Business Details
27 Years
experience
Trusted Industrial Engineering Solutions in Middlesex, NJ
Sigma Design has been a trusted leader in design, engineering, and manufacturing since 1999. Our team of experienced professionals specializes in transforming complex ideas into market-ready products through advanced engineering analysis, state-of-the-art technology, and a best-practices approach. With over 1,000 successfully completed projects, we serve diverse industries including clean energy, health and life sciences, culinary appliances, and industrial water systems. Our 20,000-square-foot facility in Middlesex, New Jersey, enables full in-house control over product development cycles, from concept to manufacturing. We combine 200+ years of collective engineering expertise with ASME, AWS, and UL certifications to deliver cost-effective, innovative solutions tailored to client needs. Our focus on reducing development risks and time-to-market has earned the trust of global manufacturing firms and leading brands.We maintain a client-centric approach, offering post-project support and leveraging cross-industry insights to solve unique challenges. Our commitment to quality is demonstrated through rigorous testing protocols and adherence to strict manufacturing standards. As a mid-sized company, we provide personalized attention while maintaining the resources of a larger organization. Our patented water conditioning systems and turnkey engineering solutions reflect our dedication to innovation. We collaborate closely with clients to ensure designs meet exact specifications, whether for new product development or build-to-print services. Our track record includes partnerships with prestigious universities, government agencies, and multinational corporations.
Services
Industrial Water Filtration
Turnkey Engineering
Design/Build Manufacturing
Advanced Engineering Analysis
CNC Machining
Welding Services
Product Prototyping
Custom Automation
System Integration
Testing & Validation
Details
- Year established: 1999
Highlights and features
- 200+ years of combined engineering experience across diverse industries
- State-of-the-art 20,000 sq ft manufacturing facility with ASME/AWS certifications
- Advanced engineering analysis reduces development risks and costs
- Complete in-house design-to-manufacturing capabilities
- Proven track record with global brands and government agencies
Associations and certifications
- ASME
- AWS
- UL
Services
Industrial Water Filtration
Sigma Industrial Water Group develops customized filtration solutions for industrial applications. Our patented systems handle high solids content, seawater desalination, and membrane protection. We provide complete turnkey installations including automated controls, UV disinfection, and differential pressure monitoring. Our engineers use 3D modeling and flow analysis to optimize system performance for clients in manufacturing, energy, and food processing industries.
Turnkey Engineering
We manage complete product development cycles from concept to production. Our services include design engineering, prototyping, manufacturing, and testing. With ASME-certified welding and UL-listed electrical enclosures, we deliver precision-engineered solutions for medical devices, clean energy systems, and industrial equipment. Our 20,000 sq ft facility supports end-to-end project execution with reduced time-to-market.
Design/Build Manufacturing
Our design/build approach optimizes manufacturing efficiency through weight reduction and part consolidation. We specialize in complex electromechanical systems requiring tight tolerances and specialized materials. Services include CNC machining, motion control systems, and thermal management solutions. Our team handles high-end builds requiring advanced engineering oversight and quality assurance protocols.
Advanced Engineering Analysis
We employ finite element analysis, computational fluid dynamics, and thermal modeling to optimize designs before production. Our engineers identify potential flaws through stress testing and motion analysis, reducing development risks. This approach supports innovation in fluid handling systems, structural components, and heat management solutions across multiple industries including medical devices and renewable energy.
CNC Machining
Our CNC machining capabilities support complex component manufacturing with tight tolerances. The facility includes advanced milling, turning, and welding equipment for prototyping and production runs. We maintain ASME Section IX welding certifications for carbon steel, stainless steel, and aluminum components. Our machining services integrate with design and engineering to ensure manufacturability and cost efficiency.
People
Gerard J. Lynch
President & CEO
Jerry Lynch has led Sigma Design since 1999, transforming it into a $4M business with 24 employees. With 40+ years engineering experience, he holds multiple patents in filtration technology and has developed new product lines for Fortune 500 companies. He earned a Masters in Business Management from Stevens Institute of Technology.
Michael A. Collins
Manager of Engineering
Mike Collins leads mechanical engineering projects at Sigma, specializing in machinery design for industrial and medical applications. A licensed Professional Engineer in New Jersey, he brings naval engineering experience and expertise in electrical panel design. He earned his Mechanical Engineering degree from Stevens Institute of Technology.
Ma. Sarah Bunales
Marketing Communications & Administrative Manager
Sarah Bunales manages administrative operations and marketing communications at Sigma. With 30 years of sales experience, she develops client engagement strategies and streamlines procurement processes. She holds a Bachelor of Science in Commerce from the University of Santo Tomas and oversees sales operations and compliance.
Questions
What industries does Sigma Design serve?
We serve clean energy, health and life sciences, culinary appliances, ag-tech, industrial water systems, and custom manufacturing sectors.
Do you handle complete product development cycles?
Yes, we manage full development from concept through manufacturing, including design, engineering, prototyping, and testing.
Are your manufacturing processes certified?
Our facility maintains ASME Section IX welding certifications and UL 508A electrical enclosure standards.
Can you develop customized water filtration systems?
Our Sigma Industrial Water Group specializes in custom filtration solutions including automated backwash systems and seawater desalination technology.
What engineering analysis tools do you use?
We employ finite element analysis, computational fluid dynamics, and thermal modeling to optimize designs before production.
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