EXPERTISE

• R&D
• Product invention/design
• Designing products that meet functional requirements while delivering customer value at the target price point
• Identifying and developing product opportunities (enhancing existing products and creating new innovations)
• Product creation using hand sketches and SolidWorks CAD/CAE
• Brainstorming conceptual ideas to iterate to better product solutions
• Human Factors Engineering (HFE) to enhance the user experience
• Hands-on prototype creation and internal/external testing on models and cadavers
• Performing prototype iterations with necessary course corrections based on results
• Design control
• Design Failure Mode Effects Analysis (DFMEA) and Process Failure Mode Effects Analysis (PFMEA)
• Optimization of selected designs for high-volume manufacturing, quality, and reliability using DFM, DFA, and DFS principles and best practices
• New Product Introductions (NPI)/transferring prototype designs smoothly from R&D to manufacturing or outsourcing to China (engineering drawings and specifications)
• Process validations (IQ/OQ/PQ)
• Hands-on troubleshooting
• Lean manufacturing principles
• Management of multiple projects, ensuring all are executed on time and on or under budget
• Management of cross-functional product design/manufacturing teams

PROFESSIONAL EXPERIENCE

• Lead the development of innovative medical devices across a range of product areas — from early-stage concept through engineering, validation, manufacturing, and commercialization — working closely with surgeons, cross-functional engineering teams, manufacturing, quality, regulatory, supply chain, and operations. Apply Design for Manufacture (DFM) and Design for Assembly (DFA) principles to improve manufacturability, reduce product cost, minimize technical risk, and enhance overall product quality. Support New Product Introduction (NPI) through prototype development, design verification, manufacturing transfer, process development, and production readiness.
  
  

  Highlights:

  • Contributed to early-stage development of an orthopedic bone plate system, including design and prototype machining, supporting the program through design verification.
  • Applied DFM/DFA principles to a surgical robotic platform, including fixturing to support manufacturability.
  • Design production fixtures, manufacturing equipment, and process improvements to support new production line launches and improve manufacturing efficiency, product quality, and production scalability.
  • Supported development of a device for tumor treatment.
  • Designed fixtures and equipment used to manufacture a novel flexible intraocular lens for cataract treatment, working within a strict clean room environment.
  • Mentor engineers and promote systems thinking, continuous improvement, and practical engineering solutions throughout the product development lifecycle.
  
  
  ACTIV SURGICAL — Boston, MA 2021 - Nov 2022
  Manager, Advanced Manufacturing Group
  Championed product designs that performed well and enhanced the user experience. Optimized prototype designs for performance, manufacturability, and serviceability in parallel, reducing development time while preserving the original design intent. Was accountable for the practical application of product design for excellence principles. Evaluated post-market surveillance data to drive continuous improvement of commercially released products.
  
  

  Highlights:

  • Career Highlight - Implemented industrial design techniques to develop packaging for multiple products that protected the product and promoted the company brand at low cost. Received Marketing Director recognition for a sleek, innovative design that reflected the high-tech look and feel of the Activ Surgical product line.
  • Designed medical sterilization trays to be easy and intuitive to use.
  • Optimized manufacturing workstations with equipment, fixtures and hand tools using lean manufacturing techniques, allowing operators to build high-quality products with low defect rates. Adopted Poka yoke, shadow boards and value stream mapping principles.
  • Facilitated the design transfer, design for manufacture, and assembly line setup of the first commercial product with designated contract manufacturer.
  
  
  CONCERT MEDICAL (Theragenics Inc - Medical device design engineering) — Norwell MA 2020 - 2021
  Senior Product Design and Manufacturing Engineer
  Rehired to modernize and enhance the company's proven Profile Grinder platform, leveraging prior design knowledge to improve equipment performance, reliability, manufacturability, and long-term production support. Focused on engineering upgrades that extended the useful life of an established manufacturing system while maintaining compatibility with existing production processes.
  
  

  Highlight:

  • Career Highlight - Specifically rehired to upgrade the highly successful Profile Grinder platform I had originally designed more than two decades earlier. After producing over three million guidewires, the equipment remained the foundation of production, and I implemented engineering improvements to enhance performance, reliability, maintainability, and long-term manufacturing capability.
  
  
  MEDROBOTICS INC (Surgical Robotics) — Raynham, MA 2017 - 2020
  Senior Product Design and Manufacturing Engineer
  Served as Senior Product Design and Manufacturing Engineer on a surgical robotics platform, applying Human Factors Engineering (HFE), DFM, DFA, and DFS principles to improve performance, reliability, and manufacturability. Used post-market surveillance data to guide ongoing design improvements, transitioning surgical solutions from R&D to production while maintaining high quality, reliability, and low cost across the product life cycle.
  
