Tag Archives: Design Engineering

Make it Better and Improve Performance!

Dymax Corporation, located in Torrington, CT, is a leading manufacturer of advanced light-curable adhesives, coatings, oligomers, light-curing equipment, and fluid dispensing systems that work together to optimize manufacturing assembly processes.  Dymax came to Sigma Design Company to improve their WIDECURE® conveyor system. WIDECURE is a 25″ wide UV curing system with 700 mW/cm² of curing power. This system is typically used in industrial plants for the curing of adhesives during the assembly of aerospace, electronic and automotive components.  Dymax Corporation is well known for making manufactures more efficient and need to update the design of the WIDECURE with additional safety and performance features. Dymax presented Sigma with a solid and dependable machine, but a machine that lacked the features needed by its industrial customers and users. Learn more about Dymax here.

Sigma took their original prototypes and examined every single nut and bolt to do a complete redesign of the original machine. Aside from adding a number of safety and performance features to the system, Sigma greatly improved the user interface of the unit and overall quality and reliability of the system. The WIDECURE is aesthetically more pleasing and a truly gorgeous machine. Operators will be very pleased with its new ergonomic design and low level machine noise. Sigma’s new design also includes provisions for lifting and transporting the machine in a safer manner. WATCH VIDEO HERE!

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Dymax WIDECURE conveyor system at Sigma Design Company facility.

Sigma engineered several important features, making the new WIDECURE system a real state of the art unit. The control scheme of the machine was redesigned to be category 3 safety compliant.  Our engineers added an Allen Bradley PLC and HMI (Programmable Logic Controller and Human Machine Interface), and an open loop stepper system to smoothly lift and lower the UV lamp assembly.  Sigma turned a dependable machine into a world class system allowing the customer to better meet the needs of the industrial marketplace.

Contact Sigma Design Company about how we can improve your designs! 

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!  

www.sigmadesign.net

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.

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.

Winning the Rat Race

The term ‘rat race’ has been described as a “seemingly pointless or endless pursuit”.   The work of today’s research scientist is hardly pointless but one aspect of the work, while not endless, was a tedious pursuit.  We are describing the work of researchers charged with the task of  observing and documenting the behavior of mice in lab settings. The job was to watch and score lengthy video recordings of the creature’s every move.  That was until Jessie Brodkin came up with an idea that he has described as “thinking inside the box”.  

Brodkin’s creation is The Behavioral Spectrometer (http://behavioralinstruments.com), a humane device that captures everything your mouse does without having to watch and score hours of video recordings.  Brodkin found SigmaDesign Company and its team of mechanical design engineers for the job.  Sigma designed, tested and now manufactures this ‘mouse house’, The Behavioral Spectrometer, right here in NJ.  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.      

Brodkin’s ‘made in NJ’ product has met with huge success in the research and pharmaceutical world. The Behavioral Spectrometer is used by Rutgers University’s Department of Neuroscience and Cell Biology, Pfizer, and other global R&D laboratories for the development of new treatments and drugs. The latest 4 systems were just shipped to a R&D laboratory in Austria. To read customer articles and references: http://behavioralinstruments.com/references

This is another success story showing Sigma Design Company’s ability to provide manufacturing engineering and product development services to people like you.Sigma Design is your single source engineering and manufacturing resource for new products and specialty machinery. 

Please contact us about your next project!  

SIGMA Helps Redesign Surgical Supplies Stand for USA Market Relaunch

SIGMA is capable of improving the functionality of various industrial, consumer and healthcare products for relaunch into the marketplace. One example is the surgical supplies stand, which was recently introduced from Europe to the US surgical market by our customer.

The global fortune 500 medical supply company identified a ‘bell weather’ product used for over 30 years in Belgium and German. This seemingly utilitarian supply cabinet plays a crucial role in hospital surgery rooms for efficient organization and on-demand availability of critical surgical supplies.

Surgical Supplies Stand, a SIGMA Redesign for US Market

Surgical Supplies Stand, a SIGMA Redesign for US Market

In order to introduce this product into the US market the customer needed to adapt its design to accommodate the different sizes of surgical supplies in the US. So the surgical cabinet drawings needed to be reworked from the metric system to the US Unit system (based on inches) for manufacturing in the US. One challenge was to produce CAD manufacturing drawings in US standards (inches) from old hand drawings (metric).

SIGMA helped in this product relaunch for the US by creating a more futuristic look, improving certain features, suggesting design improvements and recommending materials. New functionality was added to allow for carrying, pushing, spinning or connecting the surgical supplies cabinet to the wall of an operating room.

The updated product was successfully released by the customer in the US surgical market with new functionality for better productivity for surgeons and their teams.

Sigma Design Company –  Reverse Engineering and Design for Product Relaunches

Sigma’s Capabilities: Reverse Engineering for New Product Development

SIGMA Design uses in-house gage inspection techniques using 3D Scanning and FARO Technology to verify manufactured parts for products we design, as well as for reverse engineering of components supplied by our clients.

Reverse engineering is a viable method to create 3D manufacturing models from existing parts and system components. The process involves disassembly, inspection, measuring a component and reconstructing it as a 3D CAD model. Once captured the part can be manufactured anywhere to specified tolerances and materials.

