Overview
The Aviation Upholstery Foam Builder fabricates, shapes, and assembles foam components used in aircraft seating, sidewalls, headliners, crew rests, and custom cabin furnishings. This role supports interior refurbishment and completion programs by producing high-quality, ergonomically correct, and FAA-compliant foam structures that serve as the foundation for upholstered assemblies. Work is performed in a controlled shop environment using specialized cutting, bonding, and shaping techniques to meet engineering specifications and customer design requirements.
Key Responsibilities
- Build, shape, and contour foam components for aircraft seats, divans, crew seats, and cabin furnishings using approved materials and technical data.
- Interpret engineering drawings, patterns, templates, and build sheets to produce foam assemblies to exact tolerances.
- Cut, laminate, and bond multiple foam densities to achieve required firmness, comfort, and structural characteristics.
- Operate foam-cutting tools including hot-wire cutters, band saws, contour saws, sanders, and specialty shaping equipment.
- Perform ergonomic shaping and sculpting to ensure proper fit, comfort, and aesthetic alignment with upholstery covers.
- Collaborate with upholstery technicians to ensure foam assemblies integrate correctly with sewn covers and interior components.
- Inspect incoming foam materials for defects, density accuracy, and compliance with flammability requirements.
- Document materials used, build steps, and traceability information in accordance with Part 145 or company quality procedures.
- Maintain a clean, organized, and tool-controlled work area to support safety and quality standards.
- Assist with prototype development for custom VIP or corporate aircraft interior projects.
- Repair or rebuild existing foam components during refurbishment or overhaul programs.
