CASE STUDIES

The selection of Mack design & development case studies shown below represents only a few examples of Mack’s product design and development services and how they have helped customers resolve challenges and move product to market. It is not intended to provide a comprehensive listing of Mack’s involvement in any industry.

Golf Cart Canopy:

The Challenge

Yamaha Golf Car Company wanted to develop a new golf car canopy to replace their existing thermoformed version. The existing canopy gave a “low quality” impression, and assembly was tedious. Attaching the thermoformed canopy to the golf car involved drilling holes in the canopy to attach three, cumbersome aluminum extrusions (struts).

Yamaha established a set of goals for the new canopy:

• Best in industry in terms of:
  • Styling
  • Innovative Features
  • Safety
  • Serviceability
  • Customer Satisfaction
• Cost improvements over previous model
• Development time of one year

The Solution

Through the combined efforts of Yamaha, GK Design, Modelex(CAD), Delta Mold and Mack Molding’s Southern Operations, a new canopy was developed: The Ergo Shade™.

The new canopy is molded in a 3000-ton press with 20% calcium filled polypropylene via a single, cold sprue in the center of the part. This material was selected due to its combined flex and impact properties. Four separate gas channels are sequentially fired to help fill the part and form integral features.

The Ergo Shade™ has many innovative features that are industry firsts:
Inboard, molded-in, gas-assist handles for the driver and passenger
Front and rear feet with nesting features that allow parts to be stacked for shipment and storage. Also eliminates disposable packaging required with previous model, an environmental plus.
Fold-up struts (attached at the press by Mack) allow the canopy to ship as a complete assembly, and provide for easy attachment to the golf car by a single person.

The continued collaboration of all parties involved in this program provided Yamaha with a robust design, on budget, and within one year.

The Ergo Shade™ is a trademark of Yamaha Golf Car Company.

For more information about this and other Mack design & development case studies, contact sales.south@mackmolding.com.

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Barbecue Grill Table

The Challenge

Optimize a multi-functional, plastic grill table design to:

• Withstand up to 55-pound loads
• Resist high temperatures
• Meet extremely high UV requirements
• Satisfy manufacturability goals
• Assemble easily by the consumer.

Char-Broil came to Mack for both design and manufacturing assistance when it began work on its new outdoor electric grill, the Patio Bistro. The company wanted a sculpted plastic grill table that could serve several functions:

• Support the electric grill kettle
• Hold a foam insulated cooler for drink/food storage
• Incorporate holders for cooking tools
• Fasten the leg assembly to the grill.

To meet these multiple functions, the overall assembly had to withstand a 10-pound load hanging in the cooler area, a 45-pound load for the grill kettle and its contents, as well as a 55-pound distributed load across the tabletop surface.

The Solution

Mack made recommendations regarding the tool-holder design and handle placement, and helped integrate the cooler concept into the work surface. A 30 percent glass-filled polypropylene resin was chosen, along with injection molding, to provide the most cost-effective material and process solution. To provide additional support, as well as locate and isolate the grill, Mack designed a sheet metal substructure, which fits under the tabletop. Mack also determined the manufacturing detail for the tabletop, including wall thickness, ribbing and mechanical attachments, and designed the cutting board, which covers the cooler.

For more information about this or other Mack design & development case studies, contact sales.south@mackmolding.com.

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