Learn more about capabilities of SIGMA Design Company at http://www.sigmadesign.net/brochures.html 

SIGMA Design Company – Turning Smart Ideas into Product Solutions

People Power: Bob Messinger, Senior Project Design Engineer

Whether you need Finite Element Analysis (FEA) on an injected molded medical device part or on a large steel bridge structure, then Bob Messinger, Senior Project Design Engineer takes care of business. Bob is an experienced mechanical engineer and one of five Solidworks specialists at SIGMA. His recent project experience spans the Ohmsett National Testing Platform (see SIGMA blog article), Motion Power Express™ energy harvester (see SIGMA blog article) and the Rapid Vodka Chiller.

Bob Messinger, Senior Project Design Engineer, SIGMA Design Company

Bob joined SIGMA in 2004 after a 21 year career with Hayward Pool Products where he designed filters, pumps, valves and water management devices that utilize precision injection and blow molded plastic parts. Prior to that, Bob spent 4 years with Valcor Engineering Corp. designing electro-mechanical solenoid valves for aircraft, aerospace and nuclear applications. Bob has extensive training that includes Cosmo FEA (linear and nonlinear, Solidworks (Beginner in 2000, Advanced in 2000 and Advanced in 2011); Solidworks surface, SDRC Ideas Design and Drafting, and Pro/E Design and Advanced Design.

Bob is a long time Harley-Davidson enthusiast who also enjoys cabinet making in his home woodshop. What Bob likes best about Sigma is “the wide range of activities, from micro to maxi, keeps the job interesting and challenging”.

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SIGMA Upgrades National Ohmsett Testing Facility in Leonardo, NJ

SIGMA Upgrades National Ohmsett Testing Facility in Leonardo, NJ

Oil spills in waterways or the Gulf of Mexico are serious business and call for innovative water cleaning technologies. To test emerging technologies for oil spill clean up, many turn to the Ohmsett National Oil Spill Response Research & Renewable Energy Test Facility, located in Leonardo, New Jersey – right on the Raritan Bay about one hour south of New York City.  Sigma Design Company of Middlesex New Jersey (SIGMA) was awarded a contract to lead the upgrade of the Ohmsett Test Facility.

Ohmsett Test Platform - Delivery

Ohmsett Test Platform – Delivery

The Ohmsett National Oil Spill Response Research & Renewable Energy Test Facility is the largest outdoor saltwater wave/tow tank facility in North America. This is the only facility where full-scale oil spill response equipment testing, research, and training can be conducted in a marine environment with oil under controlled environmental conditions (waves and oil types).  The Ohmsett Test Facility is maintained and operated by the U.S. Department of the Interior’s Bureau of Safety and Environmental Enforcement (BSEE).

Recently the Ohmsett Test Facility served as the test site of more than seven different systems that competed for a first prize of $1.4 million in the Wendy Schmidt Oil Cleanup X CHALLENGE for highly effective oil spill cleanup methods. The facility also has the mission as a research and testing venue for wave energy conversion devices.

Ohmsett Test Platform - Placement

Ohmsett Test Platform – Placement

With such increased levels of activity, the 50 year old Ohmsett Test Facility needed an upgrade and critical components needed improvement, especially the test platform – which is affectionately called the Aux Bridge.

Unique in many ways, the Ohmsett test platform is a hybrid bridge/test platform – that is 70 feet long and weighs 35,000 lbs. Test systems are towed through the seawater tank, which is 650 feet long, 65 feet wide and 12 feet deep. The lab can also create 2 to 3 foot waves to better simulate open water challenges in firefighting and oil spill clean up.

After a competitive bidding process, SIGMA was awarded an engineering contract to design and manage the construction, as the owner’s representative, of a new test platform for Ohmsett. The major design challenges were to develop a larger test structure that was safer, easier to use allowing quicker operational set ups while reducing the overall weight, and increasing operational test load capacity.

Ohmsett Test Platform - Installation

Ohmsett Test Platform – Installation

SIGMA analyzed, designed and managed every part of the new testing system by using 3D design software, FEA structural analysis methods and mechanical engineering competencies. The platform was validated by:                1) alignment testing – to ensure “she” rolls straight when pulled 6 knots; 2) load testing- with over 80,000 lbs; and finally 3) operational testing – while being pulled 6 knots through seawater tank.

With the completed installation and acceptance of the new test platform in January 2012, the Ohmsett Test Facility is ready to serve oil spill clean up and wave energy technology testing needs for many years to come.

Sigma Design Company – Solution Analysis, Design and Construction/Installation Management 

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Congratulations to Client WATTLOTS Whose SolarArbor™ Won “Top 10 Cool Products of 2011” by NJTC

Client WATTLOTS was designated a winner of the “Top 10 Cool Products of 2011” by the New Jersey Technology Council (NJTC) on November 9th for their SolarArbor™ product. The base of the SolarArbor™ was designed by Sigma Design Company.

The SolarArbor™ is a uniquely styled parking lot canopy system that is specifically designed to retrofit existing surface parking lots providing substantial quantities of clean, renewable electrical energy where it is needed.

Sigma Design Company, of Middlesex, New Jersey,  developed the design for the base of the SolarArbor™ to provide stability and to enable rotation to maximize sun exposure. A working prototype is under testing in New Jersey and has already withstood an earthquake, a hurricane and a snow storm!

Stay tuned for more information about the development of this renewable energy product by WATTLOTS and Sigma Design Company.

Sigma Design Company – Turning Smart Ideas into Product Solutions

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