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Mack Prototype is upgrading its manufacturing capabilities with a significant investment in its machining, inspection and facility efficiencies. With a total investment exceeding $475,000, the company is revamping its CNC technology, expanding its quality lab with an advanced coordinate measuring machine (CMM) and implementing energy-efficient heating solutions.

The company, a wholly-owned subsidiary of Mack Group, is augmenting its CNC machining capabilities with the addition of a Haas VF2-SS high-speed mill, which enhances the ability to machine both plastics and metals. The unit can also perform tight-tolerance secondary operations on injection-molded parts, including PPSU, PEI and composite materials.

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“This investment allows us to improve accuracy, speed and quality in our machining operations,” says Greg Cebular, Mack Prototype president. “With a probing system integrated into the CNC, we can enhance precision and reduce variability in our production processes.”

Located in Gardner, Massachusetts, the company’s 75,000 square feet of manufacturing space is utilized for complex prototyping and low-volume production. Mack Prototype can take programs through the full development life cycle, drawing on 25-plus years of experience in additive manufacturing, cast urethane molding, CNC machining, injection molding and new product introduction.

The facility now houses 12 CNC 3-axis milling machines, some with 4-axis capabilities, utilizing Haas, Milltronics and Fadel CNC machining equipment.

To complement its upgraded CNC capabilities, Mack Prototype has also invested in a Hexagon Global S7.10.7 Scan Plus coordinate measuring machine (CMM) for its quality lab. This inspection system enables the facility to measure ultratight tolerances and complex dimensions, which is critical for medical and defense applications.

“Our customers demand extreme precision, and this CMM ensures we meet those requirements,” Cebular says. “It ties directly into our CNC operations, allowing us to inspect dimensions on parts we couldn’t inspect before and significantly improve our capabilities.”

The company is also focusing on sustainability with the installation of hybrid industrial minisplit heat pumps. These systems are designed to help maximize electric efficiency while switching to backup heating only when necessary. Through partnerships with Royal Steam Heater Co. (a Gardner-based contractor) and Unitil, the company is utilizing Mass Save industrial rebates to cover a large portion of the project’s cost.

“Our goal is to reduce reliance on traditional oil and gas while ensuring a comfortable working environment,” Cebular adds. “With rebates offsetting much of the investment, we’re able to implement these energy-efficient upgrades in a cost-effective way while achieving a 25% efficiency gain over traditional heating and cooling systems.”

The company says these investments reflect its commitment to technological advancement and sustainability. By modernizing CNC and quality inspection capabilities, and embracing energy-efficient infrastructure, the company is working to deliver the best solutions for its customers.

In addition, the company has hired Robert Gilbo has to serve as quality and compliance manager. He has more than a decade of manufacturing experience in quality, operations and leadership. Most recently, he worked as quality manager at Accumet Engineering, overseeing ISO 9001 and AS9100 compliance. His background includes roles as a quality engineer at Waiteco machine and quality control technician at Keeney Holdings. Gilbo earned AS9100D Lead Auditor and AS13001/AS9117 DPRV certifications, as well as experience in quality systems, audits and continuous improvement initiatives.

Mack Prototype is a full-service prototype and low-volume production facility specializing in injection molding, urethane casting, 3D printing, CNC machining and new product introduction (NPI) assembly. The company serves a variety of industries, including medical, defense and industrial manufacturing.