Corporate Overview- Mack Confidential & Proprietary-

WHO WE ARE

Full-service contract manufacturer Specializing in…

Custom injection molding Painting Metal fabrication Machining Assembly

Offering product development resources… Product design Prototyping Engineering services

WHO WE ARE

Founded in 1920 – privately owned & operated Headquartered in Arlington, Vermont Three operating divisions, 10 locations ~1800 employees Annual sales: $260 million No long-term debt, 5A1 D&B rating Certifications

ISO 9001 ISO 13485 (Mack North, Mack Prototype, Mack Technologies) ISO 14001 (Mack South) AS9100 (Mack Technologies) ISO/TS 16949 (Mack South)

FDA Registered (Mack North)

Mack Molding - North Mack

Molding/MackMedical Product Development Plastic Molding Metal Fabrication Paint and Assembly Contract Manufacturing

Mack Prototype

Mack Molding - South Plastic Molding Class A paint Assembly

Mack Technologies Electronics Contract Manufacturing

SMT, Turn-key System Integration, PCB/System Level Test Development

MACKGroup SLA Rapid Prototyping

Fused Deposition Modeling

CNC Machining LIM Cast Urethane Low-volume Injection

Molding & Manufacturing

CORPORATE STRUCTURE

Mack TechnologiesWestford, Massachusetts

Melbourne, FloridaJuarez, Mexico

Mack NorthArlington, Vermont (2)

Cavendish, VermontPownal, Vermont

Mack SouthStatesville, North Carolina

Inman, South Carolina

Mack PrototypeGardner, Massachusetts

LOCATIONS

WHAT WE DO

Contract manufacturing

Product design & development

Rapid prototyping & low volume manufacturing

Custom injection molding

Cleanroom molding

Finishing & assembly

Sheet metal fabrication

Full-service machining

Medical Class II/Class III contract manufacturing

DESIGN & DEVELOPMENT

Application Development Center

Engineering analysis

Supply base selection and management

Material and process selection

Tool design and management

DESIGN & DEVELOPMENT

Interactive feedback with designers

Mechanical design

Design for manufacturing

Moldflow

Finite element analysis

Process selection

MECHANICAL DESIGN

METAL-TO-PLASTIC CONVERSION

Orthopedic Ankle Clamp

INDUSTRIAL & MECHANICAL DESIGN

PART MOLDFLOW

FINITE ELEMENT ANALYSIS

PROTOTYPING/LOW VOLUME MFG

SLA rapid prototyping

Fused deposition modeling (FDM)

CNC machining

LIM cast urethane

Low-volume injection molding (10-230 ton)

Extensive finishing capabilities

CUSTOM INJECTION MOLDING

92 years of expertise

Six facilities Vermont (3) Massachusetts North Carolina South Carolina

120 injection molding machines

28-4000 tons

.6-800 ozs

MOLDING PROCESSES

Injection

Structural foam

Gas counter pressure

Gas-assist (internal & external)

