Product design + engineering for non-standard industrial equipment
Independent decision support and focused engineering delivery for fabricated systems & buildable mechanical designs
Engineering effort gets wasted — not because the work is done badly, but because the wrong thing gets defined, prioritised, or carried into design. Frugal helps clarify the right route, then deliver it.
Frugal is about the outcome: simple, elegant, cost-effective engineering solutions that avoid waste and make the most of what’s invested.
Operating as an independent mechanical engineering consultancy, Frugal provides product-definition and decision support alongside mechanical design and substantiation of non-standard industrial equipment and fabricated systems.
Specialising in tricky, non-template work where the route forward isn’t immediately obvious, Frugal helps clients clarify constraints, compare options, and define what “done” looks like before committing to detailed design.
Frugal is best suited to SMEs and owner-managed manufacturers who value careful engineering judgement and solid, manufacturable outputs — particularly where the real value lies in defining and engineering a solution, not simply adding CAD capacity.
What I help with
Practical support from problem-definition through to verified, release-ready design
Unstick the brief
When the problem isn’t clear or the team is stuck between options.
Clarify the real problem, constraints, and success criteria before time is lost taking the wrong route.
Define what “done” looks like, expose the key trade-offs, and set a direction that can be taken forward into design with confidence.
Decision-ready options
Release-ready designs
Engineering problem triage
Structural confidence
Typical outputs include:
Definition / Options Reports
Annotated Design Concepts
Option Cost Comparisons
3D CAD Models
Technical Notes / Reports
Illustrated Assembly Sequences
Design Calculations
Finite Element Analysis
Structural Verification Reports
Engineering Drawing Packages
Bill of Materials
Design for Manufacture & Assembly
Supplier / Manufacturer Support
How we can work together
Most new projects begin as either a Phase 0 or a Defined-scope sprint
Phase 0: Definition & Scoping
For when the problem is unclear or disputed
Outcome:
Clarity on the real problem and recommended next steps
Typical format:
Fixed-scope (1.5 - 5 days over a fortnight)
Defined-scope sprint
For when you know what you need delivered
Outcome:
Pre-defined outputs delivered to an agreed standard
Typical format:
Fixed-scope (pre-scheduled delivery)
Ongoing support retainer
For when you need ongoing decision support
Outcome:
Responsive engineering advice and delivery as priorities evolve
Typical format:
Prioritised time allocation (flexible tasks)
Client Feedback
Selected feedback from past clients and associates
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
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
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 a wide range of industrial organisations, including manufacturers, fabricators, engineering consultancies, contractors, and R&D teams in SMEs and startups.
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…
- Want clarity on next steps (or a second opinion on a stuck decision)
- Value explicit constraints, trade-offs, and a clear definition of “done”
- Can share the available context early (CAD, drawings, photos, etc)
- Are happy to iterate based on evidence, not just preference
- Have enough runway to do it properly (not a same-day rescue)
- Are a manufacturer or client-side decision-maker who will review and sign off the resulting outputs
Probably a bad fit
It’s probably not a match if you…
- Need immediate turnaround without time to define scope, share inputs, or do the work properly
- Need the answer to stay unchanged even when the real constraints point elsewhere
- Are mainly looking for the cheapest “CAD capacity” rather than judgement, outcomes and ROI
- Can’t share key constraints but still expect definitive answers
- Want me to take responsibility for compliance or fitness-for-purpose without an explicit checking/certification scope
- Need mainly styling or industrial design rather than engineering
If you’re unsure, email a short summary and I’ll tell you whether it sounds like a good fit
About
Frugal Philosophy
Frugal is about the outcome: simple, elegant, cost-effective engineering solutions that avoid waste and get the most from what’s invested. It’s about lower whole-life cost — not cutting corners or rushing to the wrong answer — and if that costs a little more upfront, then so be it.
Working basics:
- UK Limited Company – established 2012 (VAT registered)
- Independent – direct client work and specialist support to other consultancies on a freelance basis
- Nationwide – remote-first from my own office (not embedded on-site)
- Insured – PI/PL details available on request
- Confidentiality – as standard (happy to work under NDAs where needed)
- Outside IR35 – statement of work / deliverables-based only
- Lead times – not next-day; email context and I’ll confirm the earliest start
Product Definition & Engineering
Tom Hartley is a product-focused mechanical engineer: he works in the space between product definition and engineering delivery. He helps teams clarify what matters, compare realistic options, and agree a defensible direction - then translates that into a buildable output. His approach blends design judgement, engineering rigour and manufacturing realism, with a bias toward simple, robust solutions. The result is clearer decisions, fewer surprises, and a cleaner route to “done”.
- Chartered Engineer (CEng) since 2012
- Member of the Institution of Mechanical Engineers (MIMechE) since 2002
- Member of the Institute of Engineering Designers (MIED) since 2019
- Working in professional engineering and UK manufacturing since 2004
Formative experience
Education and earlier career:
Contact
If you need to solve a problem and you’d like to explore whether I can help, drop me an email:
What to include
To help me give you a useful reply, please mention…
- What you’re building or dealing with (one or two sentences)
- What’s going wrong, or what decision you’re trying to make
- Key constraints (budget, timescale, materials, interfaces, standards)
- What information you already have (CAD, drawings, photos, etc)
- Desired outcome (e.g. options report, CAD pack, calcs, FEA etc)
- Any deadlines and why they exist (so I can reality-check them)
Attachments
Attachments are welcome:
- All enquiries and attachments are treated as confidential by default
- If attachments are over 2MB, please use a file-sharing service such as Dropbox or WeTransfer and include a download link.
What happens next?
I’ll usually reply with a quick fit-check…
If it's a fit:
- I’ll tell you whether and how I can help
- I’ll give you some options for how we could move forward
- I’ll ask for the minimum info needed to scope it
If it's not a fit:
- I’ll say so and tell you why
- I may suggest an alternative route, if appropriate