Styrofoam Sculpting & Fabrication Technician

Overview

Role Overview

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.

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.

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.