Tag Archives: new product design

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

Our Capabilities: Nonlinear Finite Element Analysis

Sigma has recently added Nonlinear FEA to its suite of advanced engineering tools.

This new offering will allow Sigma’s engineers and designers to better tackle some of the toughest challenges by more accurately simulating nonlinear behavior, including plastics analysis, large deformation and nonlinear/time-based loading. Of particular interest is the team’s ability to effectively load and unload a part, thereby predicting any permanent deformation that may occur.

Recent clients have sent preliminary plastic models for review, enabling quick review of proposed design changes and their effects on part integrity, before more expensive prototypes and tooling are manufactured. Additionally, models were simulated at elevated temperatures to recreate the real-world testing scenarios the part was designed to withstand.

Nonlinear FEA is another tool in Sigma Design’s advanced engineering toolbox, and complements the years of plastic part experience held by Sigma’s design and engineering team.


Stress within a plastic clamp is shown as a work piece is slid into place.

Learn more about our capabilities by viewing SIGMA’S online brochures.

SIGMA Design Company- Turning Smart Ideas into Product Solutions with Nonlinear Finite Element Analysis

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: 3D Rapid Prototyping

SIGMA Prototype for Better Health

SIGMA Prototype for Better Health

SIGMA Design provides in house 3D rapid prototyping services for proof of concept review. 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 be created, manufactured and shipped in two 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.

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

Sigma Design Company – Turning Smart Ideas into Product Solutions

SIGMA Networking with Federal Labs and Licensees to Accelerate USA Tech Commercialization

US investment in R&D at federal laboratories has been the fuel for long term US technology advancement and competitiveness – from space exploration to internet development. Now, more than ever, the private sector needs to bridge the chasm between the federal laboratories and the marketplace in order to boost the economy and propel hi- tech job growth. There are opportunities to harvest the $400 billion of annual US R&D spending* for high-tech products and high-wage jobs. Sigma Design Company (SIGMA) is one private company that is taking the lead in this arena by networking with federal labs and licensees and offering its comprehensive service suite for technology commercialization and total new product development.

Major government initiatives, such as the space program and other R&D initiatives, led to significant inventions such as the microprocessor chip, specialty materials, the microwave and the internet, just to name a few. These inventions have forever transformed our communications, social exchange, and lifestyle. Other benefits were the creation of trillions of dollars of economic value and numerous high-skilled and high-wage employment in the communications, computer, aerospace, consumer, media, social network and other industries.

SIGMA is stepping up to leverage its full range of capabilities for technology commercialization with resources of the Federal Labs Consortium (http://www.federallabs.org/). As you know, SIGMA offers concept designs, drawings and prototypes as well as engineering design services in the areas of failure analysis, electrical engineering, and machine engineering. With its new expanded facility in Middlesex, New Jersey, SIGMA offers on-site contract manufacturing cells with lean production and quality assurance services in New Jersey, USA. (SIGMA has several cells available.)

But there is more. One SIGMA collaborator adds industrial and human factor design to the total process; while another SIGMA collaborator adds strategic business design, planning, finance sourcing, market development and IP strategy services.  Such a coordinated Total New Product Development approach enables interactive dialogue and early validation with customers, markets and investors, to better deliver products for market with best ROI.

Contact us today to learn more about transforming patents and technologies into products and businesses. Email us at info@sigmadesign.net or call (732) 629-7555.

*Source: 2012 Biennial report ‘Science and Engineering Indicators (SEI)’ of NSF’s NSB, January 19, 2012 as reported in Manufacturing.net.

Sigma Design Company – Turning Smart Ideas into Product Solutions

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

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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