Indie Interview: Carvalho Designs
In this interview, Holly Davis talks to Stuart owner of Carvalho Designs as he reflects on his transition from a corporate role to starting his own independent business. He shares the motivations behind his new venture, the challenges and triumphs of building a sustainable bran, and the support he’s received from the Independent Oxford community. >>
Holly: First, let’s talk about the name Carvalho. Where does it come from and what inspired you to start your business?
Stuart: Carvalho means Oak, which has a nice wooden connection and a bit of a luxury tone. To go back a bit on my journey—I’m 37 now and I’ve had quite a varied career. I started as a mechanical engineer and worked for a large FMCG company, specifically in a brewery in South Africa. I handled machine maintenance and got a love for factories, plants and automation from that experience.
I think it was then that I started thinking how great it would be to set up my own process of making something from start to finish—my way. It’s easy to get frustrated with the inefficiencies of processes you’re working with and you think, “I could do it better.” I wanted to enjoy the process of creating something.
Holly: That’s fascinating. So, did that desire to create something your way lead directly to you starting Carvalho Designs?
Stuart: Yes, in a roundabout way. After about six years in South Africa, I came to the UK to study for an MBA in Oxford. I wanted to explore the business side of things beyond engineering. Post-MBA, I worked in a completely different industry—working in an electronics company commercialising new technology from the university. I joined as their first employee and we grew the team to 50 people by the time I left. It was a great experience, but over time I realised I had this bug to create something of my own, to set up my own manufacturing process.
Eventually, I took the plunge and started bootstrapping my own startup, which led to Carvalho Designs. I started with my latest hobby, woodworking. My conservatory turned into a workshop and that’s where it all began.
Holly: So this is all self-funded initially? Are you looking at outside funding down the line?
Stuart: Initially, yes, it’s self-funded. I was hesitant to give away equity at first because this was my business, my project. But after some conversations with former colleagues and MBA classmates, I realised it’s okay to give away a bit of equity if it means becoming a smaller fish in a much bigger pond. So now, I’m actually looking for a business partner who can bring both expertise and capital.
Holly: And is this your full-time focus now?
Stuart: Yes, I’m fully focused on this. I incorporated the company in June, and though I initially planned for a longer transition, I ended up going full-time much quicker than expected. So here I am, running the company!
Holly: That’s exciting! Can you tell me a bit about your vision, particularly around scaling? What does that look like for you?
Stuart: My plan is to spend the next six to nine months working solo, outsourcing where I can, like accounting. Eventually, I’ll hire someone on the production side, maybe a budding woodworker. I’m focusing on a small range of products that I can manufacture repeatably and efficiently. That’s where my background in manufacturing comes in.
Holly: It sounds like you’ve got a clear path ahead. How about your workspace—where are you currently based?
Stuart: I’m currently renting space in a professional woodworker’s workshop, which gives me access to industrial-quality equipment. It’s a fantastic setup, but my goal is to have my own space within a year.
Holly: What part do you see sustainability playing in Carvalho once you’re established?
Stuart: Sustainability is something I’m passionate about but it’s early days. Eventually, I’d love to be in a position to dedicate a percentage of profits to reforestation or other environmental causes.
Social responsibility is also on my mind. As I grow and start hiring, I’d like to consciously hire people who may find it difficult to get jobs, offering opportunities to disadvantaged groups. And being part of the Indie Oxford community has really opened my eyes to how local businesses can connect and support each other.
Holly: Are there any challenges you’ve faced transitioning to working for yourself?
Stuart: One big challenge has been adjusting to the lack of routine. I think my output is missing that structure, so that’s something I need to focus on. Another is not having a business partner. I miss being able to bounce ideas off of someone and I think having a sounding board would help me see things from different perspectives. Finding balance is key for me.
Holly: What have you found to be the most rewarding part of the journey so far?
Stuart: I think one of the big things is just how proud my parents are, to be honest.
I was worried at first, especially when I left my previous role. You know, wondering what they’d think, whether they’d understand the risks I was taking. But now that they can see the results and how happy I am, their support has been overwhelming. That’s incredibly rewarding for me.
Holly: What impact has being part of Indie Oxford had for you and your business?
Stuart: I’ve been really surprised by how solutions to my uncertainties often come out of nowhere. For example, I was wondering how to connect with retailers and through the Indie Oxford group, I made some valuable connections without even asking directly. It’s been encouraging to see that organic networking is already really helping me and the business grow.