
textured
pump diaphragms. I also worked on several projects with various vendors
to extrude custom polyurethane tubing and foam for insulation on
implanted
electrical leads and pump housings.
My job responsibilities included
development of sonomicrometry leads, percutaneous ports, cannulae, and
cables for Vascor's
magnetically
levitated turbine heart-assist device known as the Ultracor R. I had
management
responsibilities for the machine shop, part inspection, the plastics
fabrication
lab, and the building and facilities at Vascor's location in O'Hara
township.
Four people worked for me including two machinists, a QC/mechanical
assembly
technician, and a chemical technician. My group constituted over 20% of
the technical manpower at Vascor.
During my career at Vascor, I learned to
use Solidworks, Surfaceworks and ProEngineer CAD software for part
design
as well as FloWorks for computational fluid dynamic analyses of blood
flow. I also managed several capital improvement projects
including remodeling and upgrade of
the facilities and labs, addition of an electron microscopy
lab, clean assembly area, and company wide internet capability.
1989 - 1992 General Electric
Plastics Pittsfield, MA
Applications engineer II, Group leader
In December 1988, I took a
position as an advanced automotive applications specialist at GE's
Pittsfield
headquarters. My primary responsibilities were to support the
automotive marketing efforts by working with customers to determine the
suitability of GE
materials in various automotive applications. This work involved
end-use testing of components such as bumpers, fenders, wheel covers
and
instrument panels. I also conducted failure analyses on defective parts
received from customers. The root cause of part failures (design,
material, processing, or environment) would be determined so that
corrective actions could be taken with the customer.
Initially, the laboratory
facilities were
meager,
including only a pendulum-type bumper tester and a tensile tester.
During
the next 3 years I significantly expanded the lab to include a
machine
shop, 3 walk-in environmental chambers, a pendulum type tester for knee
bolsters, drop tower, strain gage test equipment, high speed
photography,
and state-of-the-art data acquisition capabilities. I also wrote the
software
that linked our PC-based data acquisition equipment to GE's VAX
mainframe
cluster so that engineers in the field could access our test data.
During
this time I was promoted to a group leader for automotive applications
testing
with 2 engineers and 2 technicians working for me. My group
worked to support many new and existing automotive applicatons which impacted millions of pounds of GE Plastic's business at GM, Ford, Saturn, and Mazda.
I left GE Plastics
in
May 1992 to take a position with Vascor, Inc. My reasons for leaving GE
included job security concerns because of extensive layoffs from
1990-92, as well as a
desire
to return to western Pennsylvania where I grew up.
1985 - 1989 Borg-Warner Chemicals
Parkersburg, WV
Product development engineer II
In 1985 I took a job with Borg-Warner
Chemicals
as a product development engineer II. My responsibilities included
development
and product support of ABS plastics for automotive applications such as
instrument panels, interior trim, and bumper components. In my position
I worked
with customers and field-based application engineers to identify
product
needs and then developed materials to meet those needs. New material
formulations were compounded in the laboratory in small quantities and
tested to see if they were satisfactory. Typically this involved
mechanical, thermal, and chemical testing of a material to an
automotive material specification. If the material met specifications,
then I would interface with either the pilot plant or one of the
manufacturing plants to scale up the product on their equipment to make
quantities ranging from 25 to 10,000 pounds. If
the scaled-up material was satisfactory, then I would work with the
customer to conduct evaluations at their plant to determine moldability
of the material and suitability for their application. In some cases
the entire process was repeated several times to develop the best
product for the customer's needs
In 1987 I became extensively involved in a
joint program with General Motors to develop an ABS material that would
be suitable for structural bumper beams. Initially, my involvement was
focused on
material development and scale-up. I spent about a year interfacing
with
a Japanese affiliate and the Parkersburg manufacturing plant to
transfer
their high-impact ABS technology to the plant. This technology proved
to be the basis for a satisfactory ABS material for structural bumper
beams.
General Motors conducted preliminary testing on prototypes made with
the
new ABS material and found that it met their needs.
With the material issue resolved, I became
more
directly involved in the design and tooling of an ABS plastic bumper
beam
for the 1991 Chevy Cavalier. My new responsibilities included
interfacing
with the mold makers in Detroit, the engineers at GM, and the
Borg-Warner
field engineers to design and build a kirksite tool to mold bumper
beams.
In the summer of 1988 the tooling was completed, and I conducted
extensive
injection molding trials with several developmental materials. I later
became
involved with end-use crash testing of the bumper beams both at GM and
at
Borg- Warner's applications laboratory. By 1989 both the bumper design
and
material met GM's performance requirements.
At this time General Electric acquired
Borg-Warner and the program was turned over to GE's automotive
marketing department. I was offered a position in their Automotive
Applications group, which
I took. In my new position I was still involved with the bumper
program,
which later evolved to GE's solitary bumper beam program. The solitary
beam
concept has since been successfully adapted to several vehicles
including most recently the Ford Explorer and Dodge/Chrysler mini-vans.
1983 - 1985 Hercules/Himont
Wilmington, DE
Product development engineer
Upon graduation from Penn
State In 1983, I accepted a job with Himont as a product development
engineer. My responsibilities included development of new polypropylene
materials
for packaging and non-woven textile applications. In my position I
conducted processing evaluations with new materials on lab-scale
equipment for fiber spinning, multi-layer sheet co-extrusion and
thermoforming. The primary
focus of this work was to determine how the unique crystallization
characteristics of the materials affected processing and ultimately
structure-property relationships.
In 1984 my product
responsibilities were expanded to include Himont's ultra-high molecular
weight polyethylene. I worked on two interesting applications for this
material. The first was injection molding of the product as an
alternative to compression molding, which was the only method at the
time for processing the material. The
second was gel spinning of high strength fibers in a joint effort with
Allied Chemicals. I worked with Allied to develop an optimum material
formulation
for their Spectra fiber products.
I left Himont in December
1984 to
take
a position with Borg-Warner at a 20% salary increase.
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