Business Details
27 Years
experience
Your Trusted Partner for Industrial Manufacturing Solutions
Sigma Design has been a trusted partner in design, engineering, and manufacturing since 1999. Our team of licensed engineers, certified welders, and technical specialists operates from a 20,000-square-foot facility in Middlesex, New Jersey, equipped with state-of-the-art machinery for CNC milling, welding, and advanced engineering simulations. With over 1,000 successfully completed projects, we serve industries ranging from clean energy and health sciences to culinary appliances and industrial water systems. Our end-to-end approach integrates design, prototyping, and manufacturing under one roof, reducing time-to-market by up to 25% compared to traditional models.We maintain ASME, AWS, and UL certifications, ensuring compliance with rigorous industry standards. Our client-centric philosophy emphasizes transparency, with post-project accessibility as a resource specialist. The companys veteran leadership combines 40+ years of engineering expertise with business management acumen, holding multiple patents in filtration and energy-harvesting technologies. We prioritize domestic manufacturing, contributing to U.S. economic growth through innovative solutions that address global challenges.
Services
Design Engineering
Industrial Manufacturing
Build to Print Services
New Product Development
Water Filtration Systems
CNC Machining
Welding Fabrication
Automation Solutions
Prototyping
Electrical Systems Integration
Details
- Year established: 1999
Highlights and features
- 25+ years of engineering experience across 10+ industries
- In-house ASME-certified welding and UL-508A electrical panel building
- State-of-the-art 20,000 sq ft facility with CNC machining capabilities
- Proven track record with 1,000+ successfully completed projects
- Direct access to owner-managed teams for critical decision-making
Associations and certifications
- Licensed Professional Engineers (P.E.) in New York and New Jersey
- ASME-AWS Section IX and D1.1 certified
- UL 508A certified
Services
Industrial Manufacturing
Our industrial manufacturing capabilities combine precision engineering with scalable production. We specialize in CNC machining, ASME-certified welding, and UL-508A electrical panel fabrication. Clients benefit from integrated quality control processes that ensure compliance with ISO standards while maintaining cost efficiency through optimized material usage and workflow automation.
Water Filtration Systems
We design and manufacture custom water filtration systems for industrial applications. Our patented solutions include automated backwash tubular filters and high-solids separation systems. Each system undergoes rigorous validation testing to ensure performance specifications meet or exceed client requirements for efficiency and contaminant removal rates.
New Product Development
Our NPD process integrates concept development with DFM principles to reduce time-to-market. Using advanced FEA and CFD analysis, we identify design flaws early in development. Clients receive fully validated prototypes with documented testing protocols to support regulatory compliance and mass production readiness.
Build to Print Services
We execute build-to-print projects with strict adherence to client specifications. Our capabilities include complex weldments, machined components, and electromechanical assemblies. Quality assurance includes dimensional inspection using CMM equipment and first-article verification before full production runs.
Automation Solutions
Our automation services focus on custom machinery integration for manufacturing optimization. We develop PLC-controlled systems with HMI interfaces for process monitoring. Solutions incorporate motion controls, sensor networks, and safety interlocks to enhance productivity while maintaining OSHA compliance.
People
Gerard J. Lynch
President & CEO
Licensed Professional Engineer with 40+ years of experience. Holds advanced degrees in engineering management and business. Developed patented filtration technologies and led company growth to $4M+ annual revenue.
Michael A. Collins
Manager of Engineering
Licensed PE in New Jersey with mechanical engineering expertise. Specializes in industrial and medical equipment design. Former U.S. Navy shipboard systems inspector with 10+ years of leadership in engineering projects.
Ma. Sarah Bunales
Marketing Communications & Administrative Manager
30-year sales and operations professional. Manages procurement processes and client communications. Implements efficiency improvements in purchasing and sales workflows to enhance operational productivity.
Questions
What industries does Sigma Design serve?
We serve clean energy, health sciences, ag-tech, industrial water systems, and culinary appliance manufacturing sectors with specialized design and manufacturing solutions.
Can Sigma handle complete product development cycles?
Yes, we provide end-to-end services from concept development through manufacturing, including prototyping, engineering analysis, and validation testing.
Are your manufacturing processes certified?
Our facility maintains ASME-AWS welding certifications, UL-508A electrical standards compliance, and licensed professional engineering oversight.
Do you offer build-to-print services?
Yes, we execute build-to-print projects with precision welding, CNC machining, and quality assurance protocols for client-supplied designs.
How does Sigma ensure quality control?
We implement dimensional inspections using CMM equipment, first-article verification, and documented testing protocols for all critical manufacturing processes.
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