Libby Challoner
Summary
Mechanical Engineer and Materials Scientist with expertise spanning additive manufacturing, sustainable material development, product design and engineering project delivery. Currently responsible for the integration and technical delivery of steam system equipment within a highly regulated defence environment at BAE Systems.
Founder of SeaCo Designs and developer of an award-winning seaweed derived biopolymer recognised through national and international sustainability awards. Experienced in research, technical problem solving, stakeholder engagement, STEM outreach and the delivery of externally funded innovation projects. Passionate about advancing manufacturing technologies through interdisciplinary collaboration, material innovation and applied engineering research. Skills and Expertise
• Additive Manufacturing: Proficient in using various 3D printing technologies, including SLA, SLS, and FDM, ensuring high-quality production standards.
• CAD Software Mastery: Knowledge of SolidWorks, Fusion 360, AutoCAD, NTopology and TechSoft Design V3 (2D Design), with ability to quickly adapt to new tools.
• Material Development: Specialized in creating and testing biopolymers and sustainable materials suitable for additive manufacturing, with a focus on environmental impact reduction.
• Process Optimization: Skilled in streamlining manufacturing processes to enhance efficiency and reduce waste, leading to cost reduction and improved throughput.
• Project Management: Experienced in managing large-scale projects, coordinating between teams, and maintaining strict timelines and budgets.
• Technical Documentation: Proficient in drafting clear, informative technical documentation and user manuals that enhance understanding and application of complex technologies.
• Workshop and Training Development: Skilled in creating and delivering educational content that bridges the gap between technical complexity and practical usability
Overview
7
7
years of professional experience
10
10
years of post-secondary education
1
1
Certification
Work history
Mechanical Engineer
BAE Systems
Barrow-In-Furness, Cumbria
2025.04 - 2026.06
- Responsible for the design integration and technical delivery of steam system equipment within a highly regulated naval engineering environment.
- Conduct engineering calculations and technical assessments to support system design, performance, safety and compliance requirements.
- Work closely with multidisciplinary design teams to review and approve structural arrangements, ensuring equipment integration is compliant with technical, operational and spatial constraints.
- Review engineering drawings, models and design documentation, providing technical recommendations and identifying potential design risks and conflicts.
- Support the full engineering lifecycle from concept development through design, verification, manufacture and installation.
- Collaborate with stakeholders across engineering disciplines, manufacturing teams and suppliers to resolve technical issues and deliver project objectives.
- Undertake problem-solving and root-cause investigations, developing practical engineering solutions to complex technical challenges.
- Produce and maintain technical documentation, reports and engineering justification to support design decisions and project delivery.
- Work within stringent quality, safety and regulatory frameworks, ensuring compliance with defence and industry standards.
- Contribute to continuous improvement activities and knowledge sharing within the engineering team.
- Willing to relocate: Anywhere
Founder & Lead Researcher
SeaCo Designs
2021.01 - 2026.06
- Developed a seaweed-derived home-compostable biopolymer.
- Conducted materials characterisation including FTIR, Raman, SEM, EDS, DSC and XRD.
- Investigated adaptation of sustainable polymers for additive manufacturing technologies including SLA and Computed Axial Lithography.
- Secured external funding and partnerships.
- Presented research to industry, education and public audiences.
- Shortlisted and awarded multiple national and international sustainability awards.
- Led ongoing R&D programme investigating sustainable manufacturing applications.
CAD/CAM Technical Engineer
TechSoft Ltd
St. Asaph
2023.10 - 2025.03
- Provided technical expertise and consultancy across a wide range of additive manufacturing, laser cutting and CNC technologies, supporting customers in education, research and industry environments.
- Tested, commissioned and validated CAD/CAM equipment including 3D printers, laser cutters and CNC milling systems, ensuring reliable operation and compliance with customer requirements.
- Delivered technical training workshops and demonstrations for teachers, engineers, technicians and students, developing user competence across both software and manufacturing systems.
- Supported the installation, configuration and commissioning of new CAD/CAM equipment and software solutions at customer sites throughout the UK.
- Provided advanced technical support and troubleshooting for additive manufacturing systems, CAD software and digital manufacturing workflows, diagnosing issues and implementing effective solutions.
- Advised customers on machine selection, process optimisation and best practice for additive manufacturing, laser processing and CNC machining applications.
- Designed and manufactured demonstration components and application samples using CAD software including SolidWorks and TechSoft Design V3, showcasing the capabilities of emerging manufacturing technologies.
- Evaluated and tested new manufacturing equipment and software releases, producing technical documentation and application guidance for customer and internal teams.
- Created technical documentation, instructional resources and video content to support customer onboarding, training and product adoption.
- Collaborated closely with sales, technical, warehouse and installation teams to deliver successful customer projects and maintain high levels of customer satisfaction.
- Developed extensive practical experience across multiple additive manufacturing technologies, including FDM, SLA and other digital manufacturing systems, alongside laser cutting and CNC machining processes.
