Manufacturing Must Play a Significant Role in Improving the US Economy

This is the mantra inside the walls of Sigma Design Company, where we believe our talents will play a part in moving USA manufacturing innovation forward. Our manufacturing knowledge, when combined with new engineering technologies, such as 3D printing and product simulation have helped us create successful designs for new ventures single person innovators, large Fortune 500 divisions, and the military. Your ideas and our ability to bring them to life, will keep the US at the forefront of manufacturing and increased productivity.

Our beliefs are right in line with those of the NAM (National Association of Manufacturing), a group of over 11,000 manufacturing companies consisting of 12 million people who make things in America. The NAM advocates for policies that will keep the US competitive in the global marketplace.

Check Out Our New Website!


And with good reason! Our marketing team has been quite busy and is pleased to announce the launch of our new website. We hope you will find the navigation easier, the visuals more pleasing and the website more informative.

30+ development projects are now described in detail. These “success stories” highlight the many areas where SIGMA Design Company can assist you to:
  • Create better products and machines
  • Launch more designs in less time
  • Help manufacturers create new revenus streams
  • Reduce new product time to market
  • Improve quality / reliability of existing parts and designs
  • Value engineer designs to increase business profit margins

Check out our brand new Sigma Design website NOW!

Advanced Engineering & Machine Automation

Sigma Design is proud to have recently joined the Rockwell Automation OEM Program, which is part of the Rockwell Automation PartnerNetwork™ .

As we further develop this relationship we see opportunities to:

* Serve new market sectors.

* Improve technical competency in automation.

Sigma and Rockwell will review and perfect best practice architecture and control design for our new machines using Rockwell Automation components and consultation support services.

Pneumatic actuated, PLC controlled mechanisms can help manufacturers significantly reduce cycle times.

We are working on two such systems right now and are ready to get started on your project!

Sigma & Cooperative Education

When was the last time you were truly ‘off’ for the summer? Even during college more and more students spend summers working and learning in an internship opportunity.  At Sigma Design Company we are proud of our affiliation with several NJ universities and their cooperative education programs. Working with interns is a mutually beneficial experience because when we ‘teach we learn again’ and teaching an intern is just one way to recharge and revitalize.   It is a special partnership that brings great rewards to all involved. The ‘excellent intern’ brings the latest engineering theories to life in an applied setting. Our most recent intern, Dustin Heitner described his work at Sigma Design…

26a0291c-7e16-4ff5-acfa-f004bc2db98a“From learning how to conduct yourself in a working environment, to carrying out tasks relevant to your area of study, an internship exposes a student to everything they are studying for.  The value behind producing work for a customer, rather than producing work for a grade is substantially greater.  An internship gives a student the opportunity to realize what they are studying for; it can even give them incentive to work harder back in the classroom to allow them to develop their skills as a better employee.  Internships are a necessary tool in shaping a student and preparing them for the career that they hope to pursue.”

Dustin especially enjoyed refining his skills using SolidWorks on real projects (  Sigma Design uses SolidWorks in the design of new products and for simulation projects. To read about a project click here!

Prototypes with a Twist

An inventor needed a customized auger for an unusual application. The problem was that it could not be produced using traditional  CNC machine methods or as an injection molded plastic part. So, a few hours spent with a product development expert at Sigma resulted in the complex blade geometry needed for the auger in a process that could be readily manufactured.

 With our Rapid Prototyping FDM machines we can take your design concepts and grow ABS plastic parts. Used as a quick, proof of concept development tool, parts can usually be created, manufactured and shipped in just two (2) days.

Sigma Design is ready to:
*Take your geometry and produce prototypes.
*Design new geometry and produce prototypes.
*Develop and manufacture prototype devices, specialty production equipment and controls with testing capabilities in-house.

Thermal Analysis using Computational Fluid Dynamics (CFD)

Complex engineering solutions are, well, ‘complex’.  That accurately describes the challenge of recent job for a global metal manufacturing firm.  In this job Sigma was to reverse engineer and model a heat exchanger that is used in a foundry for creating alloy steel bars. In this application, hot metal flows in from one side, at 2800 °F, and is cooled by water that enters in from the other side. When the metal exits, it will be solidified to 1700 °F. The water and metal never touch, and because of the high heat, the heat exchanger itself had some very complex geometry and materials. Sigma was tasked with this project because of their engineering and design experience. The client’s heat exchanger had very poor engineering documentation (no drawings or specifications), and was largely untouched for many years. As a result, the orientation of a few components was unknown, and it became critical to understand which way the heat exchanger should be assembled.

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A SolidWorks Simulation CFD was run to determine the fluid flow profile. By running the simulation with different configurations of the heat exchanger, we could see which configuration provided better flow and therefore better system temperature control. We created areas where the flow rate could be measured, and used that data to determine the proper orientation of the components. Basically, the larger the flow rate near the hottest point in the assembly the better, because that will lead to greater convection, and essentially better heat removal.  Problem solved!

Hydraulic Power Test System Development for the United States Navy

Ken DeGraw, Sigma Design Company’s northern NJ rep recently brought in a very interesting project. We are working on a NAVSEA research program to design and build a large Hydraulic Power supply for the US Navy’s weapon testing system.CIMG3348

Sigma is very excited to work on a project with the US 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 US 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 3000psi the pressure compensation and hydraulic shock suppression systems were key features in the new design. This system joins the growing roster of Sigma’s manufactured in NJ 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.