Academic Credentials
  • 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
Licenses & Certifications
  • Professional Engineer Mechanical, Arizona, #80192
  • Professional Engineer, Maryland, #41592
  • Professional Engineer, New York, #79001
  • Professional Engineer, Pennsylvania, #PE097089
  • Six Sigma Black Belt Certification (CSSBB)
Academic Appointments
  • Worcester Polytechnic Institute Department of Mechanical & Materials Engineering, Adjunct Professor, 2025
Professional Honors
  • Tau Beta Pi
  • Pi Tau Sigma
  • Society of Plastics Engineers ANTEC Best Paper Award
Professional Affiliations
  • Society of Plastics Engineers (SPE) Senior Member
  • SPE Medical Plastics Division Member
  • ASTM D20 Plastics Committee Member
  • Plastic Pipe Institute (PPI) Member

Dr. MacLean is the practice director and a principal engineer in Exponent's Polymers & Chemistry practice. Combining his degrees in polymer science and mechanical engineering with his industrial experiences, he routinely assists clients on complex issues related to the design, development, durability, failure analysis, and intellectual property of end-use applications manufactured from polymeric materials, with an emphasis on load-bearing components and structures.

Dr. MacLean has investigated various polymer failure mechanisms including stress overload, creep rupture, fatigue, environmental stress cracking, delamination, dielectric breakdown, and weathering. For over 30 years, he has evaluated the formulation-structure-property relationships and the suitability of thermoplastics, thermosets, rubbers, elastomers, and polymer composites used in a variety of industries including automotive, sporting goods, medical and drug delivery device, consumer products, oil and gas, alternative energy, electrical, fluid handling, and construction. Dr. MacLean also assists clients in assessing risk in all stages of product life, including product qualification, reliability testing, quality control, and long-term field performance, and he routinely conveys his findings to entities including technical decision makers, government regulators, arbitrators, and juries.

Polymers and composites failure analysis

Dr. MacLean is a recognized expert in the field of failure analysis, having performed hundreds of root-cause investigations related to component parts manufactured from polymeric materials. For regulated products, he is well versed in product assessment and recall frameworks established by the U.S. Food and Drug Administration (FDA), 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, the International Organization for Standardization (ISO), Underwriters Laboratories (UL), the International Electrotechnical Commission (IEC), the Society of Automotive Engineers (SAE), and others. He leverages his Six Sigma skills and failure modes and effects analysis (FMEA) training when assessing product manufacturing processes and field performance issues.

Intellectual property for polymeric finished goods

Dr. MacLean has extensive experience in intellectual property matters involving polymers, specializing in patent infringement and validity assessments as well as trade secret and inventorship disputes. He also routinely assists clients with claim construction and Markman hearing preparation for complex IP matters. Dr. MacLean has provided testimony across a wide range of venues, including federal district courts, international arbitration panels, the International Trade Commission (ITC), and the Patent Trial and Appeal Board (PTAB).

Product manufacturing

Over the past 30 years, Dr. MacLean has worked on a variety of finished goods produced from polymer and composite manufacturing processes including injection molding, compression molding, blow molding, press blow molding, blown film, rotational molding, extrusion, fiber spinning, thermoforming, calendaring, and laminating. In addition, he has investigated material systems that include secondary operations such as metallic plating, coatings, adhesives, paints, and welding.

Industry experience

Before joining Exponent, Dr. MacLean worked in industry at General Electric Aerospace, General Electric Plastics, and SABIC, where he held several technical and leadership positions of increasing responsibility. His responsibilities included product development, material formulation, processing and selection, testing for high-demand applications, product safety and compliance assessments, failure analysis, and intellectual property analysis.