Team Leader - Foam Fabrication

About the role

The Foam Sculpturing/Fabrication Team Leader oversees the daily operations of the foam workshop, turning raw EPS or polyurethane foam into 3D props, scenic elements, and large‑scale structures for events, trade shows, and themed attractions. This hands‑on position bridges designers, production managers, and the workshop floor to deliver high‑quality, lightweight props on tight deadlines.

Key responsibilities

• Lead, mentor and schedule a workshop team to meet event timelines.
• Interpret technical drawings, 3D models and sketches to guide accurate foam fabrication.
• Carve, shape and sculpt foam using 3D robots, hot‑wire cutters, rasps, rotary tools and hand saws.
• Assemble foam blocks, glue, fit and clamp components to create structurally sound large‑scale pieces.
• Apply fine surface details with Dremel tools and finish with polyurea, epoxy or sand‑coat coatings.
• Collaborate with designers, painters, welders and electricians to integrate steel armatures and electrical elements.
• Maintain workshop equipment, enforce safety protocols and conduct daily toolbox talks.
• Inspect finished products for defects and ensure compliance with client specifications.

Required profile

• Minimum 5 years of professional experience in foam sculpting, prop‑making or scenic art.
• Proven ability to lead and motivate a workshop team.
• Strong spatial awareness to visualize 3D forms from 2D drawings.
• Hands‑on problem‑solving skills in high‑pressure, deadline‑driven environments.
• Physical stamina to stand for long periods and handle large foam components.

Required skills

• Operation of 3D robots and CNC cutting equipment.
• Use of hot‑wire cutters, rasps, rotary tools, hand saws and Dremel tools.
• Foam carving and shaping techniques for EPS and polyurethane.
• Application of polyurea, epoxy resin and sand‑coat surface coatings.
• Basic proficiency with ERP or inventory management software.
• Microsoft Excel for reporting and documentation.