Sebastian Althapp

MECHANICAL ENGINEER

Skills Overview

Sebastian is a mechanical engineer at heart, driven by a passion for building effective, lasting solutions — and helping others do the same. From launching orbital rockets to designing test stands and critical infrastructure, he brings hands-on experience in implementing sustainable systems from the ground up. With a background in working for aerospace startups and agile project management, he excels at delivering robust, multidisciplinary solutions through collaboration and attention to detail. His blend of formal education and technical knowledge makes him a valuable asset to innovative projects across the industry. Today he enjoys tackling long-standing challenges across the world of engineering, and exploring new ways to bring fresh solutions to a broad range of clients.

• AEROSPACE DESIGN & HARDWARE DEVELOPMENT – Sebastian delivers hands-on, hardware focused solutions from initial concept to commissioning. He has worked on high performance mechanical systems from rocket motors to launch vehicles and their corresponding manufacturing and test infrastructure, ensuring the integrity and performance of his designs. His exposure to real-world challenges makes him detail-focused on the drawing board and pragmatic on the workshop floor.
• CRYOGENIC & PRESSURISED FLUID SYSTEMS – In his previous positions, Sebastian designed and operated cryogenic and high-pressure systems driving rocket motors and full scale test stands. He handled the assembly, integration and test of piping, valves, and tanks under strict cleanliness and safety standards. His work directly enabled successful test campaigns, extending his technical depth with operational execution and successful launches in Brazil, Sweden, Australia and New Zealand.
• PROGRAMMING, AUTOMATION & DATA ANALYSIS – Programming tools like Python and LabVIEW are everyday companions in Sebastian’s work. In his previous positions, he contributed to flight data review and troubleshooting, by scripting ad-hoc tools for data analysis and automation, helping to improve turnaround time and reliability. His cross-domain fluency creates a strong feedback link between development and production.
• OPERATIONS & TESTING – Sebastian has extensive experience operating complex systems in high-stakes environments, from rocket test stands to orbital launches. In his previous positions, he contributed to daily test and flight operations, where quick thinking and attention to detail are critical. His ability to work under pressure and deliver effective solutions reflects in his practical mindset and strong ownership of his work.
• PROJECT MANAGEMENT & AGILE METHODS – Certified in both traditional and agile methods, Sebastian brings structure and flexibility to project execution. He has led technical teams in agile contexts and is skilled at balancing between exploratory and analytical management methods. His formal qualification helps him to enable teams to perform at their best and to keep projects on track.
• SYSTEMS ENGINEERING – From working on complex aerospace projects involving rocket propulsion and suborbital payloads, Sebastian gained a solid background in systems engineering. He has led efforts across the full development cycle from requirements specification to verification and validation of integrated systems. Skilled at managing technical interfaces and coordinating across multidisciplinary teams, he ensures systems are well-integrated, testable and maintainable.
• SHEET METAL DESIGN – Working alongside one of New Zealand’s longest-standing sheet metal shops, Sebastian developed hands-on expertise in sheet metal bending parameters, air and wipe bending techniques, as well as flat pattern design for laser cutting and punching. His work spans small-batch and serial production, ensuring manufacturability and precision from design through fabrication.
• DESIGN AUTOMATION – Sebastian has extensive experience in design automation, including full automation of configure-price-quote (CPQ) workflows. His systems generate CAD models, production drawings, and procurement BOMs automatically, with seamless SolidWorks PDM integration, streamlining engineering and manufacturing processes from concept to delivery.
• ENGINEERING MANAGEMENT – Sebastian manages engineering systems and processes across the project lifecycle, from migrating legacy design libraries into modern PDM platforms to establishing parts libraries, numbering systems, and revision control workflows. He handles configuration management, variant construction, and change control, ensuring the technical infrastructure keeps the engineering team moving forward through clear process implementations and practical execution.

Project Experience