Portfolio
THOMAS WINMILL
Engineer
I'm a CAD 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.
Examples of my work
Vacuum CNC Hose Connections – Heavy-Duty Connector Set
I modeled and developed a vaccum hose set for cnc vaccums. A basic step for maintenace and upkeep of cnc machines is to reduce swarf build up. if left the machine can build up a large excess amount of swarf that will either impact the part on the cnc or the machine itself. over time swarf builds up compacts with the moving bed which can find its way into folds or sealed compartments of the moving bed causing jams., so clearing of the machines was a often reccuring task. the vaccum used for picking up the swarf would have certain componets that would reguarly wear and reduce the suction. Parts werent replaced due to high costs for small simple plastic parts and rapid deterriation.
Because of this i decided to 3d print some variant connections as a quick easy exercise and to make cleaing of the cnc machines eaier. so i designed and made a
Part 1
Was connection from the spiral hose to the bare metal vaccum which kept coming off with slight force. i knew i wanted to use TPU with its material properties and has a level of elesaticity so having the part slighly smaller so the compresion would keep it snug on the metal connection. TPU is also a great impact resitant material and very diffciult to sand smooth which is a goo material property for a dry vaccum collecting swarf.
Part 2
The scecond part was a ectended hose connection to allow for longer hose to reach in larger cnc machines. this is essentially part 1 mirrored to allow for another hose to connect .
Part 3
Was an additional part that connected onto the end of the hose which held magents. an annoyance is that the weight of the hose would cause it to fall out of the cnc machine when trying to sweep swarf from the rear of the machine to the front. so by adding a part which had magnets inside would allow me to stick it inside or around the machine fixing the pipe in place.
After creating the parts on my own 3d printer and using them at work i then get request from other cnc machine opertors for additional attachments for their equipment which led me on to make and design more parts. this then also highlighted to the directors that 3d printing wasnt just for models or prototypes which led to the company buying sevreal printers and me tecahing them how ti use the equipment.
PROJECT 01
VACCUM CONNECTIONS
Part replacment for machines that are in contant use is just an eventuality however depending on the parts the avaliabity as well as cost for postage can make realtily cheap parts expensive. during upkeep of a cnc router machine one of the technical operators spoted a broken part for the machines vaccum. after looking at the part and seeing it was relaivly simple and the costs of the part to replace it to be very expensive i decide to model and print a replament. wiht the exisitng damaged part and a pair of calipers was able to revserse engineer the part in between maintenace schedules and created a replacement at a fraction of the cost. after a month of the install the same part broke on another cnc router in the evening after work i was able to print another replacemtn part and was fitted the next.
i attracted attention for this from the head of production and was awarded group wide. in additon to this the maintenace and servicng company noticed the part on the machine and have asked to buy parts and the 3d files for themseleves
PROJECT 01
DUST EXTRACTION - CNC ROUTER
My time in resipoint i have worked on multiple projects for high rise prefabrictaed utility rooms (PURs). with my time i have been involved in every step with the design and manufacturing process. Space allocation ensuring that the units fits in to the customer allocated space along with the mechanical and electrical elements.
Frame design for the units dimensions. the steel frame encases the entire unit and is pushed in and set into the apartment. ACM paneling lines the unit interior hdiding mechanical and electrical elements where we can
Steel fabrication and structural frame design
Large assembly modelling
Design for Manufacture and Assembly (DFMA)
Mechanical room layout
Modular construction principles
Engineering documentation and production drawings
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
ACM Panel Transport Trolley- Heavy Duty Fabricated Assembly
As part of my role, I design and develop customised variants of the Dutypoint ScubaTANK®, a packaged break tank and booster system used to provide reliable water storage and pressure solutions for commercial and residential applications.
Each project is engineered to meet individual customer specifications, requiring modifications to tank size, pipework layout, component positioning, inlet and outlet configurations, and overall assembly while ensuring compliance with design standards and manufacturing requirements. Working from customer requirements, I create fully detailed 3D models, assemblies, and production drawings that are used throughout the manufacturing process.
A key aspect of the role is balancing functional performance with manufacturability, ensuring every variation can be efficiently fabricated, assembled, and maintained. Attention is also given to serviceability, allowing critical components such as pumps, valves, and pressure vessels to remain easily accessible for installation and future maintenance.
PROJECT 01