Styrofoam Sculpting & Fabrication Technician

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.