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

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
Full read
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 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
Wind turbine tilting mast
Independent structural verification of a client-designed tilting mast in the 15–20 m height range, combining FEA, manual …
Sprint
Short read
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
Full read
Fabricated steel silos
Initially brought in for 3D CAD expertise, Frugal went on to provide broader ongoing mechanical engineering design …
Retainer
Short read
Sculpture support frame
Frugal established the geometry basis, frame architecture, critical interfaces and delivery strategy needed to turn …
Phase 0
Full read
In-house design function
Before founding Frugal, Tom designed and implemented the systems, controls and supporting records that established …
Early career project
Full read
Penstock installation
Frugal surveyed the reservoir inlet, designed the main frame that integrated four client-selected penstock units into …
Sprint
Full read
D&B contractor design support
A long-term external engineering relationship covering live bids, concept and feasibility work, non-standard mechanical …
Retainer
Short read
Geodesic screen
Working from a previously purchased geodesic frame in Chicago, Frugal developed a remote survey approach, reconstructed …
Sprint
Short read
Suspension bridge castings
Frugal developed detailed 3D models and manufacturing proposal drawings for a set of suspension bridge saddles, …
Sprint
Full read
Clarifier scum beach
With the original carbon-steel scum beaches heavily corroded and no usable design record available, Frugal surveyed the …
Sprint
Short read
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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