Styrofoam Sculpting & Fabrication Technician

Job Description

Role Overview
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 demands both artistic ability and technical precision to transform raw foam blocks into finished pieces that meet exacting design specifications.

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.
   

Qualifications

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.
   

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.