Michael D. Hayes

Michael D. Hayes, Ph.D., P.E.

Senior Consultant

Dr. Michael Hayes specializes in the analysis of mechanical parts and structural systems, failure analysis, polymers (plastics) and composites, applied mechanics, materials engineering, product development and support, durability and life prediction, and finite element analysis (FEA).

He has led complex, multidisciplinary investigations involving a wide range of materials and applications, including consumer products, packaging, medical devices, construction materials, plumbing, civil/structural, automotive, railroad, and heavy equipment.

His technical interests include solving problems at the intersection of engineering mechanics and materials science, and utilizing advanced engineering concepts and cutting-edge tools to provide simple answers to his clients. Dr. Hayes has provided testimony in matters pending before both state and federal courts.


  • Fractography in Failure Analysis of Polymers, 1st Edition, Elsevier Inc., printed by Edwards Brothers Malloy, January 2015
  • Failure Analysis of a Glass Filled Phenolic Resin Power Steering Pump Pulley, Plastics Engineering Magazine, September 2015
  • Thermomechanical Analysis of a Ceramic Cooker, Journal of Failure Analysis and Prevention, January 2013
  • Development of a Ring Tensile Test for Evaluating the Chemical Compatibility of Plastic Pipes, ANTEC 2012, April 2012
  • Failure Analysis and Fatigue Life Prediction of a Composite Structural Beam, American Society for Composites Series on Advances in Composite Materials: Vol 3, Fatigue of Composite Materials, August 2012
  • Failure Analysis of Hydraulic Fitting Brazed Connections, ASM Journal of Failure Analysis and Prevention, April 2012
  • Challenges in Investigating Chlorinated Polyvinyl Chloride Pipe Failures, Journal of ASTM International, January 2011
  • Uses of Abaqus/Standard in Failure Analysis, SIMULIA Customer Conference, May 2009
  • Failure Analysis of a Hybrid Composite Structural Beam, Composites: Part A, January 2007
  • The Effect of Non-Classical Behaviors on the Measurement of the Timoshenko Shear Stiffness, Journal of Composites for Construction, January 2007
  • See CV for further publications

Project Experience

ESi's expertise spans dozens of industries and specializations organized across several practice groups, each staffed by dozens of in-house experts with the technical knowledge, hands-on expertise, and courtroom experience required to execute projects for and with our clients from start to finish.

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