Steven MacLean
Steven B. MacLean, Ph.D., P.E.
Principal Engineer
Polymer Science & Materials Chemistry
  • Bowie

Dr. MacLean’s research is focused on the chemical and physical behavior of polymeric materials in end-use applications. His specialties include part design and analysis, failure analysis, material specification, testing and patent analysis. He has studied various polymer failure mechanisms including stress overload, creep rupture, fatigue, environmental stress cracking, delamination and weathering. Throughout his career he has evaluated the suitability of materials for the automotive, sporting goods, medical device, industrial equipment, consumer products, electrical, pipe, and construction industries. Dr. MacLean assists clients in assessing risk in all stages of product life including product development, reliability testing and long-term field performance.

Dr. MacLean is well-versed in product recall investigations led by the Consumer Product Safety Commission (CPSC), the National Highway Traffic Safety Administration (NHTSA) and the National Transportation Safety Board (NTSB). He is familiar with the processes of each federal agency regarding the investigation, analysis, and remedies of underperforming products and components. Dr. MacLean is also familiar with testing and material standards published by ASTM International, International Standards Organization (ISO), Underwriters Laboratories (UL), International Electrotechnical Commission (IEC) and the Society of Automotive Engineers (SAE).

Over the past 20 years, Dr. MacLean has worked on numerous projects related to polymer and composite manufacturing processes including injection molding, compression molding, blow molding, rotational molding, extrusion, fiber spinning, thermoforming, and laminating. In addition, he has investigated failures related to secondary operations used throughout the plastics industry such as metallic plating, adhesive joining, painting and welding.

Prior to joining Exponent, Dr. MacLean spent 16 years in the plastics industry at General Electric (GE) Plastics and SABIC Innovative Plastics where he held several technical and leadership positions of increasing responsibility. His activities included material selection and testing for high-demand applications, product safety assessments, failure analysis, and intellectual property analysis.

CREDENTIALS & PROFESSIONAL HONORS

  • Ph.D., Materials Science, University of Rochester, 2007
  • M.S., Materials Science and Engineering, Rochester Institute of Technology, 2001
  • M.E., Mechanical Engineering, Rensselaer Polytechnic Institute, 1997
  • B.S., Mechanical Engineering, Rensselaer Polytechnic Institute, 1993
  • Tau Beta Pi

    Pi Tau Sigma

    Society of Plastics Engineers ANTEC Best Paper Award

LICENSES & CERTIFICATIONS

Licensed Professional Engineer, New York, #16-079001

Licensed Professional Engineer, Maryland, #41593

National Council of Examiners for Engineering and Surveying, Record #47204

Certified Six Sigma Black Belt

Publications

Benight S, MacLean S, Garcia M, Moll, J. Microscopy of intentionally oxidized polypropylene-based mesh material. Proceedings, ANTEC, 2016.

MacLean SB, et al. Fractographic examination and tensile property evaluation of 3D printed acrylonitrile butadiene styrene (ABS). Proceedings, ANTEC, 2015.

MacLean SB, et al. Fractographic examination of failures in polycarbonate and polyoxymethylene due to impact, tensile, fatigue and creep mechanisms. Proceedings, ANTEC, 2013.

MacLean SB, et al. Comparison of mass transit material flammability requirements and trends for aircraft and train applications in Europe and North America. Proceedings, ANTEC, 2012.

MacLean SB, et al. Comparison of mass transit material flammability requirements and trends for aircraft and train applications in Europe and North America. Proceedings, EUROTEC, 2011.

MacLean SB, et al. Root cause investigation of cracked polycarbonate blender jars. Proceedings, ANTEC, 2010.

MacLean SB. Plastics, electronics and the environment: How new global regulations affect material choices. Kunststoffe International 2008 Sept; 97–100.

MacLean SB. Plastics, electronics and the environment: How new global regulations affect material choices. Telepati Aylik Telekom 2008 Mar; 74–77.

MacLean SB, et al. Monolayer barrier for small engine fuel tanks. Plastics Technology Online 2007 June.

