Mack Enhances Medical Product Development Capabilities

FOR IMMEDIATE RELEASE

ARLINGTON, Vt. (March 18, 2010) – Mack Molding and sister division Mack Prototype, Inc. have purchased two Stratasys FDM machines to enhance Mack’s engineering capabilities for its medical OEMs. Each machine is uniquely suited to fit the needs of the two divisions.

Mack Molding has purchased an FDM machine for its Application Development Center (ADC) at the headquarters plant, where MackMedical is also located. Used primarily for orthopedic applications, this system builds parts in ABS resin in an 8″ x 8″ x 10″ build envelop in .010″ thick layers.

“We use it to perform design verification and to ensure snap-fit parts are functional,” says Randy Pell, senior staff design engineer. Using flow simulation software, Mack engineers can predict part warpage, print the part in the warped condition, and realistically prove or disprove a design.

“We also use it to set up quality processes, such as part measurement,” adds Pell. “We determine the fixtures we’ll need to measure the part and produce them on the FDM system. For example, many of the components used in orthopedic surgery can look identical, while actually differing in size by just a few millimeters. With FDM, we can print out right-sized fixtures that will ensure each component is measured correctly.”

Mack Prototype invested in FDM technology (Fortus 400) that will print a much larger part – 14″ x 16″ x 14″ in resolutions between .005″ and .013″ thick layers – which is one of the largest build envelopes available through a custom manufacturer in the New England region, according to President Ric Perry. With multiple material options, Mack Prototype can print parts in either ABS 30i (ISO 10993 biocompatible material) or PC-ABS. “This versatility allows us to make parts that can not only be used in testing and clinical trials, but can actually function as end-use products,” explains Perry.

Mack Prototype also does a lot of CNC machining of components. “The FDM process results in a part that is very similar to a machined part, so we can now make parts in ABS or PC-ABS on a parallel path with machined parts,” adds Perry. FDM is also suitable for low volume parts. “In some cases, it can be more cost-effective to print individual parts rather than making a metal mold and molding parts, depending on the part and the geometry.”