In this paper we study digit frequencies in the setting of expansions in non-integer bases, and self-affine sets with non-empty interior. Within expansions in non-integer bases we show that if $\unicode[STIX]{x1D6FD}\in (1,1.787\ldots )$ then every $x\in (0,1/(\unicode[STIX]{x1D6FD}-1))$ has a simply normal $\unicode[STIX]{x1D6FD}$-expansion. We also prove that if $\unicode[STIX]{x1D6FD}\in (1,(1+\sqrt{5})/2)$ then every $x\in (0,1/(\unicode[STIX]{x1D6FD}-1))$ has a $\unicode[STIX]{x1D6FD}$-expansion for which the digit frequency does not exist, and a $\unicode[STIX]{x1D6FD}$-expansion with limiting frequency of zeros $p$, where $p$ is any real number sufficiently close to $1/2$. For a class of planar self-affine sets we show that if the horizontal contraction lies in a certain parameter space and the vertical contractions are sufficiently close to $1$, then every non-trivial vertical fibre contains an interval. Our approach lends itself to explicit calculation and gives rise to new examples of self-affine sets with non-empty interior. One particular strength of our approach is that it allows for different rates of contraction in the vertical direction.