Team Leader Foam Fabrication

The Foam Sculpturing / Fabrication Team Leader is responsible for overseeing the daily operations of the Foam Fabrication section in the event fabrication workshop aiming at transforming raw EPS (Expanded Polystyrene) or polyurethane foam into detailed 3D props scenic elements and large-scale structures for corporate events trade shows theatrical sets and themed attractions. The role involves interpreting design sketches or blueprints and using a combination of CNC-cut components and skilled manual hand-carving to produce visually stunning durable and lightweight props ensuring that elements are fabricated efficiently safely and to high-quality standards. This hands-on role involves leading a team of foam fabricators acting as the primary link between the production Managers /Designers and the workshop floor.

Key Responsibilities
1. Team Leadership & Supervision
Lead mentor and motivate a high-performing workshop team to meet tight event deadlines.
Allocate daily tasks to team members based on project schedules and skill levels.
Provide training and support to staff ensuring adherence to standard operating procedures
(SOPs).
Run daily short toolbox talks or stand-up meetings to discuss project status safety and
goals.
2. Production & Operational Efficiency
Blueprint Interpretation: Interpret technical drawings 3D models or artistic sketches and
design to translate concepts into accurately scaled physical props to guide fabrication.
Coordination: Coordinate workshop workflow to optimize production reducing waste and
downtime.
Foam Carving & Shaping: Carve shape and sculpt foam (EPS PU) into 3D models using 3D
robots hot wire cutters rasps rotary tools and hand saws.
Structural Assembly: Assemble multiple foam blocks gluing fitting and clamping parts to
create large-scale structures ensuring structural integrity for transport and installation.
Detailing & Finishing: Apply fine details to foam surfaces using hand tools (e.g. Dremel tools)
to create textures like wood grain stone or character features.
Surface Coating: Apply hard-coating materials (such as polyurea epoxy resins or sand-coat) to
ensure durability for indoor/outdoor display.
Collaboration: Work closely with designers painters and welders to integrate steel armatures
or electrical components into foam sculptures. Collaborate with project managers to update
them on progress potential delays or material issues.
Support and sometimes lead on-site installation or load-in/out during high-pressure times.
Tool Maintenance & Safety: Clean and maintain specialized workshop machinery (3d robots
and hot wires) and adhering to strict safety protocols and PPE requirements.
3. Quality Control & Safety
Enforce strict health and safety rules including wearing PPE and maintaining a 5S compliant
orderly workspace.
Inspect finished products and assemblies for defects ensuring they meet client specifications
before leaving the workshop.
Identify and resolve technical fabrication issues early to prevent delays.
4. Material & Resource Management
Manage raw materials inventory and coordinate with purchasing for necessary items.
Ensure all equipment (saws welders routers ) are maintained and in good working order.

Qualifications :

Required Skills & Qualifications
Experience: 5 years of professional experience in foam sculpting prop-making or scenic art preferably in the event or film industry.
Leadership: Proven ability to lead a team with strong interpersonal and communication skills.
Technical Proficiency: Expert skill with hand-carving tools operating 3D robots hot wires sanders and adhesive applications.
Spatial Awareness: Exceptional ability to visualize 3D forms from 2D drawings or CAD data.
Artistic Talent: Strong understanding of form texture and proportion proficiency in scenic painting and texturing techniques.
Software: Basic knowledge of ERP systems or inventory software is a plus along with Microsoft Office/Excel for reporting.
Problem-Solving: Strong hands-on problem-solving ability in high-pressure situations.
Efficiency: Ability to work quickly to meet strict event deadlines.
Physical Stamina: Ability to stand for long periods and handle 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