Business Details
27 Years
experience
Trusted Engineering & Manufacturing Solutions
Sigma Design has been a trusted partner in engineering and manufacturing since 1999, delivering over 1,000 projects for global clients. Our team of licensed engineers and technicians combines advanced simulation tools with hands-on design expertise to optimize product development cycles. With a 20,000-square-foot facility in New Jersey, we offer end-to-end solutions from concept to manufacturing, serving industries ranging from clean energy to medical devices.Our ASME-certified welding and UL-508A electrical panel capabilities ensure compliance with rigorous standards. We maintain a client-centric approach through direct feedback loops and a commitment to reducing manufacturing costs by up to 25% compared to in-house teams.
Services
Industrial Water Filtration
New Product Development
Build-to-Print Manufacturing
Advanced Engineering Analysis
Custom Machine Manufacturing
Electromechanical Engineering
Product Testing
Design/Build Systems
Industrial Automation
Prototype Development
Details
- Year established: 1999
Highlights and features
- 200+ years of combined engineering experience across diverse industries
- ASME and UL certified manufacturing capabilities in-house
- Proven track record with Fortune 500 companies and global brands
- 25% more cost-effective than traditional in-house engineering teams
- Multi-disciplinary team approach with owner-level accessibility
Associations and certifications
- ASME-AWS Section IX
- AWS D1.1
- UL 508A
- Licensed Professional Engineers (P.E.)
Services
Industrial Water Filtration
We design and manufacture customized industrial water treatment systems including automated backwash filters, UV purification units, and high solids separation systems. Our solutions integrate seamlessly with existing processes for food processing, energy production, and manufacturing applications. Systems incorporate advanced controls and monitoring for optimal performance and regulatory compliance.
New Product Development
Our end-to-end development process transforms concepts into market-ready products through rapid prototyping, engineering analysis, and design for manufacturability. We specialize in complex electromechanical systems across medical devices, clean energy, and industrial equipment. Our 20,000 sq ft facility supports full-scale testing and validation.
Build-to-Print Manufacturing
We execute precision manufacturing from client-provided designs using ASME-certified welding, CNC machining, and UL-508A electrical panel assembly. Our capabilities include heavy equipment fixtures, automated production machinery, and complex assemblies requiring tight tolerances and repeatable quality standards.
Advanced Engineering Analysis
Our simulation capabilities include structural stress, thermal, fluid flow, and fatigue analysis to optimize designs before production. Using FEA and CFD tools, we identify potential failures early, reducing redesign costs and improving product longevity for aerospace, medical, and industrial applications.
Custom Machine Manufacturing
We develop specialized manufacturing equipment including automated assembly systems, test stands, and industrial appliances. Our designs minimize part counts and weight while maximizing efficiency. Applications span food processing, pharmaceutical production, and clean energy systems with integration of motion controls and PLC programming.
People
Gerard J. Lynch
President & CEO
Licensed Professional Engineer with 40+ years' experience transforming Sigma Design into a $4M+ business serving global brands. Holds advanced engineering management degree and multiple patents in filtration technology.
Michael A. Collins
Manager of Engineering
Licensed PE in New Jersey with expertise in mechanical systems design for industrial, medical, and military applications. Leads engineering projects and client collaborations from concept through production.
Ma. Sarah Bunales
Marketing Communications & Administrative Manager
30-year sales and operations professional managing procurement, client communications, and administrative processes. Implements efficiency improvements in purchasing and sales operations.
Questions
What industries do you serve?
We work with clean energy, healthcare, food processing, industrial water systems, and culinary appliance manufacturers through our New Jersey facility.
What engineering software do you use?
Our engineers utilize CAD, FEA, and CFD tools for 3D modeling, stress analysis, and fluid dynamics simulations during product development cycles.
Are you ASME certified?
Yes, we hold ASME Section IX and AWS D1.1 welding certifications for carbon steel, stainless steel, and aluminum components.
Can you handle full product lifecycle?
We provide complete lifecycle support from concept development through manufacturing, including prototyping, testing, and production validation.
Do you offer international shipping?
Our clients include global companies; we coordinate logistics for equipment delivery worldwide from our Middlesex, NJ manufacturing center.
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