DESIGN & DEVELOPMENT
Mack Molding
Product Design & Development Services
At Mack, we understand that bringing a product from concept to market requires seamless integration of design, engineering, and manufacturing. Our comprehensive Product Design & Development services are tailored to meet your specific needs, ensuring efficiency, quality, and speed-to-market.
Our Integrated Approach
By embedding the design function within our total product development solution, we take full responsibility for your project’s lifecycle. This holistic approach eliminates the traditional “over-the-wall” handoffs between industrial design, engineering, tooling, and manufacturing, resulting in a more cohesive and efficient process.No matter where you are in your product lifecycle, Mack offers a broad range of design, prototyping, and manufacturing services, including:
Design for Manufacturability & Technical Support – Ensuring your product is optimized for production, reducing costs and potential delays.- Outsourced Engineering & Manufacturing Services – Allowing OEMs to focus on their core competencies while we handle engineering and production complexities.
- Accelerated Speed-to-Market – Our integrated processes and early-stage involvement facilitate a rapid transition from concept to market-ready product.
- Scalable Solutions – Managing development activity spikes and providing flexible resources during critical phases.
- Advanced Design Tools & Engineering Software – Mack utilizes state-of-the-art CAD, CAE, and CAM software, including: ProEngineer, AutoCAD, CADKEY, SolidWorks, Surfcam, Cimatron, SolidView, Unigraphics; as well as Engineering Analysis software such as Moldflow Mold Advisor and VisiFlo.
- CAD/CAE/CAM Software: ProEngineer, AutoCAD, CADKEY, SolidWorks, Surfcam, Cimatron, SolidView, Unigraphics.
- Engineering Analysis: Moldflow Mold Advisor, VisiFlo.
- Overhead Reduction – Streamlining operations to achieve cost savings.
- End-to-End Accountability – Eliminating finger-pointing through an integrated, seamless development process.
Seamless New Product Introduction: From Concept to Market
Bringing a new product to market requires a turnkey New Product Introduction (NPI) process that balances innovation, engineering precision, and manufacturability. Our integrated approach eliminates inefficiencies, reducing time-to-market while ensuring quality and cost-effectiveness.
A Streamlined Process Flow
- Project Definition – Product development specifications, IP review, physician feedback, market research, and competitive analysis.
- Concept Development – Brainstorming, concept evaluation, initial breadboard fabrication, and early-stage testing (animal/cadaver).
- Engineering Development – Detailed design, design Failure Modes and Effects Analysis (FMEA), bench testing, and clinical testing.
- Design for Manufacturability (DFM) & Design for Assembly (DFA) – Human factors, ergonomics, design verification, and functional prototyping.
- Design Validation – Sterilization and packaging validations, process validations, transportation testing, biocompatibility analysis, and quality/process documentation.
- Contract Manufacturing – Mold and die construction, supply chain management, Class 10,000 and 100,000 clean rooms, and order fulfillment.
Your One-Stop Solution
Whether you engage Mack for a single service or a full end-to-end solution, our mission remains the same: to provide you with a seamless product development and manufacturing experience. By integrating design, prototyping, and manufacturing under one roof, we eliminate inter-company hand-offs and transition delays, ensuring speed, efficiency, and precision. Our concurrent product management approach reduces delays, minimizes errors, and accelerates your product’s journey to market—without compromising quality.
To achieve this, we’ve built specialized teams and facilities designed to optimize every stage of your product’s lifecycle, from initial concept to full-scale production.
Application Development Center (ADC) – Vermont Headquarters
Our ADC engineers are dedicated to optimizing your product’s design and manufacturability. The team conducts thorough reviews focusing on functionality, aesthetics, processability, ease of assembly, cost-effectiveness, and time-to-market strategies. Early design input from our ADC minimizes processing challenges, shortens cycle times, and accelerates your product’s journey to market.
Synectic Product Development – Woodbridge, Conn.
Synectic Product Development, established in 1981, is a full-service product development firm specializing in the design, research, development, and manufacturing of medical devices and consumer products. As a wholly-owned subsidiary of Mack Group, Synectic enhances our design and development capabilities.
Comprehensive Services:
- Design Engineering: Synectic’s team focuses on creating innovative, functional, and manufacturable designs tailored to client needs.
- Intellectual Property Creation: They assist in developing and protecting intellectual property, ensuring clients maintain a competitive edge.
- Pre-Clinical Testing: Offering thorough testing services, Synectic ensures products meet necessary regulatory and safety standards before clinical use.
- Manufacturing: With capabilities in design for manufacturability and new product introduction, they provide a seamless transition from concept to production.
Expertise in Medical Device Development:
Synectic excels in developing Class I, II, and III medical devices, emphasizing clinical relevance, ergonomics, and cost efficiency. Their ISO 13485:2016 certification reflects a commitment to quality and regulatory compliance.
Integrated Approach with Mack Group:
Being part of the Mack Group allows Synectic to offer clients a streamlined path from product design through to full-scale manufacturing, leveraging Mack’s extensive resources and capabilities.
Synectic Product Development
Synectic’s dedication to innovation and quality significantly bolsters Mack’s mission to deliver exceptional product development and manufacturing solutions to our clients.
Mack Prototype – Gardner, Mass.
Mack Prototype is a wholly-owned Subsidiary of Mack Group focused on rapid prototyping and low-volume manufacturing, helping companies accelerate product development cycles and bridge the gap to full-scale production.
Case Studies
Read about Mack Design & Development Case Studies.
Take the Next Step
Ready to transform your idea into a market-ready product? Contact us today to learn how our Design & Development services can drive your project’s success.
