Mechanical engineering design for non-standard fabricated products and assemblies
Independent engineering support to help manufacturers reduce unnecessary cost, avoid wasted design effort, and turn awkward technical problems into buildable designs
Engineering effort often gets wasted - not because the work is done badly, but because the wrong things are defined, prioritised, or carried too far into design. Frugal helps manufacturers decide what needs engineering, what can be simplified, and what is worth carrying forward.
Frugal is about the outcome: clear, robust, cost-effective designs that make good use of the time, budget and effort invested.
As an independent mechanical engineering design consultant, I help UK manufacturers with early design direction, technical review and cost reduction through to focused design, CAD, calculations and substantiation. The work is particularly suited to awkward, non-template problems where simplifying the route forward can prevent unnecessary time, cost and detail.
What I help with
Practical support from problem definition through to substantiated, manufacture-ready design
Unstick the brief
When the problem is unclear or your team is stuck between options, I can help:
Identify the real problem, constraints and success criteria before time is lost on the wrong route.
Define the acceptance criteria and key trade-offs, then set a direction that can be taken forward with confidence.
Set out the next steps, scope and decision basis in a form stakeholders can understand, challenge, and support.
Decision-ready options
Production-ready designs
Engineering problem triage
Structural confidence
Typical outputs and support include:
Definition and options reports
Annotated design concepts
Option and cost comparisons
3D CAD models
Technical notes and reports
Illustrated assembly sequences
Design calculations
FEA and stress analysis
Verification and substantiation reports
Engineering and fabrication drawings
Bills of materials
Design for manufacture & assembly
Supplier and manufacturer support
How we can work together
Most new projects begin at Phase 0 or as a Defined-scope sprint
Phase 0: Definition & scoping
For clients who need the clarity to avoid committing to the wrong solution, scope, or spend
- Clarity on the real problem, constraints, and unknowns
- Earlier surfacing of risks, trade-offs, and weak assumptions
- Better basis for deciding what to do next, and why
- Reduced risk of wasted design effort, delay, and rework
Defined-scope sprint
For clients who know what needs to be delivered and want it progressed as a focused, bounded package
- Defined scope, so decisions and responsibilities stay clear
- Defined outputs delivered to an agreed standard
- Faster progress on a self-contained package of work
- Better planning confidence around cost, timing, and buildability
Ongoing support retainer
For clients who want a long-term technical ally for quick input, continuity, and recurring engineering needs
- Faster answers on live engineering questions
- Early challenge before costly mistakes take hold
- Continuity across separate tasks and evolving work
- Flexible access to sound engineering judgement
Note: Free, no-obligation proposals are available for suitable enquiries with enough information to define and price the work. Phase 0 and defined-scope sprints typically start from around £1,000, dependent on scope and duration. Larger programmes can be structured as sequential sprints or ongoing support.
Client Feedback
Selected feedback from clients
5.0
“Tom is an excellent design engineer who brings clarity and direction. His deliverables are great value in their own right, and the wider benefits he brings — better decisions and fewer surprises — are the icing on the cake.”
Mick, Engineering Director
Access, Lifting & Handling Equipment
East Yorkshire
5.0
“Many thanks for all your hard work — the detail is fantastic! We’ve had your design approved so we can now progress with fabrication. Thanks again for your incredible level of support and detail — we are all truly impressed with what you’ve done for us!”
Joe, Project Director
Specialist Steelwork Fabricator
Greater Manchester
5.0
“I’m impressed — very impressed. I was blown away by the quality of your work. Absolutely amazing — very pleased with it. Thank you for all your hard work and the professional results. We are all very pleased with your 3D design models.”
Oliver, Director
Industrial Machinery Manufacturer
West Midlands
Selected firms I’ve worked with directly include:
Over the years I’ve delivered practical engineering value through consultancy, contract roles and employed positions across industrial organisations including manufacturers, fabricators, engineering consultancies, contractors, SMEs, startups and R&D teams.
Is this a good fit?
A quick way to see whether I’m the right kind of support
Likely a good fit
Engagements tend to work well when you:
- Need a documented brief, with constraints, requirements and the decision basis made explicit.
- Welcome technical and commercial challenge on options, trade-offs, risks and routes forward
- Can share relevant context early, including CAD, drawings, photographs, and background information
- Allow enough timefor the work to be properly defined, reviewed and delivered
- Value evidence-led decisions, with review or independent checking where the work warrants it
May not be the right fit
The service is less suited to work that requires:
- Immediate production, without time to define the requirement or prepare and review the work
- Mainly CAD drafting, detailing or visual development, without substantial engineering input
- An embedded resource, working under close day-to-day supervision
- Formal certification or approval, where that responsibility is not part of the agreed commission
If you are unsure, send a brief outline of what you need and I will tell you whether it sounds like a good match.
About
Frugal Philosophy
Frugal is about achieving a better overall engineering design outcome: one that is simple where it should be, robust where it matters, and cost-effective without unnecessary compromise. The aim is not to minimise spend at any cost, but to avoid waste, reduce unnecessary complication, and make better use of the time, budget, and effort invested in design.
In practice, that means explicit problem definition, sound mechanical design judgement, and fewer decisions based on untested assumptions. It means being wary of unnecessary complication, and working toward solutions with clearer architectures, fewer parts, cleaner interfaces, and less to go wrong in manufacture, installation and use.
Working basics:
- UK Limited Company: incorporated in 2012, company number 08241771
- VAT registered: VAT number GB166493575
- Independent: direct client commissions and specialist project support to other consultancies
- Nationwide: remote-first from my own office, with site visits by agreement
- Insured: professional indemnity and public liability details available on request
- Confidentiality: enquiries and project information handled confidentially; NDAs welcome where needed
Mechanical Engineering Design Consultant
Tom Hartley is a Chartered Mechanical Engineer working between problem definition and engineering delivery. He helps teams define the real engineering problem, compare practical options and agree a sound design direction before turning that basis into buildable engineering outputs.
His approach combines design judgement, engineering rigour and manufacturing realism, with a preference for simple, considered and well-substantiated solutions. The result is better-defined work, fewer surprises and designs that are easier to review, manufacture and take forward.
Professional registration, memberships and business credentials:
Earlier career and education:
Contact
If you have a mechanical engineering problem, a design decision to make or a brief that needs tightening, please get in touch
What to mention
To help me give you a useful reply, include:
- What you are building or dealing with
- The problem, decision or uncertainty
- Key constraints including budget, timescale, stakeholders etc
- The information already available, such as CAD, drawings, photos
- The outcome required, such as a clearer brief, design options, CAD, drawings, calculations or FEA
- Any genuine deadline and why it matters
Attachments
Attachments are welcome:
- Enquiries and attachments are treated confidentially
- For larger files, use Dropbox, WeTransfer or another file-sharing service and include a download link
What happens next?
If the work looks like a good fit, I will:
- Confirm whether and how I can help
- Ask for any remaining info needed to define and price the work
- Provide a clear, no-obligation proposal
If another route would be more suitable, I will say so.