Two-shot molding

In-mold decorating

Overmolding

Insert molding

High temp molding

INJECTION MOLDING

Molten plastic injected into a mold under high pressure

Fast cycles

3-5 ton/sq in clamp required

Lowest part weight

Good surface finish

Low molded-in stress

STRUCTURAL FOAM MOLDING

Molten plastic injected with a chemical blowing agent

Short shot process

Thicker part wall required

Low stress

Slow cycles

¼ - 1 ton/sq in clamp required

Reduces sink issues

Rib-to-wall ratio can be greater

Poor surface finish; lots of swirl

Heavier part weight

GAS COUNTERPRESSURE

Structural foam shot into a pressurized cavity

Improved surface finish over structural foam

Cavity pressure holds out-gassing in check

Slightly heavier part than structural foam

Slightly slower cycle

Higher tool cost & maintenance

INTERNAL GAS-ASSIST

Gas confined within the part

Reduces sink

Reduces stress

Reduces press tonnage required

Longer flow lengths can eliminate need for manifolds

Licensed for any application

EXTERNAL GAS-ASSIST

Gas is pressurized between the core steel and the part

Reduces sink

Reduces stress

Must be confined by using core side part design

TWO-SHOT MOLDING

OVERMOLDING

LARGE PART MOLDING

RESIN PORTFOLIO

FINISHING & ASSEMBLY

Automated

Cleanroom

Heat staking

Testing

Ultrasonic

Laser welding

Inserting

Work cell

RFID tagging

Assembly Decorating

Heat sealing

Heat transferring

Hot stamping

Laser marking

Pad printing

Silk screening

Painting

Decorative

Conductive

Robots

Automated

Overhead lines

Walk-in booths

Class A

CNC machining

Swiss lathes

Integrex turning & machining ctr

14” optical comparator

CAD/CAM

Ultrasonic parts washing

Vibratory tumble

Machining

PREMIUM CLASS ‘A’ PAINT SYSTEM

11,000-sq-ft enclosed HEPA filter environment

1200’ of conveyor supported from underside of parts using 175 paint racks

Ultra high filtration 5-station wash & rinse system

Color changes <5 minutes

3 Fanuc model 250i paint robots

Electrostatic or HVLP

Infrared/convection curing ovens

PREMIUM CLASS ‘A’ PAINT SYSTEM

HEPA filtered air Dust & dirt free environment

Underside part support Reduces scrap generated by

standard overhead systems

5-station wash system Insures clean surfaces

Electrostatic paint system Ransburg rotary atomizer

improves transfer efficiency and final finish quality

Infrared curing ovens Reduce air movement Improve first pass yield

SHEET METAL FABRICATION

State-of-the-art soft-tooled fabrication

Complete laser, punching & forming for NPI & production requirements

Product development focus featuring rapid prototype development

SECONDARY PROCESSING

Vibration deburr

E-series press brake

Haeger insertion equipment

Auto-assist silk screening

Wash line

Automated bead blasting

Wet time-savings equipment

SECONDARY PROCESSING

Welding

Metal finishing

Fastening

SHEET METAL CASE STUDY

Commercial High-tech Blender

86 unique metal parts

Stainless steel construction

Multiple gauge materials

Riveted assembly

Laser cutting/punching

Metal forming

Hardware insertion

SHEET METAL CASE STUDY

Commercial Mail Sorting System

34 unique metal parts

CRS, pre-plated, stainless steel

Thicknesses range from 18-10 gauge

Part size: 2”x2” to 48”x96”

Laser cutting/punching/forming

Tapping

Hardware insertion

Welding: Spot, MIG

Metal finishing

MACHINING

Milling & turning

Small parts

Parts with long length-to-diameter ratios

Complex parts

DONE-IN-ONE MILLING

Mazak Integrex Mark IV

Turning & machining in a single setup

40-tool capacity

Touch probe tool setter

KM63 dual contact tool connection

2” thru-capacity

LNS Servo 65 bar feeder

CITIZEN SWISS LATHES

Two Citizen A20VII lathes

Seven-axes, 20mm machines

21 tools

C-320 bar feeders 3-20 mm barstock

capacity +0.0000”/-0.0005”

precision ground stock

Minimized cycle times via simultaneous main & sub-spindle processes, 32 m/min rapid feed rates

AUXILIARY EQUIPMENT/SOFTWARE

Ultrasonic parts washing

Vibratory tumble deburring

14” optical comparator

Surface finish analyzer

Fully integrated CAD/CAM Part-Maker -- From solid

model to complete 3D simulation to machine G-code (Swiss & Integrex)

MatrixCam – Offline conversation programming (Integrex)

