Portfolio
THOMAS WINMILL
00-Design engineer
I'm a CAD Design Engineer with over five years of experience developing products from concept through to manufacture. My background spans mechanical design, CNC programming, reverse engineering, 3D scanning, additive manufacturing, and manufacturing engineering across plastics tooling and prefabricated construction. I enjoy solving complex engineering challenges, optimising designs for manufacture, and continuously expanding my technical expertise.
ABOUT
ME
I'm a CAD Design Engineer with over five years of experience developing products from concept through to manufacture. My background spans mechanical design, CNC programming, reverse engineering, 3D scanning, additive manufacturing, and manufacturing engineering across plastics tooling and prefabricated construction. I enjoy solving complex engineering challenges, optimising designs for manufacture, and continuously expanding my technical expertise.
Selected work
Vacuum CNC Hose Connections – Heavy-Duty Connector Set
This project involved designing a range of custom vacuum hose connections for use on CNC vacuum extraction systems. The connectors were developed to provide secure, reliable hose interfaces capable of withstanding the demanding conditions of a busy workshop environment, where components are frequently subjected to impacts, repeated handling, and continuous use.
Each connector was modelled from scratch using parametric CAD techniques, incorporating threaded interfaces and ergonomic external profiles for quick installation and removal. Particular attention was given to wall thickness, thread geometry, and structural reinforcement to ensure long-term durability without compromising printability or performance.
The components were optimised for additive manufacturing, allowing rapid production and easy replacement when required. By producing the connectors in-house, replacement lead times and costs were significantly reduced while maintaining compatibility with the existing vacuum extraction system.
PROJECT 01
VACCUM CONNECTIONS
This project involved recreating and improving a worn dust extraction chute used in a production environment. The original component had become a recurring maintenance issue due to material wear and replacement costs, so I reverse engineered the existing part and developed an optimised version specifically for additive manufacturing.
The component was modelled from scratch in CAD, maintaining compatibility with the existing system while refining the geometry for reliable 3D printing. Rather than reproducing the original in rigid plastic, I selected TPU (Thermoplastic Polyurethane) to provide greater flexibility, improved abrasion resistance, and a significantly longer service life in a high-wear environment.
Working alongside a colleague, I manufactured and installed the redesigned chute for approximately £7, providing a cost-effective alternative to replacing the original component. The successful implementation improved durability while reducing replacement costs and machine downtime.
The success of this project led to me receiving a Group-Wide Excellence & Innovation Award, recognising the engineering solution's impact on operational efficiency and cost savings.
PROJECT 01
DUST EXTRACTION - CNC ROUTER
This project involved the design of a prefabricated utility room engineered to house a complete boiler system for a residential apartment development. The enclosure was designed as a self-contained plant room, providing a secure, accessible, and weather-resistant environment for mechanical services while simplifying on-site installation.
The structural framework was developed using fabricated steel sections to provide the strength required for transporting, lifting, and long-term service. Internal layouts were carefully planned to maximise the available space while ensuring adequate access for installation, maintenance, and future servicing of the boiler equipment and associated pipework.
Throughout the design process, consideration was given to manufacturability, assembly, and transportation. The modular construction allows the unit to be fabricated, assembled, and tested off-site before delivery, reducing installation time, minimising site disruption, and improving overall project efficiency.
PROJECT 01
PURs - (Prefabricated Utility Rooms)
This ACM (Aluminium Composite Material) panel transport trolley was designed to safely transport large ACM sheets between storage areas and CNC routing machines within a manufacturing facility. The objective was to create a robust, mobile solution capable of handling heavy panel loads while improving operator safety and material handling efficiency.
The chassis was designed as a fully welded steel fabrication using square hollow section (SHS) steel to maximise rigidity while maintaining a practical overall weight. The frame geometry distributes loads evenly across the structure, reducing deflection under heavy use and ensuring long-term reliability in a demanding production environment.
Designed with a 5-ton load capacity, the trolley incorporates reinforced cross-members, strategically positioned support legs, and heavy-duty swivel castors to provide stability, manoeuvrability, and durability. Integrated handles allow operators to safely manoeuvre the trolley throughout the workshop, while the open-frame design supports a variety of panel sizes without unnecessary weight.
Throughout the design process, consideration was given to fabrication methods, weld accessibility, material utilisation, and ease of assembly to ensure the design could be manufactured efficiently while meeting structural requirements.
PROJECT 01
DUST EXTRACTION - CNC ROUTER
This ACM (Aluminium Composite Material) panel transport trolley was designed to safely transport large ACM sheets between storage areas and CNC routing machines within a manufacturing facility. The objective was to create a robust, mobile solution capable of handling heavy panel loads while improving operator safety and material handling efficiency.
The chassis was designed as a fully welded steel fabrication using square hollow section (SHS) steel to maximise rigidity while maintaining a practical overall weight. The frame geometry distributes loads evenly across the structure, reducing deflection under heavy use and ensuring long-term reliability in a demanding production environment.
Designed with a 5-ton load capacity, the trolley incorporates reinforced cross-members, strategically positioned support legs, and heavy-duty swivel castors to provide stability, manoeuvrability, and durability. Integrated handles allow operators to safely manoeuvre the trolley throughout the workshop, while the open-frame design supports a variety of panel sizes without unnecessary weight.
Throughout the design process, consideration was given to fabrication methods, weld accessibility, material utilisation, and ease of assembly to ensure the design could be manufactured efficiently while meeting structural requirements.
PROJECT 01
PURs - (Prefabricated Utility Rooms)
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