Manufacturing Engineering Expert Witnesses: 5

Thomas W. Caldwell, PE, has over 40 years of experience in Materials Research and Development, Process and Product Development, and Manufacturing Operations in the Precision Cast and Machined Products industry.

Mr. Caldwell has designed and manufactured components for consumer and industrial products, including safety-critical applications such as aircraft landing gear brakes, seat belt lockup devices, windshield wiper, and window lift motor systems. He has experience creating and guiding technology development and manufacturing partnerships in Europe and Asia, licensing and selling intellectual property and creating supply chains in China.

Mr. Caldwell has lectured in the USA, Germany, Switzerland, and India on manufacturing premium quality metal products and manufacturing processes, and was a technical paper peer reviewer for 20 years for the Society of Automotive Engineers. A United States patent holder, he has published peer reviewed research in electrochemistry and materials processing, and has written and spoken numerous times on the subject of Materials Selection.

Litigation Support - Thomas W. Caldwell, PE, is a testifying and consulting expert for both plaintiff and defense counsel. His cases involve product failure for ferrous and non-ferrous alloy products such as hand tools, recreational and exercise equipment, fire fighting apparatus, rotating industrial machinery, construction hardware, piping, and lighting fixtures. Mr. Caldwell utilizes destructive and non-destructive methods for insuring product integrity.

Areas of Expertise:

Design Engineering Materials Failure Analysis Materials Engineering Mechanical Engineering Metallurgy Power Tools Products Liability Design Defects

Manufacturing Defects Fitness for Use Equipment Operation and Maintenance Accident Reconstruction Material Selection Manufacturing Process Design and Scale Up Safety Component Product Quality Control Safety Component Quality Systems Management

View Thomas A. Caldwell's Consulting Profile.

Richard Fincher is a consulting and testifying expert witness with over 40 years of Engineering, Semiconductor Manufacturing, Software, Industrial Automation, and executive leadership experience. He provides expert witness and litigation consulting services in U.S. federal and state courts, international arbitration, the U.S. International Trade Commission, and international proceedings.

 Litigation Support - Mr. Fincher has prepared expert, rebuttal, and technical reports and has provided deposition and trial testimony. His engagements have included multi-billion-dollar semiconductor disputes, semiconductor equipment valuation, software copyright and source-code analysis, patent invalidity and non-infringement, automotive electronics failure analysis, industrial machinery disputes, immersive simulation systems, and manufacturing technology matters.

His technical work has included source-code review under stipulated protective orders, establishment of specialized PLC and electronics laboratories for independent testing, semiconductor manufacturing and equipment-market analysis, accelerated-life and specification testing, root-cause analysis, and evaluation of engineering, commercial, and industry-practice issues.

Areas of Expertise:

Semiconductor Manufacturing and Economics Semiconductor Equipment Valuation and Secondary Markets ASIC Cost & Manufacturing Economics Yield, Capacity, and Utilization Analysis Software IP and Source Code Copyright and Trade Secret Disputes

Patent Litigation Embedded Systems Industrial Automation and Process Control PLC Systems Product Reliability Electronic Failure Analysis

Background Experience - Mr. Fincher’s industry experience includes leadership roles as VP of Engineering, CTO, General Manager, and senior engineering manager in semiconductor, electronics, software, and manufacturing organizations. He has led engineering and technology operations across the U.S., Europe, China, India, and Australia.

He holds an MBA from SMU Cox School of Business, an MS in Computer Science from SMU Lyle School of Engineering, and a BS in Computer Science from the University of Texas at Dallas. He is a PMP – Project Management Professional and a Lean Six Sigma Master Black Belt.

Expert Background: Dr. Thomas L. Read is the Principal and CEO at A. Read Consulting, LLC. He received his PhD. from Stanford University in 1972 and has over 25 years of manufacturing experience in electronics, metallurgy, factory safety, failure analysis, glass fracture, glass failure and bottle failure. As a member of the electronics industry, he has earned process patents and has an extensive background in manufacturing techniques. In parallel, Dr. Read has spent over twenty five years as a consultant to attorneys and engineers. He has given more than 100 depositions and has appeared in court numerous times. Company Profile: Read Consulting, LLC is a full service laboratory providing services in the following areas:

• Failure Analysis; Factory Safety and Personal Injury (including machine guards and manufacturing safety)
• Glass Failure Analysis - Glass Fracture, Glass Failures and Bottle Failure
• Metal and Ceramic Failure
• Grinding Wheel Failures
• Intellectual Property and Patent Disputes
• Product Liability and Product Quality
• Manufacturing Disagreements (such as Intellectual Property, Failed equipment and Contract Disputes)
• Reverse Engineering

Mechanical Solutions, Inc. (MSI) performs litigation support through its extensive engineering capabilities, and when required, through expert testimony. MSI uses advanced finite element analysis (FEA), rotor dynamics, and torsional analysis tools, and uses computational fluid dynamics (CFD) to analyze 3-D steady or unsteady fluid flows and heat transfer, enabled by its 230 high speed processor supercomputers.