Bar staff
Shepheard Neame
London
2022.09 - 2023.11
- Supervised and coordinated front-of-house and bar teams in a fast-paced, high-volume hospitality environment, ensuring exceptional customer service standards were maintained during peak trading periods.
- Acted as a key point of contact for staff and customers, confidently resolving customer complaints, managing difficult situations, and making operational decisions to maintain smooth service.
- Supported the training and development of new team members, providing guidance on service standards, cash handling procedures, and operational processes.
- Took responsibility for daily operational duties including cash handling, end-of-shift cash reconciliation, stock control, cellar management, line cleaning, and compliance with health and safety procedures.
- Managed multiple social media platforms, creating engaging content and supporting promotional campaigns to increase customer engagement.
- Collaborated with management to develop and deliver seasonal and themed cocktail menus, contributing to customer experience and commercial performance.
- Assisted with stock takes, inventory management and ordering processes to ensure efficient operation and minimise waste.
- Demonstrated strong leadership, communication and problem-solving skills while working under pressure and coordinating teams during busy service periods.
Future Chemists Project ambassador
Cornwall council/Falmouth university
Cornwall
2021.05 - 2023.06
- Secured external funding and sponsorship from the Royal Society of Chemistry, Next Steps South West and Cornwall Council to develop and deliver a STEM outreach programme based on my sustainable biomaterial research.
- Transformed university-level research into an accessible, school-friendly educational project, enabling students to explore the extraction of polysaccharides from red seaweed and the development of sustainable materials.
- Designed and delivered interactive workshops for secondary school students across Cornwall and Devon, combining practical experimentation with real-world applications of science, engineering and design.
- Led hands-on laboratory-style activities with Year 9 and Year 10 students, demonstrating scientific principles, material development processes and sustainable manufacturing concepts.
- Advocated for greater integration of science, engineering, art and design within education, highlighting the value of interdisciplinary approaches to innovation and problem-solving.
- Engaged with teachers, school leadership teams and funding partners to coordinate workshop delivery and maximise educational impact.
- Developed educational resources and presentations to communicate complex scientific concepts to a wide range of audiences in an engaging and accessible manner.
- Promoted awareness of sustainable materials, circular economy principles and careers in STEM, encouraging students from diverse backgrounds to explore further education and industry opportunities.
Hotel Receptionist
Thornton Hall Hotel & Spa
Wirral
2022.07 - 2022.09
- Managed guest check-in and check-out processes, ensuring a professional, efficient and welcoming experience while maintaining high standards of customer service.
- Acted as a primary point of contact for guests, responding to enquiries, resolving issues and ensuring customer expectations were met throughout their stay.
- Handled telephone enquiries and reservation bookings, maintaining accurate records and coordinating guest requirements.
- Worked effectively under pressure in a busy hotel environment, balancing multiple priorities while maintaining attention to detail and service quality.
- Liaised closely with housekeeping, spa, restaurant and management teams to coordinate guest services and ensure smooth day-to-day operations.
- Processed payments, managed cash handling responsibilities and completed daily banking and reconciliation procedures in accordance with company policies.
- Followed and completed shift handover and operational procedures, ensuring continuity of service and accurate communication between teams.
Front of House Waitress
Merchant's Manor Hotel
Falmouth
2022.04 - 2022.06
- Delivered high standards of customer service within a busy hotel and spa environment, ensuring guests received a professional and welcoming dining experience.
- Prepared and served food, beverages, teas and coffees efficiently while maintaining quality and presentation standards.
- Worked collaboratively with kitchen, bar and front-of-house teams to ensure smooth service during busy breakfast and dining periods.
- Assisted with restaurant preparation and set-up, ensuring dining areas were presented to a high standard and ready for service.
- Maintained cleanliness and organisation throughout service, including clearing, resetting and preparing tables for subsequent guests.
- Responded professionally to guest requests and enquiries, helping to resolve issues and ensure customer satisfaction.
- Demonstrated strong time management and prioritisation skills while working in a fast-paced environment with competing demands.
- Contributed to the delivery of a positive guest experience through effective communication, teamwork and attention to detail.
Senior student ambassador
Falmouth University
Falmouth
2020.05 - 2022.06
- Led and coordinated teams of Student Ambassadors during university recruitment, outreach and applicant experience events, ensuring activities were delivered safely, professionally and efficiently.
- Supervised and supported ambassador teams throughout events, allocating responsibilities, monitoring performance and resolving issues to ensure smooth operation.
- Played a key role in the recruitment and selection of new Student Ambassadors, participating in assessment and onboarding activities.
- Delivered training and mentoring to new ambassadors, supporting their development and ensuring consistent standards of professionalism and customer engagement.
- Acted as a liaison between university staff, prospective students, parents and ambassador teams, adapting communication styles to a wide range of stakeholders.
- Assisted in the planning, organisation and delivery of large-scale university events including Open Days, Applicant Days and outreach activities.
- Demonstrated strong leadership, problem-solving and decision-making skills whilst managing competing priorities in busy event environments.
- Contributed to continuous improvement of ambassador training and event delivery processes through feedback and peer support.
