Category Archives: Filtration

University Collaboration

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.

Max Perhach, Sigma certified in-house welder, works on the Ultrasonic Water Treatment System

Max Perhach, Sigma certified in-house welder, works on the Ultrasonic Water Treatment System.

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.

The Ultrasonic Water Treatment System

The Ultrasonic Water Treatment System

Global Manufacturer of Engine Filters Saves 3 Months and Thousands of Dollars in Cyclic Fatigue Testing Program

A globally known filter manufacturer had a fast-paced program and needed help to reduce their test program time.

A non-linear plastic simulation analysis.

A non-linear plastic simulation analysis.

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.

After further simulation review we found that there were certain areas in the molded housing that were suspect to failure. As often found in these analyses, the defects were less than obvious.

The software and Sigma’s engineering analytical skills uncovered these areas, which saved the client needed time and money. The client modified the design and went to physical testing, saving 2 to 3 weeks of iterations. This insight got their 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 other specialized engineering software.

Design/Build Liquid Process System

A look into the design/build liquid process of a US Navy Mobile Filtration Laboratory:  http://youtu.be/dsGIgcqiSqU

A product design, prototyping, engineering and manufacturing company, Sigma designs and optimizes creative engineering solutions for the medical/laboratory, renewable energy, clean technology, consumer products and other sectors.

Learn how Sigma can turn your smart ideas into product solutions: http://www.sigmadesign.net

SIGMA Design Co and UNIQUE Wire Weaving Collaboration Boosts Productivity of US Industrial Wire Weaving

How do American manufacturers compete effectively in the industrial wire weaving business that supplies the medical, electronics, filtration, process and other industries? First, take a proven machine design; second work with the right US based design engineering/manufacturing firm; third, be creative and redesign the machine to double output using the same floor footprint; and four, manufacture and assemble the machines in the USA. This is the exact story of how two New Jersey companies – Unique Wire Weaving Company, Inc. of Hillside, New Jersey and Sigma Design Company of Middlesex, New Jersey collaborated to double US productivity through successful reengineering and production of a redesigned “Loom 16 Machine”.

Unique Wire Weaving Company Inc., located at 762 Ramsey Avenue, Hillside, New Jersey is  led by Mr. Ken Beyer, a fifth generation wire weaver. In business since 1946, Unique Wire produces and supplies wire mesh and filter cloth in specialty alloys and exotic metals, weaving wire as fine as 0.0008” diameter. They are known for their strong technical capabilities and quality products and are committed to producing in the USA for supply to the medical, electronics, filtration, process and other industries.

The challenge for Unique Wire was that it had several 1950s looms that worked well, but they needed these machines to have greater precision and higher production speed thereby adding capacity at their existing facility at minimal cost. For this machine conversion project, Ken Beyer turned to Sigma Design Company, LLC, a company that offers comprehensive services – including prototyping and mechanical design engineering through machine and product manufacturing, validation and assembly at its ‘Technology Commercialization and New Product Manufacturing Center’ in central New Jersey.

Unique Wire Weaving Loom 16The result was that Ken Beyer and Sigma Design developed and built a modified loom – Loom 16, using the common base, but completely redesigned and built a new wire feed system and drive train assembly. This allowed a two-fold increase in both production speed and production volume using the same machine footprint that had been used for years – thus increasing productivity in the same space. The redesign also improved controls to allow them to broaden the products that are manufactured on this machine – such as weaving precise tungsten mesh  that was previously not possible  on these machines. Sigma Design will continue to work together with Unique Wire to find ways to help them to build more capacity with solid ROI. This type of ongoing collaboration, four years to date by these two New Jersey companies, is the foundation of creating a New Manufacturing Era for New Jersey and the USA.

SIGMA Design Company – Collaborative Engineering for Improved USA Productivity

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Sigma Design Company Exports Fuel Filter Testing System For Army Desert Vehicles – A Global Collaboration

Anyone who has waited too long between car oil changes knows how things start to slow down and wear out. Now imagine sitting in a military vehicle in the desert on a critical mission; well this is not the time for your diesel fuel filter to be clogged or you will be a “sitting duck”. What to do? Well the Army conducts extensive testing on automotive fuel filters to avoid such events and to ensure efficient operation of military vehicles used in desert terrain. For this important preventative work the Army is using a new state-of-the-art Fuel Filtration Testing System that was made by Sigma Design Company Middlesex, New Jersey. On December 1, 2011 Sigma Design and IFTS Inc. USA shipped the first system for export to the Middle East.

Fuel Filter Test System of Sigma Design Company

The order was initiated from Chrysler Egypt and US TACOM earlier this year and IFTS, Inc. USA collaborated with Sigma Design Company to develop and fabricate the system. The Fuel Filtration Testing System was designed from scratch and the work started with a visit to Cairo by Jerry Lynch, President of Sigma Design, for a pre-concept engineering design meeting with the Egyptian Army engineers. Parts were designed and sourced in the USA, then assembled into a complete system and finally validated through strict protocols prior to shipment of the 10 x 5 x 7 foot laboratory system.

This diagnostic laboratory based filtration equipment will test diesel fuel filters for efficiency and dirt holding and retention capacity for mission critical vehicles to be used by the Egyptian Army. This effort is part of global automotive filter manufacturers’ requirement under ISO 4020 for diesel fuel filter testing. The laboratory system is being procured under the “Buy America” project of the United States Army.

Fuel Filter Testing System (inner)      of Sigma Design Company

The Fuel Filter Test System determines the filtration efficiency and lifecycle capacity per ISO 4020. The Army will test filters for use on various fleet vehicles including Diesel / Petrol engines (2.4 & 4.0L gas engines, 2.8LVM diesel engines, 4 / 6 / 8 Cylinder Jeeps).

“This is a great example of Sigma Design’s role in bringing global manufacturing for export back to New Jersey”, explained Jerry Lynch, President of Sigma Design.  “With increased orders for filtration laboratory equipment like this, Sigma Design expects to hire additional engineers in 2012”, he added.

The client turned to IFTS and Sigma Design Company due to their special expertise in applied engineering and science for filtration for all types of substances – such as oil, water, blood and other fluids. Sigma Design was selected by IFTS because Sigma had previously designed and supplied the United States Navy with a filter test system to evaluate desalination pre-filters on the CVNX Aircraft Carriers as well as their experience in the development of laboratory equipment and appliances.

Lynch, who is also co-owner of IFTS, Inc. USA, has been active for 25+ years in the area of filtration systems design and testing and has served on the Board of the American Filtration and Separations Society (AFS) for over 10 years (http://www.afssociety.org/). In fact, Lynch was the AFS National Chairman for 2006-2007.

With this set of competencies and manufacturing track record, the Sigma Design/IFTS collaboration is ready to deal with any type of filtration challenge. And with Sigma Design’s new 20,000 square foot Technology Commercialization and New Product Manufacturing Center that opened October 2011, Sigma looks forward to designing and assembling many new highly engineered filtration systems in the coming years.

Sigma Design Company – Promoting a New Manufacturing Era in New Jersey and USA

Visit Website of Sigma Design Company and visit blog Home page of SigmaDesignCo