Services

Ceramic Engineering—an intricate discipline within Materials Science and Engineering—demands the harmonization of numerous interdependent variables, from raw materials and processing routes to microstructural evolution and long-term performance in service environments. Successful design and failure mitigation require a deep, system-level understanding of material behavior, process dynamics, and the interplay of manufacturing conditions.

Dr. Carty brings a rare and exceptional caliber of expertise to this field. His career synthesizes decades of academic research, industry-sponsored projects, and practical experience solving complex challenges in diverse manufacturing and application contexts. Having consulted for over 300 companies across traditional and advanced ceramic sectors, Dr. Carty is known for applying meticulous analytical reasoning and diagnostic clarity to identify root causes and devise technically sound, durable solutions.

Technical Consulting: Process Development and Diagnostics

Dr. Carty specializes in high-level manufacturing consulting—particularly process development, failure diagnosis, and quality optimization. Known for his systems-thinking approach, he consistently isolates the primary variables that govern product outcomes rather than merely treating symptoms. His background spans raw materials (ore beneficiation, feed processing, comminution and sizing, quality control), traditional ceramics (tableware, sanitaryware, tile, electrical insulators), and high-performance ceramics (aerospace, electronics, batteries, automotive, and beyond).

A hallmark of his consulting practice is the precise identification of process-induced defects using advanced techniques such as fractography, microstructural imaging, and mineralogical assessment. His advice is grounded in data, honed by years of hands-on experience, and always framed with an engineer’s eye for practical implementation.

Expert Witness (patent, trademark, insurance claims, etc.)

Dr. Carty has provided authoritative testimony in cases involving patents, trademarks, trade disputes, insurance claims, and product liability. His technical scope includes ceramic and glass materials, catalysts, industrial and artistic product failures, and performance degradation mechanisms. His testimony is recognized for its clarity, scientific rigor, and impartiality.

Analytical Testing

With over 30 years of laboratory experience, Dr. Carty offers advanced analytical testing with an emphasis on holistic data interpretation. He has developed unique approaches for correlating test results across multiple techniques to ensure consistency and uncover anomalies. Available capabilities include:

Powder and Suspension Characterization:

  • Particle size distribution (X-ray sedimentation)
  • Surface area (BET analysis)
  • Density (He-pycnometry)
  • Particle packing efficiency and green body density
  • Surface chemistry (pH, etc.)
  • Rheological behavior
  • Flow characteristics (custom analysis available)
  • Chemistry (via trusted external partners)
  • Forming body formulations

Ceramic Material Analysis:

  • Fractography and failure analysis
  • Microstructural evaluation
  • Mineralogical analysis (qualitative and quantitative)
  • Phase and microstructure evolution studies (tailored to specific need)

Educational Offerings: Workshops & Short Courses

Dr. Carty’s educational programs are recognized for their technical depth, clarity, and adaptability to specific client needs. Programs are typically offered as 3- to 5-day modules and can be scheduled flexibly over a multi-week period. Each session is carefully designed to bridge foundational theory with hands-on, application-driven insight.

Available Courses Include:

  • Introduction to Ceramic Materials
    Tailored for non-ceramic engineers or cross-disciplinary teams, this course covers the distinct physical and thermal behaviors of ceramics, the fundamentals of powder processing, and the underlying principles of ceramic fabrication, and an introduction to drying and sintering.
  • Ceramic Processing and Firing
    Designed for engineers and scientists, this course covers the end-to-end processing of ceramic materials—from powder handling and forming to drying, sintering, and quality control—emphasizing process-structure-property relationships.
  • Defect Elimination in Ceramic Manufacturing
    This intensive course examines root causes of ceramic defects, drawing connections between mechanical stress evolution and processing steps. Real-world case studies and participant samples are integrated into the discussions.
  • Phase Diagrams in Ceramic Design
    This course demystifies phase diagrams, showing how to interpret them for both equilibrium and non-equilibrium systems. Focus is placed on using phase data to predict mineralogy, microstructure development, and processing outcomes.
  • Ceramic Science for Artists
    A unique fusion of art and science, this hands-on course explores the chemistry and physics behind glaze formulation, firing behavior, and defect mitigation. Ideal for studio artists looking to elevate technical control in their craft.