Learn more about Mack Molding, a 90+ year-old company that supplies custom plastic injection molding and contract manufacturing services to a variety of industries. 10 locations. ISO 13485. ISO 9001.
2. WHO WE ARE
Full-service contract manufacturer
Specializing in…
Custom injection molding
Painting
Metal fabrication
Machining
Assembly
Offering product development resources…
Product design
Prototyping
Engineering services
3. WHO WE ARE
Founded in 1920 – privately owned & operated
Headquartered in Arlington, Vermont
Three operating divisions, 10 locations
~1800 employees
Annual sales: $260 million
No long-term debt, 5A1 D&B rating
Certifications
ISO 9001
ISO 13485 (Mack North, Mack Prototype, Mack Technologies)
ISO 14001 (Mack South)
AS9100 (Mack Technologies)
ISO/TS 16949 (Mack South)
FDA Registered (Mack North)
4. Mack Molding - North
Mack Molding/MackMedical
Product Development
Plastic Molding
Metal Fabrication
Paint and Assembly
Contract Manufacturing
Mack Prototype
Mack Molding - South
Plastic Molding
Class A paint
Assembly
Mack Technologies
Electronics Contract
Manufacturing
SMT, Turn-key System
Integration, PCB/System
Level Test Development
MACK
Group SLA Rapid Prototyping
Fused Deposition Modeling
CNC Machining
LIM Cast Urethane
Low-volume Injection
Molding & Manufacturing
CORPORATE STRUCTURE
5. Mack Technologies
Westford, Massachusetts
Melbourne, Florida
Juarez, Mexico
Mack North
Arlington, Vermont (2)
Cavendish, Vermont
Pownal, Vermont
Mack South
Statesville, North Carolina
Inman, South Carolina
Mack Prototype
Gardner, Massachusetts
LOCATIONS
6. WHAT WE DO
Contract manufacturing
Product design & development
Rapid prototyping & low volume
manufacturing
Custom injection molding
Cleanroom molding
Finishing & assembly
Sheet metal fabrication
Full-service machining
Medical Class II/Class III
contract manufacturing
7. DESIGN & DEVELOPMENT
Application
Development Center
Engineering analysis
Supply base selection
and management
Material and process
selection
Tool design and
management
8. DESIGN & DEVELOPMENT
Interactive feedback with
designers
Mechanical design
Design for manufacturing
Moldflow
Finite element analysis
Process selection
17. INJECTION MOLDING
Molten plastic injected into a
mold under high pressure
Fast cycles
3-5 ton/sq in clamp required
Lowest part weight
Good surface finish
Low molded-in stress
18. STRUCTURAL FOAM MOLDING
Molten plastic injected with a
chemical blowing agent
Short shot process
Thicker part wall required
Low stress
Slow cycles
¼ - 1 ton/sq in clamp required
Reduces sink issues
Rib-to-wall ratio can be greater
Poor surface finish; lots of swirl
Heavier part weight
19. GAS COUNTERPRESSURE
Structural foam shot into a
pressurized cavity
Improved surface finish over
structural foam
Cavity pressure holds out-
gassing in check
Slightly heavier part than
structural foam
Slightly slower cycle
Higher tool cost & maintenance
20. INTERNAL GAS-ASSIST
Gas confined within the part
Reduces sink
Reduces stress
Reduces press tonnage
required
Longer flow lengths can
eliminate need for manifolds
Licensed for any application
21. EXTERNAL GAS-ASSIST
Gas is pressurized between the
core steel and the part
Reduces sink
Reduces stress
Must be confined by using core
side part design
26. FINISHING & ASSEMBLY
Automated
Cleanroom
Heat staking
Testing
Ultrasonic
Laser welding
Inserting
Work cell
RFID tagging
Assembly Decorating
Heat sealing
Heat transferring
Hot stamping
Laser marking
Pad printing
Silk screening
Painting
Decorative
Conductive
Robots
Automated
Overhead lines
Walk-in booths
Class A
CNC machining
Swiss lathes
Integrex turning &
machining ctr
14” optical
comparator
CAD/CAM
Ultrasonic parts
washing
Vibratory tumble
Machining
27. PREMIUM CLASS ‘A’ PAINT SYSTEM
11,000-sq-ft enclosed HEPA
filter environment
1200’ of conveyor supported
from underside of parts using
175 paint racks
Ultra high filtration 5-station
wash & rinse system
Color changes <5 minutes
3 Fanuc model 250i paint
robots
Electrostatic or HVLP
Infrared/convection curing
ovens
28. PREMIUM CLASS ‘A’ PAINT SYSTEM
HEPA filtered air
Dust & dirt free environment
Underside part support
Reduces scrap generated by
standard overhead systems
5-station wash system
Insures clean surfaces
Electrostatic paint system
Ransburg rotary atomizer
improves transfer efficiency and
final finish quality
Infrared curing ovens
Reduce air movement
Improve first pass yield
29. SHEET METAL FABRICATION
State-of-the-art soft-tooled
fabrication
Complete laser, punching &
forming for NPI & production
requirements
Product development focus
featuring rapid prototype
development
32. SHEET METAL CASE STUDY
Commercial High-tech Blender
86 unique metal parts
