Styrofoam Sculpting & Fabrication Technician

Role Overview
The Styrofoam Sculpting & Fabrication Technician is a specialist craftsperson responsible for designing cutting and sculpting expanded polystyrene (EPS/Styrofoam) into large-scale props decorative elements signage and structural components for custom event builds. This role demands both artistic ability and technical precision to transform raw foam blocks into finished pieces that meet exacting design specifications.

Key Responsibilities

• Sculpting & Shaping: Cut carve and sculpt EPS foam blocks using hot wire cutters CNC routers rasps and hand tools to create props letters themed elements and structural forms.
• Design Interpretation: Read and work from technical drawings 3D renders and design briefs to accurately replicate shapes dimensions and surface details.
• Surface Finishing: Apply hardcoat fibreglass gypsum and other coating systems to foam pieces to achieve durable paintable surfaces.
• Scale Modelling: Produce scaled prototypes and test pieces for client or internal approval prior to full-scale fabrication.
• Large-Scale Construction: Assemble multi-component foam structures using appropriate adhesives armatures and internal supports for structural integrity.
• Collaboration: Work closely with painters carpenters and project managers to coordinate finishing schedules and ensure on-time project delivery.
• Material Management: Manage foam stock adhesives coatings and consumables; minimise waste through efficient cutting patterns.
• Workshop Safety: Maintain a clean dust-controlled workspace; safely handle and dispose of foam off-cuts and chemical coatings.
   

Qualifications :

Required Qualifications & Skills

• Minimum 4 years of experience in foam sculpting/fabrication preferably for events theatre theme parks or retail displays.
• Proficiency with hot wire CNC manual hot wire tools rasps and rotary carving tools.
• Experience applying hardcoat fibreglass or gypsum coatings to foam substrates.
• Ability to accurately interpret 2D drawings and 3D renders to produce fabricated pieces.
• Understanding of structural requirements for large-scale foam builds including armature design.
• Strong spatial awareness and attention to sculptural detail.
• Knowledge of foam-safe adhesives and coating compatibility.
• Physical stamina for sustained manual work with large materials.
   

Additional Information :

Typical Working Conditions
Environment: Must be able to work in a workshop environment which may include loud noise dust and heat with some on-site installation work.
Hours: May require working evenings weekends and holidays to meet event deadlines.
Physical Requirements: Ability to work in a fast-paced environment and handle tight deadlines and to work on site which may include lifting standing for long periods and working in varied conditions.

Remote Work :

No

Employment Type :

Full-time