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Experience

Selected project examples to help you judge fit, approach and delivery style

Since 2004, I’ve delivered mechanical engineering design work across hundreds of projects for dozens of end clients, mainly involving bespoke and low-volume industrial equipment, mechanical products and fabricated systems.

My work spans early definition and concept development through to CAD, drawings, FEA, verification and substantiation, including against Eurocodes, product-specific standards, machinery requirements and client-specific acceptance criteria where applicable.

The examples below show the kinds of problems I help solve, how I approach them and the outcomes I deliver.

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Some recent and commercially sensitive work cannot be shown publicly. The examples below are therefore a representative sample rather than a complete project record.

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Orbiton vibrating lamella

Orbiton had already proved its acoustic keyboard concept with a working prototype before a series of focused Phase 0 studies and ongoing technical input developed a secure tip-mass and tuning method, profiled lamella geometry and a frequency-correlated parametric model that supported the selection of practical candidates for the next prototype generation.

Phase 0

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A 6-tonne Type 10 yard ramp developed as part of the wider range rationalisation programme.

Mobile yard ramp range

Before founding Frugal, Tom led a phased redesign of a mobile yard ramp range, cutting the weight of principal models by …

Early career project

Full read

Orbiton keyboard prototype being played, using the riveted tip masses developed during the work

Orbiton vibrating lamella

Orbiton had already proved its acoustic keyboard concept with a working prototype before a series of focused Phase 0 …

Phase 0

Full read

Example FEA stress plot from the structural report

Wind turbine tilting mast

Independent structural verification of a client-designed tilting mast in the 15–20 m height range, combining FEA, manual …

Sprint

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Simplified 3D model of the revised bespoke fixing

Support bar fasteners

What first appeared to be a supplier-quality issue proved to be an under-defined bespoke component. A Phase 0 …

Phase 0

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Exterior view of fabricated steel storage silos

Fabricated steel silos

Initially brought in for 3D CAD expertise, Frugal went on to provide broader ongoing mechanical engineering design …

Retainer

Short read

Internal steel support-frame design overlaid with the reinforced-concrete sculpture.

Sculpture support frame

Frugal established the geometry basis, frame architecture, critical interfaces and delivery strategy needed to turn …

Phase 0

Full read

Example records from the design control system

In-house design function

Before founding Frugal, Tom designed and implemented the systems, controls and supporting records that established …

Early career project

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Installed main support frame integrating four penstock units into the reservoir inlet, with an adjacent maintenance platform

Penstock installation

Frugal surveyed the reservoir inlet, designed the main frame that integrated four client-selected penstock units into …

Sprint

Full read

Biomass handling scheme involving 3D coordination and delivery of selected mechanical packages

D&B contractor design support

A long-term external engineering relationship covering live bids, concept and feasibility work, non-standard mechanical …

Retainer

Short read

Final screen assembled by the client in Chicago from Frugal’s flat-pattern and assembly outputs

Geodesic screen

Working from a previously purchased geodesic frame in Chicago, Frugal developed a remote survey approach, reconstructed …

Sprint

Short read

3D CAD model of a suspension bridge saddle developed for a bid-stage package

Suspension bridge castings

Frugal developed detailed 3D models and manufacturing proposal drawings for a set of suspension bridge saddles, …

Sprint

Full read

Model view of the replacement scum beach assembly

Clarifier scum beach

With the original carbon-steel scum beaches heavily corroded and no usable design record available, Frugal surveyed the …

Sprint

Short read

Detailed 3D manufacturing model of the woodchip hopper, support frame and access platform

Woodchip hopper

A small industrial equipment package within a wider plant layout called for a woodchip hopper, support frame and access …

Sprint

Short read

Common questions

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