CONTRACT MANUFACTURING

Program management

Global supply management

DFM/DFT

FMEA

Electronic integration & test

Order fulfillment & distribution

PROJECT TEAM

ProgramManager

Supplier Selection /Management

Tooling

Prototyping

Design

Order Fulfillment

ManufacturingServices

Plastic Molded Products

Soft Tool Metal

Product Assembly

Quality & RegulatoryCompliance

Mack TechnologiesWestford, MAMelbourne, FLJuarez, Mexico

Mack NorthArlington, VT (2) Cavendish, VTPownal, VT

Mack SouthStatesville, NC Inman, SC

Mack Prototype

Gardner, MA

MARKETS WE SERVE

Medical Devices Disposables Instrumentation

Transportation Heavy truck parts Recreation/utility vehicles

Computer & business equipment

Consumer

Defense/aerospace

Energy Batteries Solar-powered products Fuel cell technology

Industrial Structural HVAC Furniture & seating Industrial & building

supplies Lawn & garden

41 Mack: Company Confidential

MEDICAL ACCOUNT SAMPLES

CLEANROOM MOLDING

Class 100,000 molding cleanroom

Installation complete, 12/11

Dedicated to reusable & disposable medical applications

46’ x 44’ modular design Removable panels to allow

for future expansion Dual air-lock doors, 8’ wide

Rapid roll-up doors Ease of product flow, tool

changes

CLEANROOM PRESSES

Six Toshiba 110-ton electric presses

60% less energy consumption than hydraulic

High-precision machines Outfitted with high

pressure water controllers More versatility in resin

selection

ENVIRONMENTAL MONITORING

Gowns/personal protective equipment required

Particulate airborne monitoring according to ISO 14644-1 standard

Particulate control plan includes: Alert level Action level

Ensure compliance with GMPs

WHITEROOM PRESSES

Currently operational Adjacent to new Class

100,000 molding cleanroom

Engel hydraulic presses Low-volume, multi-

color products requiring quick resin/tool changes

24-hour operation for orthopedic trials, medical disposables

CLEANROOM ASSEMBLY

Class 100,000 cleanroom assembly

30’ x 70’ Non-sterile packaging

for medical disposables Light sonic weld

assembly Temperature &

humidity-controlled functional testing

CONTRACT MANUFACTURING

Project management

Supply management

Regulatory compliance

DHF/DMR/DHR management

Design verification

Process validation

Training

DFM/DFT

Order fulfillment/distribution

QUALITY ASSURANCE CONTROL

Quality system 21 CFR 11 & 820 compliant Electronic DMR & DHR

retention

Advanced product quality planning Process flow diagrams Risk assessment/pFMEA Control plans Dynamic control plans

QUALITY ASSURANCE CONTROL

Component & process qualification/validation PPAP IQ/OQ/PQ Reqs traceability/supplier

change controls Config controls/validated

software

Measurement systems CMMs (3) Optical systems (4) NIST-traceable calibration Gage R&R Minitab & DataMite

Post-prod risk assessment

Advanced product quality planning

Process flow diagrams

Risk assessment/pFMEA

Control plans

Dynamic control plans

Supply management

Regulatory compliance

DHF/DMR/DHR management

Design verification

Process validation

Training

DFM/DFT

Order fulfillment/distribution

DEVICES

Class II/Class III PMA products

FDA registered

Clean room molding & assembly

White room molding

Complaint investigation

Obsolescence management

FRU/kitting

CASE & TRAY SYSTEMS

Custom designs based on OEM requirements

Validated manufacturing process

Plastic, stainless steel, titanium & aluminum

Laser welding Hermetically sealed weld bead Free of gas, air, contaminants

JIT stocking arrangements with full lot code

Complete kitting and ship-to distribution services

INSTRUMENTATION

Soft-touch ergonomic handles

Disposable & reusable

Material analysis Lipid resistant resins Gamma stable resins Anti-microbial resins Autoclaveable ergonomic

resins

Overmolding Insert molding Final assembly

CASE STUDY

Therapeutic Device, Photopheresis

Class III PMA device

1,921 total components

616 unique components/80 suppliers

49 subassemblies

Dedicated work cell

Dedicated product support team

8 functional tests

CASE STUDY

Therapeutic Device, Photopheresis

Class III PMA device

1,400 total components

358 custom parts/65 suppliers

18 subassemblies

Component qualification

Dedicated work cell

Dedicated product support team

10 functional tests

TRANSPORTATION

ENERGY

COMPUTER & BUSINESS EQUIPMENT

CONSUMER

INDUSTRIAL

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