MSI also uses top-of-the-line testing equipment, including multichannel FFT analyzers (up to 200 simultaneous channels) to accurately read the outputs of various vibration, stress/strain, and pressure sensors, as a function of both time and frequency. As a unique additional test capability, MSI uses motion magnification video cameras to amplify and display scene vibration by 1000x. MSI uses calibrated exciters while equipment remains running, to locate structural, rotor, and acoustic natural frequency resonances as they exist at any particular operating point, without interfering with machinery operation. In addition, MSI performs stress, acoustic, dynamic pressure pulsation, electric current spectrum, and aero/hydraulic performance testing.

Areas of Expertise:

New Equipment Design Computer-aided Analysis Installed Equipment Field Testing and Problem Solution Broken Component (e.g. blades, disks, seals, bearings)  Forensic Analysis Pumps Compressors Fans Turbines

Motors Centrifugal and Positive Displacement (e.g. reciprocating) Configurations Hydraulic Turbine Generators Aircraft Gas Turbine Engines Land-based Gas or Steam Turbine Power Generation Systems Green Energy Power Industry Petrochemical Industry Paper Industry Water Resource Industry

Solving Challenges with Rotating Machinery Vibrations

William D. Marscher, PE, performs expert witnessing and engineering work in the field of Fluid Systems and their Rotating and Reciprocating Machinery, particularly large turbines, generators, compressors, and pumps. His typical work responsibilities include design, analysis, and testing of all types of plant machinery, as well as other types of fluid and mechanical systems. Mr. Marscher has background in various types of turbines (including hydraulic, steam, and gas), as well as various types of pumps, including centrifugal as well as positive displacement (e.g. reciprocating, gear, rotary, and screw).

Mr. Marscher's expert witnessing experience includes 27 cases over the course of his 50+ year career, for which he provided detailed engineering reports in support of the case. This legal support experience includes witnessing in front of tribunals four times, and testifying in Federal Court in four cases. He also has performed depositions 11 times. 

For the past 45 years, Mr. Marscher has been a voting member of the ASTM Fatigue Standards Committee E9, as well as the ASTM Wear & Erosion Standards Committee G2. He is also the past Board of Directors Chairman for the Machinery Failure Prevention Technology Society (MFPT), and has been active in the Vibration Institute. Mr. Marscher is a 23-year member of the Texas A&M Turbine-Pump Users Symposium Advisory Committee (essentially the Board of Directors for the Symposium). For ASME, he was Chair of the Predictive Maintenance committee and was Organizing and Presiding Chair of the 1993 RoCon Rotating Machinery Conference and the 1995 Tribology Conference.

Dr. Edward Bennett is MSI’s VP of Fluids Engineering.  Dr. Bennett graduated from the Naval Academy, following which he was a navy test pilot.  Later he received his PhD in Fluid Dynamics from Johns Hopkins University. Dr. Bennett has been a well-known leader in Fluid Dynamics and the Aero/hydrodynamic Design of Turbomachinery for the past thirty plus years.  

In 1995, Dr. Bennett founded ASC Turbo, a design house that combined the CFD software from Advanced Scientific Computing and specialized turbomachinery design software.  During this time, he worked on the development of BladeGen, a 3-dimensional turbomachinery blade geometry kernel, and also performed a key role design work that included the starter turbine and vapor cycle compressor for the F-22 Raptor fighter, several biomechanical cardiac pumps, a LOX rocket turbopump, as well as numerous more “conventional” turbomachinery designs. After this, he served as Director of Turbopumps for Gencorp Aerojet, and authored the hydraulic design methodology that is still in use by that organization.

At MSI, Dr. Bennett oversees fluid dynamic design and analysis of pumps, compressors, and turbines, including various sizes of hydroturbine generators.  This work includes detailed computational fluid dynamic (CFD) analysis, as well as test rig design, and flow loop/ wind tunnel validation testing.  Recently, he has supported major law firms with expert report writing and detailed two-phase flow unsteady CFD analysis of 100MW and 400 MW hydroturbines in the US and Canada.

