Team Leader - Foam Fabrication

Job Description

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.