Styrofoam Sculpting & Fabrication Technician

About the role

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 combines artistic ability with technical precision to meet exact design specifications.

Key responsibilities

• 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.
• Interpret technical drawings, 3D renders and design briefs to replicate shapes, dimensions and surface details.
• Apply hardcoat, fibreglass, gypsum and other coating systems to achieve durable, paintable surfaces.
• Produce scaled prototypes and test pieces for client or internal approval before full‑scale fabrication.
• Assemble multi‑component foam structures with appropriate adhesives, armatures and internal supports.
• Coordinate with painters, carpenters and project managers to ensure on‑time delivery.
• Manage foam stock, adhesives and consumables, minimizing waste through efficient cutting patterns.
• Maintain a clean, dust‑controlled workshop and safely handle foam off‑cuts and chemical coatings.

Required profile

• Minimum 4 + years of experience in foam sculpting or fabrication for events, theatre, theme parks or retail displays.
• Physical stamina for sustained manual work with large materials and ability to work evenings, weekends and holidays.
• Ability to read 2D drawings and 3D renders and produce accurate fabricated pieces.
• Understanding of structural requirements for large‑scale foam builds, including armature design.

Required skills

• Proficiency with hot‑wire CNC, manual hot‑wire tools, rasps and rotary carving tools.
• Experience applying hardcoat, fibreglass or gypsum coatings to foam substrates.
• Knowledge of foam‑safe adhesives and coating compatibility.
• Strong spatial awareness and attention to sculptural detail.