MacLean SB. Environmental effects of poly(phenylene ether) blends due to long-term exposure to potable hot water. Ph.D. Dissertation, University of Rochester, 2007.

MacLean SB, et al. The effects of recycling and heat history for select high polymers. Proceedings, ANTEC 2001.

MacLean SB, et al. Poly(phenylene ether) engineering thermoplastic provides creep resistance, toughness and fire resistance required for high performance pallets. Proceedings, ANTEC 2000.

Presentations

MacLean SB, Moll J. The importance of polymer structure-property relationships in preventing failure in medical devices. Medical Grade Polymers Conference, Woburn, MA, 2015.

MacLean SB. Fundamentals of plastics fractography. ANTEC, Cincinnati, OH, 2013.

MacLean SB. Challenges associated with replacing metal with plastic. Material Science and Technology Conference, Pittsburgh, PA, 2012.

MacLean SB, et al. Fractography of unfilled thermoplastic materials subjected to common mechanical failure modes. Material Science and Technology Conference, Pittsburgh, PA, 2012.

MacLean SB. Common analytical techniques for failure analysis – A Resin Manufacturer’s Perspective. ANTEC, Boston, MA, 2011.

MacLean SB, et al. Plastic failure analysis and prevention expert panel. ANTEC, Boston, MA, 2011.

MacLean SB. Root cause investigation of cracked polycarbonate blender jars. ANTEC, Orlando, FL, 2010.

MacLean SB. Diffusion of potable hot water in poly(phenylene ether) blends. American Chemical Society Conference, Binghamton, NY, 2006.

MacLean SB. Changes in polycarbonate and ABS mechanical properties due to multiple heat histories. Society of Plastics Engineers ANTEC, Dallas, TX, 2001 (with Korzen).

MacLean SB. Yield Improvement for gas assist panels using statistical methods. Society for the Plastics Industry Conference, Vancouver, BC, 2000.

MacLean SB. Design methodologies for metal to plastic conversion. General Electric Plastics Innovation Seminar, Columbus OH, 2000.

MacLean SB. Fundamentals of polymer science. General Electric Plastics Customer Design Workshop, Pittsfield, MA, 1998, 1999.

MacLean SB. Designing for injection molded parts. General Electric Plastics Customer Design Workshop, Pittsfield, MA, 1998, 1999.

MacLean SB. Mechanical behavior of polymeric materials. General Electric Plastics Engineering Workshop, Pittsfield, MA, 1997.

Prior Experience

Director, Global Agency Relations & Product Safety, SABIC Innovative Plastics, 2007–2011

Global Technical Manager, General Electric Plastics, 2003–2007

Six Sigma Black Belt, General Electric Plastics, 2001–2003

Senior Application Development Engineer, General Electric Plastics, 1998–2001

Plastic Design and Analysis Leader, General Electric Plastics, 1996–1998

Edison Engineer, Lockheed Martin Corporation, (Formerly General Electric Aerospace), 1994–1996

Professional Affiliations

Society of Plastics Engineers (Senior Member)

SPE Failure Analysis & Prevention Group – Board Member and Treasurer

ASTM D20 Plastics Committee Member

Knowledge

News & Events

CREDENTIALS & PROFESSIONAL HONORS

  • Ph.D., Materials Science, University of Rochester, 2007
  • M.S., Materials Science and Engineering, Rochester Institute of Technology, 2001
  • M.E., Mechanical Engineering, Rensselaer Polytechnic Institute, 1997
  • B.S., Mechanical Engineering, Rensselaer Polytechnic Institute, 1993
  • Tau Beta Pi

    Pi Tau Sigma

    Society of Plastics Engineers ANTEC Best Paper Award

LICENSES & CERTIFICATIONS

Licensed Professional Engineer, New York, #16-079001

Licensed Professional Engineer, Maryland, #41593

National Council of Examiners for Engineering and Surveying, Record #47204

Certified Six Sigma Black Belt