Contract Manufacturer Wins First Place Award

May 8, 2005

3 Min Read
Contract Manufacturer Wins First Place Award

Originally Published MPMN May 2005


Contract Manufacturer Wins First Place Award

Susan Wallace

Mack Molding used gas-assist, overmolding, and insert molding to create 20 parts for the AED Pro from Zoll Corp.The device is made of a number of materials that will endure severe impact while keeping all working components intact.

Mack Molding (Arlington, VT;, with the help of its customer Zoll Medical Corp. (Chelmsford, MA;, captured a first place award in the Society of the Plastics Industry’s (SPI) structural plastics div. conference in March 2005 in Lake Buena Vista, FL. The award was given for achievement in the medical/scientific division, and the company also won the overall Conference Award.

The winning application, the Zoll AED Pro, is an automated external defibrillator. It is designed with advanced capabilities to support both basic life support and advanced life support professional emergency responders. The 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 noteworthy 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.” According to the company, the AED Pro is the only AED in the industry to pass a 1.5-m drop test. It also has an IP55 rating for dust and water resistance.

Jack Avery, an industry expert who surveyed the entries for the media, says the AED Pro is a prime example of the industry’s improving capabilities. The defibrillator uses three different injection molding processes and three materials in one compact package, he notes.

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.”

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