Team Leader - Foam Fabrication

Overview

• 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.

• 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.

• 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.

• 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.

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.

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.