When there's smoke, there's firmware.

Firmware refactoring and debugging
DMX512 Protocol
RS485 Bus Analysis
KiCad
C
Embedded Firmware
PCB Design
Program Recovery
Hardware Testing
Sigma Services

Overview

"The joy of seeing code go boom (safely). What could be better?!" – LeafLabs Team
"The joy of seeing code go boom (safely). What could be better?!" – LeafLabs Team
Sigma Services is a full-service production and special effects company that's worked on everything from high-octane sports events to immersive theme park experiences. Known for their large-scale effects and creative problem-solving, their work blends engineering precision with theatrical flair, often involving fire, fog, and a whole lot of spectacle. LeafLabs assessed and refactored Sigma Service's firmware and PCBs to ensure stability and enable compatibility with multiple protocols, resolving critical safety concerns in their flame cannon systems.
microscope image of probes
microscope image of probes
Sigma Services

The Challenge

Sigma Services came to LeafLabs with a blazing problem: unpredictable bugs in their flame cannon firmware were causing unreliable behavior and safety concerns. The mix of aging hardware and cryptic code made the issues tough to pin down, but too risky to ignore.
Sigma Services came to LeafLabs with a blazing problem: unpredictable bugs in their flame cannon firmware were causing unreliable behavior and safety concerns. The mix of aging hardware and cryptic code made the issues tough to pin down, but too risky to ignore.
Mockup
Mockup
Mockup
Mockup
Mockup
Mockup
VR Glasses
VR Glasses
VR Glasses
LeafLabs identified two critical issues: erratic behavior under faster refresh rates causing unpredictable misfiring, and RS485 bus instability limiting system scalability. Combined, these bugs made the system fragile and hard to scale—an unacceptable risk when working with live fire effects.
LeafLabs identified two critical issues: erratic behavior under faster refresh rates causing unpredictable misfiring, and RS485 bus instability limiting system scalability. Combined, these bugs made the system fragile and hard to scale—an unacceptable risk when working with live fire effects.
Sigma Services

The Solution

LeafLabs started with an architecture review and deep dive into Sigma Services' existing firmware and hardware setup to diagnose the root causes of both the refresh rate instability and RS485 bus limitations. We identified the critical timing mismatches and bus-loading inefficiencies that were baked into the legacy code.
LeafLabs started with an architecture review and deep dive into Sigma Services' existing firmware and hardware setup to diagnose the root causes of both the refresh rate instability and RS485 bus limitations. We identified the critical timing mismatches and bus-loading inefficiencies that were baked into the legacy code.

DMX512 Protocol RS485 Bus Analysis KiCad C Embedded Firmware PCB Design

Sigma Services

Performance Results

Sigma Services now operates their flame cannon systems with confidence and reliability. The refactored firmware eliminated safety concerns and enabled stable performance under demanding conditions. Through this collaboration, LeafLabs resolved critical issues that had been limiting both safety and scalability of their special effects operations.
Sigma Services now operates their flame cannon systems with confidence and reliability. The refactored firmware eliminated safety concerns and enabled stable performance under demanding conditions. Through this collaboration, LeafLabs resolved critical issues that had been limiting both safety and scalability of their special effects operations.
Critical Issues Resolved
Critical Issues Resolved

Refresh rate instability and device scaling issues fixed.

2
2
2
Scalability Improvement
Scalability Improvement

Enhanced device capacity from ~20 to 32+ controllers.

42%
42%
42%
Protocol Compliance
Protocol Compliance

Full RS485 specification achieved.

82%
82%
82%

The firmware updates have been deployed across Sigma Services' flame cannon systems for reliable special effects operations.

Sigma Services

Publications & Info

Sigma Services on YouTube

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The teams who trust us with their hardest problems.
The teams who trust us with their hardest problems.
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