Rich Dewald
Rubber Process Engineering Leader
Rubber Expert Witness
Rich Dewald
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Rich is an expert in rubber processing technology, tool development, metal treatment and adhesives, coating application, and plasma treatment. He has expertise in compounding polytetrafluoroethylene (PTFE) for wear resistance and employs plasma etching processes for bonding to PTFE. Rich has expansive experience in process engineering, manufacturing operations, design management, and project + process oversight. He is committed to utilizing expertise, new technologies, and keen knowledge of rubber molding processes to meet organizational objectives—while displaying confident adaptability to new process types.
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Experience
September 2020 - Present
Avus Design, LLC, Self-Employed Consultant
Ann Arbor, Michigan
2019 - 2020
Tenneco (previously Federal-Mogul Powertrain), Technical Specialist, Process R&D
Plymouth, Michigan
Designed and established critical process parameters for chemical-based processes within sealing systems—specifically within the areas of adhesives/conversion coatings, coatings, elastomeric mixing, elastomeric molding and virtual molding analysis, and metal stamping.
2005 to 2019
Federal-Mogul Powertrain, Manager, Process Design
Plymouth and Ann Arbor, Michigan
Directed and motivated process design team to optimize chemical and materials processes for sealing systems division—in support of 10 manufacturing locations producing $1B in sales—across three continents. Led complex projects with goal of improving division-wide process capability and quality; tracked completed projects to ensure positive impact on plant performance measures (safety, quality, throughput, and cost.) Initiated cross-functional collaboration to define current and future processes for new product and manufacturing strategies.
1999 to 2005
Federal-Mogul Powertrain, Materials Engineer
Ann Arbor, Michigan
Developed rubber and PTFE formulations for use in automotive sealing applications—specifically engine and transmission sealing. Led and trained cross-functional team in test process implementation, rubber compound testing, and manufacturing procedure optimization for elastomer molding processes and seal inspection. Ensured all formulations aligned with customer requirements. Researched new materials and processes to enhance company’s technical and financial competitive advantage.
Earlier Career Experience:
Federal-Mogul Powertrain Senior Process Engineer, Process Engineer
Education
Patents
Affliations
September 2020 - Present
Avus Design, LLC, Self-Employed Consultant
Ann Arbor, Michigan
- Launch of Process Development Facility for Bumper Plate Molding
- Evaluated potential sites for development of crumb rubber mixing, compression molding, and final assembly processes
- Specified mixing equipment, compression mold presses, mold tooling design, and assembly press along with all of the ancillary equipment needed
- Specifying raw materials for use in manufacturing of bumper plates
- Coordinated testing of competitor product with outside laboratory to determine potential raw material sources and formulation
- Hired a team of technicians to work on the development
- Developing process for mixing including time of mix and recipe formulation
- Developing process for molding of the bumper plates including cure time, temperature, and pressure. Evaluating mold release and tooling plating to optimize part removal and minimize downtime for cleaning
- Developing Production Process for Bumper Plate Molding
- Determining overall layout of facility in coordination with process owner
- Evaluating and specifying delivery systems of materials to the mixer
- Evaluating and specifying cellular manufacturing layout for the molding operation
- Creating process work instructions and troubleshooting documents for mixing and molding processes
- Developing critical processes and their parameters for manufacturing of crumb rubber bumper plates for the fitness industry – specifically within the area of compound development, powder and liquid handling, mixing of materials, compression molding, and metal insert forming.
- Led compression mold press selection and design for cellular molding concept
- Leading tooling design for molding of 10 to 45 pound bumper plates including automation of part removal
- Developing mixing process for manufacturing crumb rubber compounds for use in molding – includes delivery of raw materials to the mixer and establishing the process controls for the operation
- Establishing ergonomic controls to allow operators to safely handle heavy plates in the manufacturing process
2019 - 2020
Tenneco (previously Federal-Mogul Powertrain), Technical Specialist, Process R&D
Plymouth, Michigan
Designed and established critical process parameters for chemical-based processes within sealing systems—specifically within the areas of adhesives/conversion coatings, coatings, elastomeric mixing, elastomeric molding and virtual molding analysis, and metal stamping.
- Championed complex project management for new product technologies and manufacturing processes development
- Exhibited operational expertise in developing dynamic compression molding process for engine crankshaft seal requiring tight dimensional tolerances—effectively analyzed costs and secured a savings of $500K in capital investment
- Led tooling design and initiated project for two-compound compression molding of engine crankshaft seals
- Employed mastery of CAD and FEA modeling technology for tooling designs
- Spearheaded development project for producing robust prototypes for inkjet printing of OD coating for bore sealant on crankshaft seals
2005 to 2019
Federal-Mogul Powertrain, Manager, Process Design
Plymouth and Ann Arbor, Michigan
Directed and motivated process design team to optimize chemical and materials processes for sealing systems division—in support of 10 manufacturing locations producing $1B in sales—across three continents. Led complex projects with goal of improving division-wide process capability and quality; tracked completed projects to ensure positive impact on plant performance measures (safety, quality, throughput, and cost.) Initiated cross-functional collaboration to define current and future processes for new product and manufacturing strategies.
- Conceptualized and implemented molding process and quality systems for new engine seal product—worth $10M in annual revenue
- Established inventive manufacturing process with valve-gated injection molding for new engine seal and transmission bonded piston programs
- Secured potential company savings of $400K/year via development of process for treating PTFE to improve rubber adhesion to various materials
- Synthesized process for coating exhaust gaskets with reclaim of overspray of coating
- Motivated and guided talented team to devise optimized new process for molding elastomeric magnets and mixing compounds to use across multiple encoder applications
1999 to 2005
Federal-Mogul Powertrain, Materials Engineer
Ann Arbor, Michigan
Developed rubber and PTFE formulations for use in automotive sealing applications—specifically engine and transmission sealing. Led and trained cross-functional team in test process implementation, rubber compound testing, and manufacturing procedure optimization for elastomer molding processes and seal inspection. Ensured all formulations aligned with customer requirements. Researched new materials and processes to enhance company’s technical and financial competitive advantage.
- Forged supplier partnership to invent process that improved fuel vapor resistance of elastomeric gaskets by 30%—without a significant cost hike
- Produced novel PTFE compound for supercharger applications, and garnered a 25% increase in wear resistance
- Spearheaded development of in-house process to manufacture free-flowing PTFE compounds; captured annual savings of $500K
- Led training of quality engineers and technicians in rubber compound evaluation to determine acceptability—and improve understanding of materials—as part of assignment in Kunsziget, Hungary (summer 2004); designed quality inspection processes for facility for incoming rubber compound, evaluated storage conditions and safety procedures, and made strategic recommendations for change
Earlier Career Experience:
Federal-Mogul Powertrain Senior Process Engineer, Process Engineer
Education
- University of Cincinnati, Cincinnati, Ohio, Bachelor of Science, Chemical Engineering
Patents
- Substrate and Rubber Composition and Method of Making the Composition (2016, # 9382451)
- Method of Fabricating a PTFE Seal Element and a Shaft Seal Assembly Therewith (2013, # 8343370)
- Substrate and Rubber Composition and Method of Making the Composition (2012, # 8182646)
- Gasket Containing Fuel Permeation Barrier (2009, # 7574990)
- Integrated Sensor-Seal Module for Detecting Angular Position of a Crankshaft (2008, # 7341257)
Affliations
- ACS, Rubber Division
- Detroit Rubber Group
- Michigan Rubber Group