Foam Fabricator / Soft-Goods Prototype Builder (Contract)

Spratt Labs, a pet wellness hardware company, is looking for an experienced foam fabricator to build the foam core of a prototype pet bed from engineering drawings. This is a one-off prototype build that will serve as the master reference for our overseas manufacturer.

What you’ll build

• 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