Capabilities

In addition to the Application Development Center at its Vermont Headquarters plant, Mack operates a product development and engineering services firm in Woodbridge, Connecticut — Synectic Engineering — and a distinct division devoted  to rapid prototyping and low-volume manufacturing in Gardner, Massachusetts – Mack Prototype. Mack offers the full gamut of product design & development services, including custom mechanical, biomedical engineering and industrial design; design-for-manufacturability; engineering analysis; quality and regulatory support; rapid prototyping; voice of customer; contract manufacturing; and order fulfillment.

Mack has design expertise in plastics, metals and electronics, including board prototyping and layout. In light of the company’s recognized manufacturing leadership, designing for assembly, cost and manufacturability takes on real-world meaning. Designers have first-hand knowledge of equipment and processes, and solicit manufacturing input every step of the way. They have in-depth experience with the materials and processes that will ultimately be used to manufacture the product. Whether or not your product is ultimately made at Mack, our practical, streamlined, design-for-manufacturing orientation will provide you with a better design, shorter time-to-market cycle and reduced costs.

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Design Tools

Mack’s evolution into product design and development accelerated significantly in 1998. We have invested substantially since that time to grow our design/build capabilities. We offer extensive design-for-manufacturability and engineering analysis services. Behind the technology, we have engineers absorbed in both part and manufacturing design, resulting in plastic and metal parts for medical devices, electronic enclosures, office furniture, business machines, industrial batteries, trucks, and other utility vehicles, to name just a few of the market segments we serve.

Mack Molding supports the latest versions of the following software packages:

CAD/CAE/CAM
ProEngineer
AutoCAD
CADKEY
SolidWorks
Surfcam
Cimatron
SolidView
Unigraphics

Engineering Analysis
Moldflow Mold Advisor
VisiFlo

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Rapid Tooling

Through its prototyping center in Gardner, Massachusetts, Mack offers rapid injection molds in both aluminum and steel. Our range of tool development includes everything from a two to four-week mud frame aluminum tool to a six-week steel production tool.

CNC Milling/Turning Equipment	Tools	Travel
		X”	Y”	Z ”
Partner VMD30 3-axis machining center	12	70	30	20
Partner VI 3-axis machining center	12	45	25	24
(2) Partner VM 16 3-axis milling center	12	30	15	20
Partner I 3-axis machining center	12	30	16	20
Partner I 3-axis machining center	6	30	16	20
(3) Fadal VMC 4020 3-axis machining center	21	40	20	20
Fadal VMC 4020 3-axis with dual pallet changer	21	40	20	20
Fadal VMC 6030 3-axis machining center	21	60	30	32
Milltronics 3-axis knee mill		30	9	5
(4) Protrak MX2 2-axis knee mill		28	10
(2) Bridgeport Trak AGE 2-axis knee mill		30	12
Harig surface grinder (6″x18″)
Deckel single-lip cutter grinder
Harrison M20 lathe, 11″ swing
Clausing Metosa lathe, 6″ swing

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Short Run Production

Mack can build your prototype, develop tooling, and finally, sample the tool and provide limited production parts. We can quickly get you to market while you decide whether or not to build a production tool.

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Injection Molding

Mack supports small-to-medium part injection molding with seven presses at its Gardner location:

Polyurethane Molding

The precision alternative to injection molding, RIM, structural foam molding or machining, polyurethane molding is especially effective in low volume applications of 3-100 parts. First parts can be available within one week. Typical deliveries range from two to four weeks. Available resins include custom colored, clear and custom tinted clear, glass-filled, and UL94-VO rated materials. Mack has two polyurethane injection systems, which can produce up to 10 parts per mold, per day.