Category Archives: New Product Development

Contact Us With Your Project Needs!

sigmapicSince 1999, we have been trusted by hundreds of manufacturing firms for our engineering and manufacturing services and would love to transform your smart ideas into successful products and machinery. Please give us a call or e-mail us about the projects you are currently working on!  http://www.sigmadesign.net/contact/

Prevention Invention

Anyone with a gas stove has probably had the scary experience of realizing that they have left the stove burner on. Unlike today’s refrigerators that call you back to the room when you have left the door ajar, most gas burners provide no indication that they are still on. A simple mistake could lead to a deadly fire in your home. Burner Disc

Matthew Porraro came to Sigma Design with a solution to prevent kitchen fires. Porraro invented a plastic disc that attaches to each knob on the stove, which illuminates when the burner is on. Sigma Design took his initial design and prototype and improved it, integrating a light circuit and an audible alarm.

BurnerAlert™ is the only reminder and timer product on the market that will retrofit on gas and electric stoves.

This is just one example of the projects that come to the Sigma Design team. Like BurnerAlert™, let us take your smart idea and turn it into a viable product!

A Great Time to Finally Turn Your Smart Ideas Into Product Solutions

Many of us set New Year’s resolutions, but how many of us actually keep them? Have you had an idea, but don’t have the engineering and design tools? Start your new year off by letting Sigma Design refine your idea.

For the fee of $500 you will be able to sit down with a Sigma engineer for 4 hours and help you through the product development process. Sigma Design believes that manufacturing is critical to the health of the country and the state of New Jersey.

Most inventors don’t realize the extent of what it takes to develop a product from start to finish. The process is costly and complex. Contact us today and find out how Sigma can make your idea into a reality.

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.

No Toying Around

Think toys are merely child’s play? Think again.

Toy

CAD Designer Hayati Dirim works on Loveable Lola.

Sigma was hired to design and create a working prototype for the animatronic children’s dog toy, Loveable Lola, which can be used for further manufacturing and design efforts.

Lola, a female boxer canine talks when the front right paw is pressed. She then walks, wags her tail, wiggles her hips, moves her head up and down and side to side.

Sigma used mechanical design, electrical design, and auxiliary component design skills in the making of this intricate prototype.

Contact us today and find out how Sigma Design Company can make your product a reality.

SIGMA Design Company- Turning Smart Ideas into Product Solutions

Summertime Toy Ready to Hit the Waves

Sigma Design helped turn inventor John O’Shaughnessy’s beach toy idea into a reality.

The Swash Board prototype built by Sigma Design.

The Swash Board prototype built by Sigma Design.

Swash Board is a circular disk with handles on each side and a rope handle that children can use to play in the ocean. Sigma created the first working prototype.

O’Shaughnessy came up with the idea after he watched his kids sit on their boogie boards along the sand and wait for waves to ride up along the shore. “Once the waves came up along the shore the kids would be moved around by the water. We thought it would be better if the device they were sitting on was round then they could spin, move around faster and farther. Also, having small children, we liked the idea of the kids being able to play on a watercraft close to the shore and not too far out in the ocean. So once we returned home from the shore we decided to go for it and have a prototype made,” he said.

The design can float holding a person weighing 60 pounds or less. Sigma created the disc using density foam, layered with fiberglass to create a hard finish. Orange neoprene was put on the topside to create a soft pad to sit on and to create a colorful look.

Contact us today and find out how Sigma Design Company can make your product a reality.

Photo Realistic Plastic Design

A new venture start-up company had a unique idea for a baby bottle, which was easy to clean, BPA free and has a slow to medium flow rate. The bottle features two interchangeable lids and a wide-neck body design. In order to take their idea to a reality, they contacted Sigma Design.

Armed with only a Photoshop image of what they wanted, Sigma was able to create a photo realistic 3D CAD model that can be used for product marketing going forward.

Client's artist rendering, left, and Sigma's 3D CAD model.

