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Industrial Art Produces Alternative Energy
June 14, 2021 8:09 pm Leave a Comment
Customer: WattLots, NJ
Industry: Alternative Energy

Sigma Design Company Engineers make solar parking canopies aesthetically designed and functional
Sigma Design Company engineers make solar parking canopies aesthetically designed and functional engineering services were provided to a renewable energy company that had an idea that updated the look and efficiency of solar parking canopies. Unlike the typical large, bulky structures dropped onto parking lots all over the place, these were different in both form and function. Sigma developed the unique trackers for the PowerArbor™, which allows this solar canopy to capture 25% more energy than stationary grids.

Besides good looks and performance, Sigma had to make sure that it was structurally safe and sound. A variety of tests were done to determine its ability to withstand hurricane winds. Then Hurricane Sandy happened. The installation was half installed when it hit—and as expected the system passed the most critical test of all with no damage.

We performed a simulated hurricane wind analysis to better determine wind-induced loads. Sigma studied and used this data to update various structural components which improved the arbor’s ability to withstand 120 mph hurricane winds.

Services Performed: Concepts, wind-land simulation, detail design, electronics, product development, testing & manufacture.

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Assisting Drug Discovery
7:50 pm Leave a Comment
Customer: Inventor
Industry: Medical Devices

The Behavioral Spectrometer is a humane device that captures everything a research mouse does without having to watch and score hours of video recordings. Sigma designed, tested and manufactures this ‘mouse house’ in its New Product Manufacturing Center. The job required advanced engineering analysis and skills to incorporate LED lighting, vibrations sensors, and isolation dampers. It has the capability of using advanced video and vibration analysis to record the most detailed description of mouse behavior ever.

This product has met with huge success in the research and pharmaceutical world including Rutgers University’s Department of Neuroscience and Cell Biology, Pfizer, and other global R&D laboratories for the development of new treatments and drugs. Additional systems have recently been shipped to a R&D laboratory in Austria.

Services Performed: Electronic/mechanical advanced engineering

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Pharmaceutical Process Products
4:35 pm Leave a Comment
Customer: Amesil, NJ
Industry: Pharmaceutical Process Products

Developing Medical Quick Clamps That Don’t Fail – Pharma Hose Clamp Analysis
Developing plastic clamps that are user friendly and reduce finger and wrist fatigue is not as simple as it seems. A major clamp and tubing manufacturer was having problems with product failures and needed a remedy. Medical personnel clamp and unclamp hoses dozens of times per day and the new design needed to be comfortable as well as durable. Sigma Design was brought in to review and analyze the parts for a new clamp design that would eliminate failures in the field and also have the feel and control needed. These new parts were made to be manufacturing smart injection molded.

Services Performed: Medical device product development, computational plastic stress analysis, design for manufacturing, material selection, 3D rapid prototyping
Building a Better Tissue Embedder
4:00 pm Leave a Comment
Customer: Life Science Systems Manufacturer
Industry: Medical Devices

Industrial Design Produces Ergonomic Instruments
Sigma Design Company designs and builds a device for Tissue Analysis

A company was looking for a new tissue embedder and cryo system with unique features and capabilities. When Sigma Design Company took on the job they got all of that in a sleek and user-friendly design. Using photo realistic imaging and paraffin flow modeling in SolidWorks™, the designers analyzed various layouts and the human factors. These variables were meticulously checked in 3D prior to prototyping. All prototyping housing components were made in-house using Sigma’s 3D FDM printer.

Services Performed: Concept development, photo realistic simulation, detail design, electronics, product development, prototype manufacturing & testing.

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Color Accuracy Device
3:57 pm Leave a Comment
Customer: Datacolor, NJ
Industry: Retail Products

The Color You See is the Color You Get – Color Accuracy Device

Photographers, artists and other creative professionals must be able to maintain a high degree of color accuracy in their designs. This includes image capturing, digital editing and printing. Sigma Design has worked with Gordon Randal Perry Design (GRPD) in New York City on numerous projects over the past 20 years. On this specific project the client needed a unique and ergonomic new shape and form for their proprietary color analyzing system. GRPD developed the shape and human form factors and Sigma Design took the sketches developed detail parts and an assembly suitable for injection molding mass production. Sigma developed the final assembly including all part geometries and 3D printed a functional prototype for client review. We then developed a complete design package including a set of detailed manufacturing drawings for production.

The Spyder3Pro was the third generation colorimeter with new state-of-the-art optical design and photo-centric user interface providing accurate, reliable and consistent color.

Services Performed: New Product Development, Human factors, Design for Manufacturing, Material Selection, Injection Molded Design, and 3D Printed Prototypes.