  

  Highlights:

  • Career Highlight - Diagnosed a reliability and manufacturability issue in the robotic arm support mechanism and conceived a simple, sub-$5 in-field repair using a Belleville washer, allowing existing units to be fixed on-site rather than returned to the plant. This low-cost solution avoided a costly global product recall and was recognized by the Director of Manufacturing as a novel, high-impact fix.
  • Career Highlight - Lead product designer for redesigned robotic arm for improved locking performance and intuitive operational locking/unlocking tactile and audible feedback. The new design was praised by the sales and marketing team for transforming the customer experience.
  • Lead product designer on new surgical instrument support to allow deeper surgical procedures and use of a wider range of instruments and products. The new instrument support had more features than the previous design and allowed surgeons easier access to the auxiliary port which was previously obscured.
  • Provided direction and mentorship for interns, peers and colleagues.
  
  
  CONCERT MEDICAL LLC (formerly Accellent Inc., medical device design & manufacture) — Norwell, MA 2005 - 2017
  Senior Product Design & Manufacturing Engineer
  New product concept development and transition from R&D to production. Performed design revisions and cost reduction through better manufacturing and outsourcing to add quality and value. Supported all phases of the product life cycle.
  
  

  Highlights:

  • Career Highlight — Co-inventor of patented design for lap joint for wire hybrid stainless steel and nitinol guidewire (Patent US 20070282270 A1). Joint design and consumable tooling were designed to allow ease of assembly by the assembler.
  • Career Highlight — Co-inventor (PCT/US 2014030339) regional anesthesia infusion device to aid surgeons during surgical procedures. Patient Safety Innovation of the Year award 2020 issued by HSJ (Health Service Journal), London, UK, September 2021. Human factors were important criteria contributing to the success of this product, especially the foot pedal. This high-volume, single-use device required extensive design optimization to achieve the necessary low selling price. Strategic outsourcing to China was also necessary.
  
  
  Accellent Inc (formerly Microspring Inc., Medical device design & manufacture) — Norwell, MA 1999 - 2005
  Senior Lead Product Design & Manufacturing Engineer
  Served as project manager / product design lead for a cross-functional team of technicians, machinists, electronics engineers and draftsmen. Managed resource allocations, budgets, and milestone adherence.
  
  

  Highlights:

  • Co-designed and developed Urology Stone Cone lithotripsy prototype device with transfer of prototype device from R&D to production. The product was designed with visible markers which could be seen under a fluoroscope to help the doctor position the wire. The wire was made out of shape memory wire (NITI) so the wire would transform into the shape required with minimal doctor intervention.
  • Career Highlight - Co-designed and manufactured a specialized corewire to allow a built-in blood pressure sensor to be embedded in it. Helped transition this prototype design into production.
  • Career Highlight - Designed lean manufacturing fast changeover tooling for grinders, reducing setup times by 60%. Tooling was optimized to minimize the number of tools required to install/remove it. Poka yoke principles were employed to help minimize operator error.
  
  
  Microspring Inc (Medical device design & manufacture) — Norwell, MA 1996 - 1999
  Lead Product/Equipment Design Engineer
  Served as project manager / lead designer for a cross-functional team of technicians, machinists, electronics engineers and draftsmen. Managed resource allocations, budgets, and milestone adherence. Designed equipment and fixtures for mechanical performance and optimal man-machine mechanical and GUI interfaces to increase productivity, minimize fatigue and improve quality.
  
  

  Highlights:

  • Career Highlight - Project Manager/Lead Design Engineer of cross-functional team in charge of $1,000,000 budget to design and manufacture 7 state-of-the-art precision guide wire grinding machines to grind precision shapes in 0.014" dia. stainless steel and nickel titanium wire to 0.001" +/- 0.0001". Project completed on time and on budget and still in operation today.
  • Career Highlight - Project Manager in charge of setting up infrastructure for new grinding facility, which included the seven new state-of-the-art grinders and all necessary support equipment.
  • Designed and implemented a variety of high-speed 0.014" dia. stainless steel coil winding equipment with automated feeding and unloading systems. Machine controls and functionality were designed for easy operator setup and running.
  
  
  Glebar — Franklin Lakes, NJ 1988 - 1996
  Research & Development Engineer
  
  

  Highlights:

  • Designed equipment operator interfaces and cell layouts for specialized grinding equipment.
  • Conceived or improved grinding machine equipment and tooling designs to achieve low cost manufacturing.
  
  

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  EDUCATION & CREDENTIALS

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  Loughborough University — Leicestershire, England, UK
  BSc (Hons) Design and Manufacture Engineering, 1988

  Loughborough University — Leicestershire, England, UK
  Diploma in Industrial Studies, 1986

  Mass Art — Boston, MA
  Industrial Design Continuing Education Class Credits, 2017

  American Management Association, Certificate in Business Management (1996)