Client’s artist rendering, left, and Sigma’s 3D CAD model.

 

 

 

Learn more about how Sigma can turn your smart ideas into product solutions.

Sigma Launches Food Industry Page

Sigma Design Company provides new product development and process equipment design for the food industry. From novel kitchen gadgets, to appliances, and process systems, Sigma will work with you from concept to market on your food-related needs.

Philips Manufacturing Technology Center’s (PMTC) 600 cup per minute filling system and spin weld cap system.

Sigma’s capabilities include, but are not limited to: food-processing machinery, water processing appliances, electrical housewares and portable appliances, commercial appliances and household cooking appliances, analytical appliances, testing equipment and water filtration appliances.

In addition to acquiring culinary skills, students at Middlesex County College (MCC) are thoroughly trained in sanitation, HACCP, and safe equipment use. In fact, Sigma Design and MCC have an agreement to collaborate in the review and testing of new food product designs.

Click here to view Sigma’s food industry page.  

Contact us today and find out how Sigma Design Company can make your product a reality.

Our Capabilities: Fiberglass Pattern and Mold Making

Sigma Design used a suite of skills to develop the design for the base for WATTLOTS Power Arbor’s™ solar parking lot canopy system. The system is designed to provide renewable electrical energy where it is needed to existing surfaces.

Charles Horvath, Sigma engineer tech, works on the plug for the fiberglass mold.

The process began with designing a 3D model in CAD. The design was then printed in the fused deposition modeling (FDM) machine and the pattern for the fiberglass decorative protective base covers were built. The base provides stability to enable rotation to maximize sun exposure.

The covers will be used with the Power Arbor’s™, which will be installed at Runnells Specialized Hospital of Union County located in Berkeley Heights, NJ. The pattern can be used to make exact duplicates for years to come.

To learn more about Sigma’s capabilities, please visit http://www.sigmadesign.net

For more information about WATTLOTS visit: http://www.wattlots.com

Bird-Friendly Wind Power Brings Manufacturing Jobs to New Jersey

Raymond Green, a World War II veteran and retired welder and operating engineer has hired Sigma Design Company located in Middlesex, NJ to test, analyze, refine, optimize and manufacture his patented invention: Catching Wind Power® (CWP) Compressed Air Enclosed Wind Turbine. Once launched, it will bring 25+ new technology jobs to New Jersey.

The blades of traditional wind turbines can kill bats, birds, and other flying wildlife. This was a concern to Green, so he designed a system that eliminates external blades. The patented “Inner Compression Cone Technology” (ICCT) squeezes the incoming air, compressing it as it is drawn through the turbine and multiplies it creating more power. The ICCT technology also creates virtually no noise. The blades are internal, closer together, and smaller therefore eliminating the sound traditional blades make as they spin and swoop past the tower. The turbine is offered in different sizes ranging from personal portables to massive wind farm units. This versatile product is very cost-efficient for any location and allows the user to take green energy anywhere they go.

Catching Wind Power® turbines can replace or be added to existing wind farm towers.

Green, who is 89 years old and resides in Jackson, CA, felt strongly about entrusting this project to a veteran-owned company. He found Sigma Design, owned by Jerry Lynch, P.E., a U.S. Navy veteran. Green’s vision is the launch of this alternative energy product, which will create jobs in America for U.S. veterans.

Catching Wind Power® pilot test set-up at Sigma Design Company in Middlesex, NJ.

CWP is an early-stage company and has patents in the USA, which were granted on 02/13/2007 and 03/16/2010. The company also has patents in New Zealand, Australia, China and 27 countries in Europe. These patents and IP will become major assets of the company. CWP products will have numerous applications such as military and remote installations; these systems have global market appeal.

Sigma and Raymond Green are forming an investment team to bring the product to market. Interested investors are invited to contact Sigma Design.

Contact us today and find out how Sigma Design Company can make your product a reality.


For more information about Catching Wind Power® please visit: http://www.catchingwindpower.com/