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Hydraulic Power Systems
12:46 pm Leave a Comment
Customer: NAVSEA
Industry: Industrial Power Systems

Sigma Design supports U.S. Navy shipboard defense systems
Sigma was very excited to work on another project with the U.S. Navy. Talk about a project in ‘our wheelhouse’ as they say. Jerry Lynch, a ‘tin can sailor’ who served as a destroyer GMG2 gunner was thrilled to have the opportunity to work on this special project supporting shipboard defense systems for Navy operations.
Michael Collins, the lead engineer on the NAVSEA project worked for the U.S. Navy in Philadelphia before coming to Sigma. This project requires the creative design of safety features while providing 50% more power through their hydraulic power supply system. With operating pressures in excess of 3000 psi, the pressure compensation and hydraulic shock suppression systems were key features in the new design. This HPU joins the growing roster of Sigma’s products designed and built in NJ. Sigma is proud to have the opportunity to work with the Navy to improve operational shipboard defense systems used around the globe but made in NJ.

Services Performed System engineering, detail design, CAD drafting, electronics, welding services, machining and fabrication, testing & start-up, system training, and on-site validation.

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Giving a Wire Weaving Company a Competitive Edge
12:43 pm Leave a Comment
Customer: Unique Wire Weaving Company, INC
Industry: Industrial Machinery

Sigma Design Company Unravels Equipment Challenges for a US Wire Weaving Company.
An industrial company in business since 1946 knew it needed to boost its productivity in order to continue production in the USA. The company came to Sigma Design to convert their original wire weaving machinery to increase production speed and also broaden the uses of the equipment. Sigma developed and built a modified loom and new wire feed system and drive train assembly to successfully meet those goals. A doubling of production speed and output using the same machine footprint was exactly what the customer envisioned. That experience, and keeping manufacturing and jobs in the US drives much of the engineering design and manufacturing work done at Sigma Design Company.

Sigma manufactured the machinery upgrade.

Services Performed: Field engineering, concept analysis, load simulation, machine design, detail design drawings, electronic controls, fabrication, manufacturing and testing.

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Test System Design/Build
12:37 pm Leave a Comment
Customer: The Egyptian Army
Industry: Filtration and Filter Testing

Verifying the Quality of After Market Filters
Sigma Designs Fuel Filter Testing Systems for Desert Vehicles
Imagine your car breaking down on the turnpike. Now imagine a similar breakdown but this time you are in a military vehicle in the desert during a critical mission. The clogging of a diesel fuel filter can be a real setback in such circumstances. Sigma Design Company was hired to develop and fabricate a state-of-the-art Fuel Filtration Testing System that tests diesel fuel filters for efficiency and dirt holding and retention capacity for mission critical vehicles to be used by the Egyptian Army. Sigma was selected due to their special expertise in applied engineering and the filtration of all types of substances – such as soil, water, blood and other fluids. Parts were designed in-house and then assembled in Sigma’s 20,000 square-foot Technology Commercialization and New Product Manufacturing Center.

Sigma is also the manufacturer of the test system.

Services Performed: Machine design, test systems development, welding services, machining and fabrication, testing and validation.

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Engine Filter Housing Analysis
10:28 am Leave a Comment
Customer: Global Filter Manufacturer
Industry: Automotive Filtration
Sub Heading: Sigma Design Company’s advanced engineering skills and experience using analytical software uncovered problem areas to save a client time and money.

Engine Filter Housing Analysis.
A globally known filter manufacturer had a fast-paced program and needed help to reduce their test program time. Starting with a first-pass iteration of a filter canister design, Sigma engineers used non-linear plastic simulation analysis to determine whether long-term cyclic loading would be likely to cause permanent deformation, and worse yet, failure. Sigma’s advanced engineering skills and experience using analytical software uncovered problem areas, which saved the client time and money. This insight got the client’s program back on track and on budget. Sigma’s engineering experience helps product launches stay on schedule by removing the unforeseen obstacles that delay new product development progress. Our team is capable of performing Linear Stress, Non-Linear Plastic Deformation, Computational Fluid Analysis, as well as using other specialized engineering software.

Plastic Deformation and Stress Simulation, Detail Design Improvements, Design for Manufacturing, Product Development.

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University Collaboration for Water Treatment
June 13, 2021 8:36 pm Leave a Comment
Customer: Montclair State University, NJ
Industry: Water Treatment Technologies

University Collaboration for Ultrasonic Water Treatment System
At universities all over the country, scientists are churning out the research that can potentially lead to innovative new products. But many of these great ideas get stuck in academic labs because university scientists lack the business experience to develop a commercial product. Today’s universities are supporting these products further and assist in the commercialization process.
Montclair State University (MSU) had just such a project; a design for an ultrasonic water treatment system. The system was designed, fabricated and assembled in-house by Sigma Design. Then the system was tested for electronic and water processing at Sigma’s 20,000 sq. ft. facility.
For innovators in academia, Sigma Design provides the bridge to the business world with the experience to build the most challenging technical devices and then guide them to market. Sigma Design can assist with prototypes, manufacturing, product testing, packing & transport, and even insurance.
Dr. Meiyin Wu, a professor at MSU and the lead scientist on this venture, described her experience working with Sigma Design as an extremely pleasant and productive experience. “Sigma’s staff are highly professional with exceptional skills. Collaboration between MSU/higher education and Sigma is an example of the future of innovation,” Dr. Wu said.
Sigma Manufactured the Ultrasonic Water Treatment System.

Services Performed:
System Design, Flow Simulation, Detail Design, Electronics, Product Development, Testing & Manufacture.

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