Foam Fabricator
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* The complete foam assembly of a large-format bolster-style pet bed: base pad, bolster walls, and inner sleep surface
* Precision cuts, channels, and cavities in the foam at specified positions to house internal hardware components (dimensions and positions provided in CAD/STEP and PDF drawings)
* Fabric cover is not in scope. The finished foam core will be handed to our manufacturer for the shell. How the work runs
* You'll work directly with our mechanical engineer, who owns the CAD and will answer dimension and tolerance questions
* We'll supply the STEP files, 2D drawings, and a parts list for the hardware the cavities need to fit
* Deliverable: one finished foam core, plus a short build note listing the foam densities/types you used and any cut-sequence tips for a factory to reproduce it
* Hardware fit check with the engineer before sign-off What we're looking for
* 3+ years fabricating polyurethane or similar foams: hot wire, bandsaw, CNC foam cutting, or hand tools with tight tolerances (±1/8" or better)
* Experience bonding/laminating foam layers and cutting clean internal pockets and through-holes
* Comfortable reading engineering drawings and STEP files (or working from the engineer's 2D exports)
* Upholstery, furniture, pet-product, or case/insert fabrication background is a plus
* Greater Philadelphia area preferred so the prototype can be inspected and handed off in person; remote candidates considered if you can ship the finished core Terms
* Fixed-price contract for one prototype. Quote your price and lead time with your application.
* NDA required before design files are shared
* Potential follow-on work for revision rounds and additional sizes To apply Send 3-5 photos of foam work you've cut to spec (inserts, cases, cushions, custom shapes), your tooling/method, your location, and your typical turnaround for a job of this type Harold@sprattlabs.com.
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