Design Engineering Consultant, Edinburgh, UK

Engineering Products from Concept to Manufacture

Providing design engineering expertise to entrepreneurs, founders and start-ups. Solving the hard technical problems and reducing the risk and cost in the product development process.

Shipped & recognised Ooni Volt 2 · Red Dot Design Award 2026 Ooni Karu 2 · iF Design Award 2024 Ooni Karu 2 Pro · iF Design Award 2025 3 patented or patent-pending inventions Sold worldwide
01 · Services

How I can help you in your project

Your specific needs aren't one size fits all, you can start with a single fixed-scope service, or hire me to run the full journey from the seed of an idea to the product in a shipping container.

The full journey, idea to production

Product Development

One experienced engineer owning the path from a first idea to a product that's ready to manufacture, bringing in a trusted network of specialists as the product needs them. Delivered in scoped, gated phases, so you commit one step at a time. The standalone services below are each a phase of this.

Explore Product Development →
02 · Selected Work

Previous Projects out there in the world

I spent over 4 years at Ooni working across design, mechanical engineering, firmware, thermal performance, specialist testing, and manufacture for premium consumer products, of which many have reached the market and received international recognition or are in production stages. Some highlights shown below.

Ooni Volt 2 electric pizza oven on a kitchen counter at 450 °C with a pizza baking inside
CASE 01

Ooni Volt 2: Indoor Electric Pizza Oven

Performance Hardware Designer · Firmware Development Lead · User Experience & Product Validation

Designing the function, user experience and performance of a compact indoor oven capable of reaching 450 °C, via both hardware and firmware development. Building the patent-pending adaptive cooking firmware, a thermal-estimation algorithm for accurate stone control from a single sensor, and the oven hardware such as heating elements and inner shells.

Control systems Thermal modelling Thermal simulation UI/UX Firmware Heating element design High-performance design Design for manufacture Safety compliance Part & subassembly design Product validation Technical documentation

Read the full case study →

Outcomes
◆Red Dot Design Award
◆Pizza Intelligence™
◆20–450 °C temperature range
◆30% smaller footprint
◆70% better stone temperature distribution
◆23% faster heat-up with a 64% larger window
Ooni Karu 2 multi-fuel oven burning wood outdoors, with a Neapolitan pizza on a peel
CASE 02

Ooni Karu 2: Multi-Fuel Outdoor Pizza Oven

Performance optimisation · Door design & sub-assembly · Verification & test

I redesigned an expensive, hard-to-manufacture and low-performing glass pizza oven door to invent the patented ClearView™ technology. I solved high-temperature magnetic latching through flux-path analysis, and tuned multi-fuel airflow and chimney thermal safety to stay compliant across every fuel type, whilst boosting performance and efficiency.

Door design Mechanism design DFM / DFA Sheet metal design Casting design Injection moulding design CFD / airflow Combustion optimisation Thermal simulation Structural simulation Magnetics Specialised testing User testing Compliance Technical documentation

Read the full case study →

Outcomes
◆iF Design Award 2024 · German Design Award 2024
◆~70% BOM reduction, larger viewing window
◆Assembly time from 24 h → <1 min
◆ClearView™ scaled to iF-winning Karu 2 Pro
◆−27% solid fuel consumption vs the previous generation
◆4.7★ across 1,700+ customer reviews
Ooni dough proofing box with a bamboo lid and a dough ball, on a wooden kitchen counter
CASE 03

Ooni Dough Proofing Boxes

Design Engineer · from concept to production

A deceptively simple stackable, nestable proofing system, but with a tightly constrained architecture including regional fridge envelopes, nesting draft, large-format injection moulding and tolerance stack-up across every stacked state. I formalised the competing constraints into a trade-off model, conceptualised the industrial design, and took them through verification, DFM and manufacture.

Industrial design Concept design Geometric design Constraint modelling Tolerance analysis Injection moulding design Structural simulation DFM / DFA Manufacturing optimisation Range compatibility Verification & test Technical documentation

Read the full case study →

Outcomes
◆Sold by Ooni for 3+ years
◆Predicted scrappage borne out in production
◆Large-format injection moulding, single-shot tooling
◆4.8★ across 460+ reviews
03 · About

A bit about me

I spent over four years designing high-end consumer products at Ooni, working on projects from first concept and taking them through to volume manufacture. I've produced production parts, sub-assemblies and assemblies, and developed both the UI and functional production firmware. That experience gave me a practical understanding of what it actually takes to ship real products. Performance, cost, safety and manufacturability must all be balanced while working within tight timelines and development budgets.

Today I work as an independent design engineer and product-development consultant to founders and start-ups. Many have a strong product vision but limited access to experienced engineering. One key aspect of my work is providing structure and rhythm to the design process, challenging initial assumptions to future-proof design work, and holding a steady plan that balances the costs of development with reducing risk in investment. When a problem is hard, I stay with it: some of the work I'm proudest of took months of pushing, internally and with suppliers, to get right.

Throughout my work, I try to explain the engineering clearly, without gatekeeping the technical aspects, so you know exactly why the decisions and trade-offs are made.

Alongside commercial work, I give part of my time to pro-bono engineering for projects with social or environmental impact. I think engineering should be used in a meaningful way and be a force for good. This philosophy affects all of my work.

01 Integrity
Decisions are evidence based and transparent, with clear communication on where trade-offs need to be made.
02 Thoughtful Innovation
Creative solutions to practical engineering problems that aren't complex for the sake of complexity.
03 Long-Term Solutions
In both design and process, ensuring early work is done properly to reduce the risk of re-work.
04 Positive Impact
Engineering should be a force for good, used meaningfully whether in a commercial or pro-bono setting.
04 · In Their Words

What people I work with said

A few words from colleagues and clients.

“His work consistently demonstrates a rare blend of deep technical insight, creative problem-solving, and practical innovation.”
“The way he deconstructs complex problems, whether mapping application layers or analysing how a pizza cooks through energy flow and thermodynamics, reflects an exceptional mind at work.”
“He is a genius!”
“He demonstrated exceptional dedication, battling for months both internally and externally to make that complex vision a reality, and he succeeded.”
“His product knowledge is excellent, and he possesses an unwavering clarity on the standards that define truly good design.”
“Tom was the mastermind and driving force behind the Volt 2's operating system, virtually building it single-handedly from the ground up.”
“He can seamlessly deliver technical details at the exact right level for any audience, a critical skill in this game.”
“A major contributor to some of Ooni's most successful and technically complex products.”
“His contributions to Volt 2 have ensured it is not only a massive step forward but a clear leap ahead of the competition.”
“His definition of application-layer architecture stands as the gold standard for how such systems should be mapped.”
“His idea to [redacted], on the [redacted] system, was a master stroke, blending scientific thinking with real-world improvement.”
“Tom's impact is profound; he will be greatly missed.”
Let's talk

Have an idea you want to turn into a real product?

Take your first step now! Get in touch with a message or book a call and tell me about your idea, whether it's a first concept or a full design that needs to be made manufacturable. I'll tell you whether I can help and where.

Send a message

Book a free intro call

No obligation · video or phone · up to 45 minutes

  • Talk through where you are and what a sensible first step looks like
  • Get an honest view on whether and where I can help
  • Pick a slot that suits you and you'll get a calendar invite