Receptionist
Falmouth Exeter Plus
Penryn
2021.06 - 2021.09
- Acted as the first point of contact for guests, delivering a professional and welcoming customer experience throughout the booking and check-in process.
- Managed guest arrivals and departures, including key distribution, payment processing and resolution of customer enquiries.
- Coordinated communication between guests and internal departments, ensuring maintenance requests, housekeeping requirements and operational issues were addressed efficiently.
- Responded to telephone, email and face-to-face enquiries, providing accurate information and resolving issues in a timely and professional manner.
- Worked closely with housekeeping, maintenance and finance teams to ensure the smooth day-to-day operation of the holiday park and high levels of customer satisfaction.
- Maintained accurate booking, payment and guest records while handling confidential information in accordance with company procedures.
- Managed multiple competing priorities in a fast-paced environment, demonstrating strong organisational, problem-solving and customer service skills.
- Assisted in resolving guest complaints and operational challenges, ensuring positive outcomes while maintaining company standards.
student ambassador
Falmouth University
Falmouth
2019.10 - 2020.05
- Represented the University at a wide range of recruitment, outreach and student engagement activities, acting as a professional and approachable ambassador for the institution.
- Engaged with prospective students on university's online 'Ask a Student' platform, offering advice and sharing personal experiences to facilitate informed decision-making.
- Delivered campus tours and provided prospective students, parents and visitors with information about university life, academic courses and student support services.
- Coordinated delivery of Open Days, Applicant Days, UCAS fairs, graduation ceremonies, webinars and virtual events, enhancing attendee experience and engagement.
- Worked collaboratively with university staff and fellow ambassadors to deliver events efficiently and maintain high standards of customer service.
- Utilised excellent communication and interpersonal skills to engage effectively with diverse stakeholders, including prospective students, parents, teachers and university staff.
- Participated in school, college and widening participation initiatives, encouraging access to higher education and supporting students from diverse backgrounds.
- Adapted confidently to both in-person and virtual environments, delivering accurate information and responding to enquiries in a professional manner.
Education
MSc - Advanced Material Science
University College London
London 2022.09 - 2023.09
BA (Hons) - Sustainable Product Design
Falmouth University
Cornwall 2019.09 - 2022.06
A-Levels - Biology, Chemistry, Product design, Global perspectives and research (Cambridge board)
West Kirby Grammar School
Wirral 2017.09 - 2019.06
GCSE's - English literature, English Language, Maths, Biology, Chemistry, Physics, French, History, Product design, Drama
West Kirby Grammar School
Wirral 2012.09 - 2017.06
Skills
- FDM
- SLA
- SLS
- Design for Additive Manufacturing
- Process Optimisation
- Polymer Development
- Biomaterials
- Materials Characterisation (FTIR, Raman, SEM, EDS, DSC, XRD)
- Engineering Calculations
- Design Integration
- Technical Documentation
Additive Manufacturing:
Materials Science:
Engineering:
- Root Cause Analysis
- Project Delivery
- Steam system design
- SolidWorks
- Fusion 360
- AutoCAD
- Rhinoceros 3D
- nTopology
- Technical Training
- Stakeholder Engagement
- Workshop Delivery
- STEM Outreach
Software:
Leadership & Communication:
Accomplishments
- National Sustainability Awards 2024 – Innovation Category Shortlist
- Sustainable Design Awards 2024 – Winner
- Green Concept Award 2024 – Finalist (New Materials Category)
- D&AD Future Impact Award 2023 – Shortlisted
- Surface Design Show New Talent Award 2023 – Finalist
- Dezeen Sustainability Award 2022 – Longlisted
- FXPlus Sustainability Award 2022 – Winner
- Andy Hocking Community Impact Award 2022 – Finalist
Certification
- RSA Fellow
- Advanced DBS
- Full UK Driving License
- First Aid Certification
Timeline
Mechanical Engineer
BAE Systems
2025.04 - 2026.06
CAD/CAM Technical Engineer
TechSoft Ltd
2023.10 - 2025.03
MSc - Advanced Material Science
University College London
2022.09 - 2023.09
Bar staff
Shepheard Neame
2022.09 - 2023.11
Hotel Receptionist
Thornton Hall Hotel & Spa
2022.07 - 2022.09
Front of House Waitress
Merchant's Manor Hotel
2022.04 - 2022.06
Receptionist
Falmouth Exeter Plus
2021.06 - 2021.09
Future Chemists Project ambassador
Cornwall council/Falmouth university
2021.05 - 2023.06
Founder & Lead Researcher
SeaCo Designs
2021.01 - 2026.06
Senior student ambassador
Falmouth University
2020.05 - 2022.06
student ambassador
Falmouth University
2019.10 - 2020.05
BA (Hons) - Sustainable Product Design
Falmouth University
2019.09 - 2022.06
A-Levels - Biology, Chemistry, Product design, Global perspectives and research (Cambridge board)
West Kirby Grammar School
2017.09 - 2019.06
GCSE's - English literature, English Language, Maths, Biology, Chemistry, Physics, French, History, Product design, Drama
West Kirby Grammar School
2012.09 - 2017.06