Paul A. Boyadjis is Director of Rotating Machinery Analysis for MSI.  Mr. Boyadjis has a BS and MS in Mechanical Engineering from Lehigh University where he graduated summa cum laude.  He has over 35 years of diverse experience in the analysis and Design of Centrifugal Pumps and Pumping Systems, as well as Centrifugal Compressors. His specialty includes complex 3D solids modeling for stress and vibration analysis using advanced finite element techniques, and he has worked as a lead analytical engineer for major manufacturers. 

Mr. Boyadjis is also an expert at rotordynamics, and field testing. He has enjoyed participating as a Hydraulic Institute Standards Partner for over a decade, and became vice chair of its Vibration Committee, and was named Standards Partner of the Year in 2021.  Paul played a key role in various standards. 

Years ago, Mr. Mr. Boyadjis developed the solids modeling and advanced finite element analysis capabilities at the Government Marine Business unit of Ingersoll-Rand, and wrote many of the structural and vibration analysis procedures for that division. As mergers took place, he then transferred these analytical capabilities to the Research and Development group of Ingersoll-Dresser Pump and later Flowserve.

While with MSI, Mr. Boyadjis has conducted detailed 3D finite element analysis of failed casings and impellers, performing forensic investigations, and when necessary, providing successful design enhancements for industrial and municipal customers. He has directed or participated in many testing and troubleshooting projects, particularly for water and wastewater pumping systems.

View MSI's Consulting Profile.

William R. Acorn is founder of Acorn Consulting Services, LLC, an engineering firm. As a consulting mechanical engineer, Bill provides project analysis, forensic reconstructions and litigation support services relating to the design, delivery, and functioning of high-tech manufacturing facilities, semiconductor fabrication facilities, institutional laboratories, data centers, health care facilities and a variety of commercial buildings. He is a recognized expert in the evaluation of deficiencies in HVAC systems, cleanrooms, piping systems, refrigeration systems, construction defects, building and fire code compliance, and patent and trade secret disputes. He represents both plaintiffs and defendants.

Bill has more than 40 years of experience as a professional engineer and is a recognized expert in assessing, evaluating, remediating and providing testimony on complex project design, construction and operational matters. His consulting expertise has been influential in shaping approaches to code compliance and life safety in semiconductor and similar advanced technology facilities.

Certifications and Designations:

• Registered as a Professional Mechanical Engineer in the States of Arizona, California, Colorado, Illinois, Iowa, Nevada, New Hampshire, New Mexico, Oregon, Texas, Utah and Washington.
• Registered with the National Council of Examiners for Engineering and Surveying NCEES (Certificate No. 6999)
• Fellow in the HVAC industry leading organization ASHRAE
• Visiting lecturer at the Arizona State University Del E. Webb School of Construction in Tempe, AZ
• Advisor to CREATE, ACE – Alliance for Construction Excellence and the IAB – Industry Advisory Board, all affiliated with ASU

Building Systems Analysis:

HVAC and Refrigeration Process and Power Piping Plumbing Systems Standard of Care in Design and Construction

Chemical Exposures in the Workplace Cleanroom Design and Performance Codes and Standards Patent and Trade Secret Disputes

Litigation Support: Bill’s pragmatic approach to both forensic and litigation consulting as well as project consulting is based on more than 40 years of real-world experience as a design professional, mentor and forensic analyst, as well as many years as an instructor in professional and academic settings. Represented both plaintiffs and defendants in a variety of jurisdictions throughout the US and Asia. Bill’s ability to explain complex issues to non-technical audiences, including juries, mediators and judges, is a key to successfully solving your litigation challenges.

• Forensic Analysis
• Strategic Litigation Consulting
• Trial Demonstratives
• Expert Testimony

Acorn Consulting Services

Consulting Services: Services range from peer review to conceptual design to development of strategies and programs for expedited project delivery.

Bill frequently acts as an owner’s agent and mentor, functioning as an extension of the owner’s project team. On other projects, Bill serves as a subject matter expert assisting project delivery firms in their development of viable solutions and review of construction documents.

As a project consultant, Bill assures the project gets off to the right start and provides his expertise through completion and operation to maximize return on investment.

Consulting Expertise Includes:

• Project Design and Management Consulting
• Forensic Analysis and Litigation Consulting
• Mentoring & Advanced Education