New Product Development Designed for Manufacturing

At Sigma Design, effective new product development begins with smart engineering, purposeful design, and a clear focus on manufacturability. For more than 20 years, we’ve supported clients with advanced product analysis, detailed prototyping, and streamlined production planning that helps bring innovative ideas to life.

Our engineers use thermal, structural stress, motion, fatigue analysis, and complex fluid flow modeling tools to uncover potential issues early. This approach allows us to reduce costs, minimize redesigns, and improve long-term product performance. With licensed engineering professionals on staff and in-house manufacturing, Sigma Design is a trusted partner for companies seeking complete support through every stage of development.

Product Development

Sigma Design delivers tailored product development services that help clients reduce risk and create manufacturable designs from the start. Our team works closely with each customer to align creative goals with engineering requirements and production timelines.

Our capabilities include:

• Idea creation and concept development
• Engineering and product analysis
• Material selection
• Rapid prototyping
• Complex mechanism development

We’ve helped launch a range of unique products including exercise equipment, feline pet houses, electronic camera flash systems, and uphill racing bicycles. Clients such as Frigidaire, NutriSystem, Horizon Group, and Uphill Racing Bicycle have trusted us to help develop their next-generation products.

Concepts and Prototypes

Once an idea is defined, we focus on visualizing and testing it through detailed design and prototyping. Our team develops concepts with manufacturability in mind, helping reduce delays, errors, and cost inefficiencies during full-scale production.

Our capabilities include:

• Complete design and build
• Stress, heat transfer, fatigue, and flow analysis 
• 3D modeling and complex geometries
• Specialty prototyping for unique requirements
• Scalable product rollout

Sigma offers creative design solutions that elevate product performance and market appeal. Prototyping allows us to visualize and refine each concept, while regular design reviews and quick iterations keep development moving efficiently. Using advanced engineering analysis, we identify hidden flaws early and develop manufacturing-friendly designs that help reduce costs and simplify production.

Custom Products

Sigma Design has completed more than 1,000 custom product development projects. These include everything from food processing systems and medical products to filtration solutions used at the Hoover Dam. Our experience spans a wide range of industries and product types, many with unique performance and compliance requirements.

We’ve supported products in areas such as:

• Ag-Tech. Agricultural biotechnology test equipment and analytical devices
• Medical & Pharma Devices. Process and analytical equipment development
• Clean Energy. Bioenergy, hydropower, biogas, and conditioning process systems
• Food Processing and Culinary Equipment.
• Sigma Industrial Water Group. Automated pump and treat filtration and UV disinfection systems, plus dewatering systems

You can explore our past work through case studies like Building a Better Tissue Embedder, Assisting Drug Discovery, and Pharmaceutical Process Products.

Sigma Design’s New Product Development Services

Sigma Design is a recognized leader in new product development, backed by licensed engineers and a fully equipped facility in Middlesex, New Jersey. Our Technology Commercialization and New Product Manufacturing Center houses the tools, teams, and experience needed to support complex product challenges.

We are proud to be an NVBDC-certified veteran-owned business with a strong reputation for reliability, precision, and service. Contact us to learn more about how we can help turn your ideas into manufacturable products.