Michael Hayes, Ph.D., P.E. Email & Phone Number

VP and Member of Board of Directors at ESE Carbon, the first manufacturer of one-piece carbon fiber composite automotive wheels in North American. Led the Engineering Department, consisting of Product Development and Mold Design Teams. Worked with CEO/President and Business Development to explore new business opportunities and set direction of new product development. Co-developed the “E3” wheels. Played key role in winning and managing development projects for eVTOL, commercial trucking, and military customers. Managed DOE-funded “LightMAT” grant that partnered company with Oak Ridge National Laboratory (ORNL) to develop a material property database for our laminates. Served on task force for SAE J3204 Aftermarket Composite Wheel Recommended Practice and SAE J175 “Lateral Impact” working group. Served on SAE Wheel Committee.Other highlights: Our team developed a 22.5” x 8.25”all-composite truck wheel for commercial and military applications, weighing just 31 lbs, a 30% weight savings vs. the current aluminum wheel. The wheel met all testing requirements in the initial project scope, as well as a stretch goal for radial fatigue per SAE J1992. We also developed a 19.5 lbs all-composite 2-piece wheel for the U.S. Army’s High Mobility Multipurpose Wheeled Vehicle (HMMWV) with a wheel load rating of 4540 lbs (load range “E”) through a partnership with ACP-T as part of a program funded by NCMS (The National Center for Manufacturing Sciences), achieving a high Technological Readiness level.

Co-invented the "E2" carbon fiber wheel (patent filed) and led design & layup improvements to pass all requirements of SAE J2530, J328, J175, & J2562. Built out the company’s Product Development processes, including Finite Element simulation of laboratory wheel tests. Managed the Product Development team consisting of Mechanical Engineers and Stress Analysts. Provided root cause analysis support to Manufacturing to address process-related problems in lay-up, tool closure, infusion, cure, post-curing, coatings, and ancillary metallic mounting hardware. Interfaced with resin and chemical suppliers to solve processing and performance related issues. Managed laboratory and proving grounds testing and postmortem analysis of prototype wheels.

Developed familiarity with SAE Recommended Practices for Wheels. Analyzed existing "E1" wheel and recommended design changes to improve fatigue life. Served as in-house authority for mechanics and materials related issues, including the application of micromechanics models, laminate theory, stress analysis, finite element analysis, composite failure models, and damage theories to guide wheel design. Guided and interpreted performance testing of wheels. Introduced and managed the use of non-destructive test (NDT) methods to assess manufacturing quality and diagnose failure modes. Coordinated material testing with laboratory.

Aurora, Il, Us

Provided engineering consulting services in failure analysis, product development, and general mechanical & structural analysis to manufacturers, insurance companies, and attorneys. Led large-scale, multidisciplinary consulting engagements across a wide range of products, applications, and industries. Court-recognized expertise in both Mechanical Engineering and Materials Science (esp. Polymers & Composites). I was occasionally called on to present my findings via sworn testimony in matters pending before both state and federal courts.

Provided consulting services in failure analysis, forensic engineering, applied mechanics

Houston, Tx, Us

Provided consulting services in product development/improvement, stress analysis, and general engineering analysis.

Clermont-Ferrand, Auvergne-Rhône-Alpes, Fr

Supported tire designers and manufacturing plants in issues related to metallic and textile reinforcements and associated rubber compounds.

Ph.D., Engineering Mechanics

M.S., Engineering Mechanics

B.S., Engineering Science And Mechanics