Mack Molding, with the help of its new customer ZOLL Medical Corporation (NASDAQ: ZOLL), captured the first place award in the Medical/Scientific division, as well as the overall Conference Award, at the Society of the Plastics Industry’s (SPI) Structural Plastics Division conference this spring in Lake Buena Vista, Fla.

The winning application, the ZOLL AED Pro from ZOLL Medical Corporation, is an automated external defibrillator that is designed with advanced capabilities to support both Basic Life Support and Advanced Life Support professional emergency responders. ZOLL’s products are used globally in emergency medical settings, hospitals, and public venues as part of early defibrillation programs.

From a processing perspective, the unit is innovative because it is made of a combination of materials (polycarbonate, thermoplastic polyurethane, and thermoplastic elastomer) that will endure severe impact while keeping all working components intact. “We designed the AED Pro for extreme environments so that EMS personnel can focus on taking care of the patient rather than the device,” says Richard A. Packer, president and chief executive officer of ZOLL. “We are excited that ZOLL and Mack have been recognized by industry experts for this advanced design, as well as the innovative use of plastics.” With superior plastics and a solid overmolding, the AED Pro is the only AED in the industry to pass a 1.5-meter drop test. It also has an IP55 rating for dust and water resistance.

The defibrillator uses three different injection molding processes and three different materials in one compact package. Gas-assist, overmolding and insert molding are the processes used to mold 20 parts for the AED Pro. Gas-assist is used to fill out thick sections; insert molding provides a watertight seal for a clear window in a colored part; and overmolding is used for the gasketing and to provide a layer of impact-absorbing resin.

“These awards are particularly meaningful for Mack because they demonstrate our commitment to a strategic market shift initiated four years ago,” says Jeff Somple, president of Mack’s northern operations. “From a primary focus on the high-end sector of the computer and business equipment industry, Mack has now charted a new course toward large-part molding and overall market diversification with an emphasis on medical applications. Today, the medical field accounts for 25 percent of our customer base and sales, and we expect that to grow to 50 percent within the next few years.”

Contact: Jeff White, Program Manager
jlw@mack.com

Bonnie Simon and Tom Revane have joined Mack Molding’s headquarters plant in Arlington, Vt. Simon is manufacturing manager, where she will be responsible for all assembly and product manufacturing operations beyond plastics molding and sheet metal fabrication. She brings over 20 years of manufacturing management experience to the job, most of it in the medical-device arena. Previous employers have included Tyco and Mallinckrodt Medical. Simon holds a bachelor’s degree in business management/economics from SUNY Empire State College, Saratoga Springs, N.Y.

Tom Revane brings 25 years of injection molding experience to his new position as molding department manager. Most recently with Hussey Seating Company where he served as plastics engineering manager, Revane was responsible for a 100,000-sq-ft injection and blow molding facility. A graduate of the University of Massachusetts-Lowell, Revane holds a bachelor’s degree in industrial plastics.

Michael Fox has joined Mack in Statesville, N.C., as a tooling engineer, where he will be responsible for providing design support for all tooling requirements to ensure best possible part and mold design. He has 17 years of engineering and manufacturing experience with such companies as Oneida Molded Plastics, Tessy Plastics and Ace Precision Tool & Design. Fox is a plastics technology graduate of SUNY Morrisville, Morrisville, N.Y.

Terry Campbell is new to Mack’s Inman, S.C., facility, where he works as a manufacturing engineer. Previously with Seeber USA, Duncan, S.C., as an injection technology specialist, Campbell brings 18 years of plastics industry experience to the job. He is currently a plastics technology student at Greenville Technical College, Greenville, S.C., and has also completed lean manufacturing, work cell design and other industry-related coursework.