Stainless steel construction
Multiple gauge materials
Riveted assembly
Laser cutting/punching
Metal forming
Hardware insertion
33. SHEET METAL CASE STUDY
Commercial Mail Sorting System
34 unique metal parts
CRS, pre-plated, stainless steel
Thicknesses range from 18-10 gauge
Part size: 2”x2” to 48”x96”
Laser cutting/punching/forming
Tapping
Hardware insertion
Welding: Spot, MIG
Metal finishing
34. MACHINING
Milling & turning
Small parts
Parts with long length-to-
diameter ratios
Complex parts
35. DONE-IN-ONE MILLING
Mazak Integrex Mark IV
Turning & machining in a
single setup
40-tool capacity
Touch probe tool setter
KM63 dual contact tool
connection
2” thru-capacity
LNS Servo 65 bar feeder
36. CITIZEN SWISS LATHES
Two Citizen A20VII lathes
Seven-axes, 20mm
machines
21 tools
C-320 bar feeders
3-20 mm barstock capacity
+0.0000”/-0.0005” precision
ground stock
Minimized cycle times via
simultaneous main & sub-
spindle processes, 32
m/min rapid feed rates
37. AUXILIARY EQUIPMENT/SOFTWARE
Ultrasonic parts washing
Vibratory tumble
deburring
14” optical comparator
Surface finish analyzer
Fully integrated
CAD/CAM
Part-Maker -- From solid
model to complete 3D
simulation to machine G-
code (Swiss & Integrex)
MatrixCam – Offline
conversation programming
(Integrex)
38. CONTRACT MANUFACTURING
Program management
Global supply management
DFM/DFT
FMEA
Electronic integration & test
Order fulfillment &
distribution
39. PROJECT TEAM
Program
Manager
Supplier Selection /
Management
Tooling
Prototyping
Design
Order Fulfillment
Manufacturing
Services
Plastic Molded
Products
Soft Tool Metal
Product Assembly
Quality & Regulatory
Compliance
40. Mack Technologies
Westford, MA
Melbourne, FL
Juarez, Mexico
Mack North
Arlington, VT (2)
Cavendish, VT
Pownal, VT
Mack South
Statesville, NC
Inman, SC
Mack Prototype
Gardner, MA
MARKETS WE SERVE
Medical
Devices
Disposables
Instrumentation
Transportation
Heavy truck parts
Recreation/utility vehicles
Computer &
business equipment
Consumer
Defense/aerospace
Energy
Batteries
Solar-powered products
Fuel cell technology
Industrial
Structural HVAC
Furniture & seating
Industrial & building
supplies
Lawn & garden
42. CLEANROOM MOLDING
Class 100,000 molding
cleanroom
Installation complete, 12/11
Dedicated to reusable &
disposable medical
applications
46’ x 44’ modular design
Removable panels to allow for
future expansion
Dual air-lock doors, 8’ wide
Rapid roll-up doors
Ease of product flow, tool changes
43. CLEANROOM PRESSES
Six Toshiba 110-ton electric
presses
60% less energy consumption
than hydraulic
High-precision machines
Outfitted with high pressure
water controllers
More versatility in resin selection
44. ENVIRONMENTAL MONITORING
Gowns/personal protective
equipment required
Particulate airborne
monitoring according to
ISO 14644-1 standard
Particulate control plan
includes:
Alert level
Action level
Ensure compliance with
GMPs
45. WHITEROOM PRESSES
Currently operational
Adjacent to new Class
100,000 molding
cleanroom
Engel hydraulic presses
Low-volume, multi-color
products requiring quick
resin/tool changes
24-hour operation for
orthopedic trials, medical
disposables
46. CLEANROOM ASSEMBLY
Class 100,000 cleanroom
assembly
30’ x 70’
Non-sterile packaging for
medical disposables
Light sonic weld assembly
Temperature & humidity-
controlled functional
testing
47. CONTRACT MANUFACTURING
Project management
Supply management
Regulatory compliance
DHF/DMR/DHR management
Design verification
Process validation
Training
DFM/DFT
Order fulfillment/distribution
48. QUALITY ASSURANCE CONTROL
Quality system
21 CFR 11 & 820 compliant
Electronic DMR & DHR retention
Advanced product quality
planning
Process flow diagrams
Risk assessment/pFMEA
Control plans
Dynamic control plans
50. DEVICES
Class II/Class III PMA products
FDA registered
Clean room molding & assembly
White room molding
Complaint investigation
Obsolescence management
FRU/kitting
51. CASE & TRAY SYSTEMS
Custom designs based on OEM
requirements
Validated manufacturing process
Plastic, stainless steel, titanium &
aluminum
Laser welding
Hermetically sealed weld bead
Free of gas, air, contaminants
JIT stocking arrangements with full
lot code
Complete kitting and ship-to
distribution services
53. CASE STUDY
Therapeutic Device, Photopheresis
Class III PMA device
1,921 total components
616 unique components/80 suppliers
49 subassemblies
Dedicated work cell
Dedicated product support team
8 functional tests
54. CASE STUDY
Therapeutic Device, Photopheresis
Class III PMA device
1,400 total components
358 custom parts/65 suppliers
18 subassemblies
Component qualification
Dedicated work cell
Dedicated product support team
10 functional tests