Dr. Panchal is currently developing next-generation in-mold sensing technology for the plastics injection molding industry especially for the medical device, automobile and high precision molded parts manufacturers.

I joined Abbott in March 2012 as a part of global pharmaceutical operations (GPO). GPO was spun off into new company- AbbVie in Jan 2013.I am a part of Combination Products division of Science & Technology (S&T) area. Primary focus of Combination Product division is to support Operations group by development, innovation & assessment of new technology, problem solving etc. related combination products/ devices.Currently I am supporting design and development of drug delivery systems like auto-injectors for Humira (Drug to treat Rheumatoid Arthritis, Crohn’s disease, & Psoriasis and drug delivery pump for DuDopa ( drug for Parkinson's disease). I am heavily involved with the device testing, device component manufacturing, mold development and validation.I manage projects related to new/ alternate material selection, rheology & mechanical properties characterization of the polymeric materials, and validation of multi-shot and multi cavity tools with hot runner systems. I work closely with outside vendors as well internal customer to communicate and fulfill the technical requirements, provide technical guidance including but not limited to print review, tool design review, generating 3D-2D database, process development, trouble shooting, statistical analysis support, and documentation.Also, I support and manage projects related to product design, prototyping , product design & tool design evaluation using MoldFlow simulations. I support the activities related to design for reliability, manufacturability and assimilability, and design verification and validation testing prior to market launch.I am the first team member who introduced and successfully implemented the in-mold sensing technology for new device component molds. Also, I successfully introduced, implemented and validation the real time multivariate analysis technology for injection molding using MKS SenseLink. These projects have demonstrated significant cost saving as well quality improvement.

My major job function was to provide a technical support to all injection molding related activities like coordinating with vendors for production set up/ schedule, process validation and re-validation, cycle time and yield improvement, tool development and maintenance, quality check for multi cavity(16-32 cavities) molds as well to provide technical support to internal R&D and automation departments for new product development, new resin selection, new / existing assembly line trouble shooting. This company was been acquired by BD in Jan 2012 and then after it was shut down permanently.

- Handled new injection molded part development projects for implantable medical devices like pace makers, ICDs etc. I worked in multiple cross functional teams having team members from various technical disciplines. I developed FMEAs, FTAs, injection molding process for insert molding, SOPs, inspection methods, GR&R, DOEs, process validation plans & reports, etc. for polymer part development and validation according to FDA regulations as well Medtronic quality requirements.Also provided technical expertise in catheter extrusion line trouble shooting, thermoforming, print reviews, GD&T, new technology brain storming, etc. I received extensive training in statistics and design for reliability and manufacturability (DRM).

Vaidation of closed loop process monitoring system for the injection molding process.Validation of the multivariate analysis concept for injection molding.

Research Assistant - Worked on several projects besides MS and PhD research work.Evaluation of Photo chromatic die based Cellulose Butyrate Acetate compound for lenses. Developed the extrusion processes for various compounds, as well for PC-PET blends.Recycling of plastics waste.Polymer rheology characterization using capillary rheology, MFI.Lead installation of new injection molding machines, process monitoring systems like ShotScope, RJG eDart, Primus, Kistler, MKS SenseLink etc.Teaching Assistant:Provided the injection molding, extrusion and other lab training to new Teaching Assistants.Taught injection molding process development, process monitoring and quality control lab.

Process Validation according to FDA regulation - Supported IQ, PQ, OQ, SPC, SQC activities and executed process development, DOE, Molding window selection for OQ.

I was the first employee of Fine Care and started the auto-pipette development project.Where I,Lead Design, development and commercialization of auto-pipette.Successfully designed and developed the auto-pipette for various micro liter volume ranges - 0.5-5 uL, 5-50 uL, 50-200 uL, 200-1000 uL etc. as well several fixed volume auto-pipettes. Successfully executed the market launch.

Tool Design - press tools, injection molds, gauge, fixtures, special cutters etc. for new product development (Bearing Cages - sheet metal, brass, copper, plastics etc...)