Sugarcane farming plays a vital role in the rural economy of India. However, the farmers have been using traditional tools for farming activities. As a result, sugarcane farmers experience serious health injuries like cuts on the face, neck, fingers, feet, etc. The manual harvesting tools often injure farmers, and the labor-intensive process reduces productivity. This study aims to design and develop a “Frugal Sugarcane Harvester” to address farmers’ health drudgery and enhance productivity. An integrated de-thrashing mechanism is incorporated into the harvester that offers a novel approach by incorporating user-friendly features to streamline the post-harvest process, significantly reducing the burden on workers and increasing overall productivity and efficiency. A manually operated flexible actuating mechanism with ergonomically designed contour grips and cutter-empowered peripheral tip is incorporated in the final design. The proposed intervention is expected to reduce the health drudgery of the farmers. This research endeavor aims to bridge the gap between traditional manual harvesting techniques and modern mechanized approaches, empowering sugarcane farmers with a safer and more productive device.