Staff

Dr. Troy A. Hayes is a Principal Engineer in Exponent’s Materials and Corrosion practice. He is currently the General Manager of Exponent Science and Technology Consulting (Hangzhou) Co. (Exponent China), which is a subsidiary of Exponent Inc. Dr. Hayes has extensive experience solving complex technical problems in a variety of industries including consumer products, medical devices, vehicles, industrial equipment, and technology product development. He conducts technology due diligence reviews of emerging technologies and intellectual property (IP) for investment firms, IP owners, and companies interested in purchasing IP or the associated products.

Dr. Hayes’ consumer product work includes design reviews, targeted testing of new products before they are introduced into the marketplace, management of product and process changes during the course of production, use of risk methodologies, substantiation of product performance claims, failure analysis of field-returned products, consumer product recall-related investigations, and product liability. He often works with companies addressing the technical aspects of consumer product recalls.

He routinely performs failure analysis investigations on both commercial and industrial products, and addresses issues related to the mechanical behavior and degradation of materials including metal, polymer, and glass components. He has expertise in the areas of materials characterization, fatigue, fracture, and creep.

Dr. Hayes conducts engineering audits for processes such as battery cell manufacturing and battery pack assembly, consumer electronics assembly, printed circuit board assembly (PCBA), chemical etching, injection molding, and metal casting and forming. The focus of such audits is to improve the quality, reliability, and safety of the products and minimize reject rates through a detailed evaluation of the equipment, processes, and quality control in the factory.

Dr. Hayes works extensively on projects involving battery design, manufacturing, and failure analysis. In addition to performing root cause analyses of portable consumer products involving battery failures, he has conducted more than 30 on-site audits of battery manufacturers. He assists clients by conducting design reviews of batteries and battery packs to evaluate the potential for safety issues or field failures. Dr. Hayes also helps many clients evaluate and choose vendors that can produce batteries with the quality and safety that the client requires.

Dr. Hayes has performed accident reconstruction for automobile, tractor-trailer, heavy equipment, elevator, train, motorcycle, and bicycle accidents. He has performed numerous investigations of industrial accidents including evaluations of the proper use and effectiveness of personal protective equipment (PPE).

Before joining Exponent, Dr. Hayes served as a Senior Scientist with The Institute of Risk & Safety Analyses in Woodland Hills, California. He has successfully qualified and testified as an expert in trials, depositions, and arbitrations in California and Nevada.

Read more about Troy Hayes on Exponent, Inc.