Senior Illusion Maker (Project Hire/Internal Assignment)

About the Role & Team:

Walt Disney Imagineering is the creative force that imagines, designs, and brings to life all Disney theme parks, resorts, attractions, and cruise ships worldwide. Working across a spectrum of disciplines that range from creative and conceptual to scientific and technical, Imagineers blend an innovative mixture of storytelling, art, science, and technology to create immersive experiences, memorable destinations, and innovative entertainment for families around the globe.

Nearly every project at Walt Disney Imagineering includes a first-of-its-kind. Innovation is in our DNA, and Imagineers constantly push the boundaries of technology and invent new goals as well as the solutions to achieve them. As Imagineers, one of our greatest rewards is knowing that the experiences and environments we create inspire others. The diversity of expertise at Imagineering makes us uniquely capable of influencing positive changes in our communities and around the world. And knowing that we have helped make a difference is incredibly fulfilling and inspiring for all of us.

Within the Creative Show Design & Delivery studio we produce the magic. Our processes and tool sets take us from concept design or mockups to full production, assembly and installation. You will work as part of the team creating world-class attractions. Thinking outside of the box and creative problem solving is a must. We’re looking for professionals who are thirsty for diverse experiences, who are eager to learn and who are confident they can uphold the Disney quality that our guests expect. If this sounds like you, please apply today!

You will report to the Mgr-Illusion Maker.

This is a Project Hire position, without any guarantee of permanent placement.

What You Will Do:

As an Illusion Maker Sr., focusing on Surface Development, you will:

Be responsible for the digital design of 3D printed shells for complex Audio Animatronic figures, as well as digital design of 3D printed tooling for intricate figure parts. This includes documenting and archiving shell, skin, and tooling digital files according to project requirements.

Fabricate, assemble, and clean up 3D printed parts, fiberglass components, cast parts, and vacuum-formed pieces. Additionally, you will handle the fabrication and clean-up of silicone skins, ensuring all materials meet the durability and maintenance standards required.

Troubleshoot, test, evaluate, and modify figure shells, parts, skins, and tooling are integral aspects of your role. You will problem-solve, mock-up, and test solutions for complex plastic part issues, continually improving designs for longevity and ease of maintenance.

Partner with Figure Finishing, Mechanical, and Electrical teams to ensure that costumes are fully integrated into the overall figure system. Collaboration with Walt Disney Imagineering Creative teams—including I.P. partners—is essential to develop figure shells and skins that fulfill the creative intent and match the overall look of the show. You will also work closely with Dimensional Design’s digital and physical sculptors to ensure clearances, thickness, shapes, offsets, and other factors are considered during model development.

Be responsible for developing tooling, shell, and skin estimates, as well as Surface Development design and production schedules. You will track and adhere to established schedules and budgets, efficiently executing change management as needed. Sourcing and ordering materials and working with vendors and suppliers to ensure quality and timely deliveries are also part of your duties.

Train park maintenance partners in the installation, removal, handling, and care of Audio Animatronic figure shells, skins, props, and related components. Additionally, you will develop and author standards and guidelines pertaining to Surface Development products and deliverables.

Travel, including internationally, is required to fulfill project needs and support installations and training at various locations.

Required Qualifications & Skills:

• Demonstrated proficiency in SolidWorks for design and engineering tasks

• Minimum of 5 years’ hands-on experience in plastics, mold, and part design and fabrication, with a strong focus on Audio Animatronics

• Familiarity with Design X, Magics, and Rhino software tools

• At least 5 years of specialized experience designing and fabricating Audio Animatronic figure tooling, shells, and skins

• Deep understanding of plastic and skin material properties as they relate to fabrication and durability

• Ability to read, interpret, and evaluate material Safety Data Sheets (SDS) and Technical Data Sheets (TDS)

• Practical experience with 3D printing, including knowledge of various additive manufacturing processes and materials

• Proven ability to collaborate effectively with cross-functional teams and other disciplines

• Exceptional planning and organizational capabilities

• Excellent verbal and written communication skills

• Comprehensive knowledge of Audio Animatronic figures and the end-to-end figure production pipeline

• Strong analytical and problem-solving skills, with a talent for creative thinking and innovation

• Experience in operating, maintaining, and troubleshooting 3D printers

• Experience in fabricating and finishing 3D printed parts

• Knowledge of matrix mold fabrication, including tooling processes

• Experience with epoxy mold fabrication and related tooling techniques

Education:

Bachelor’s degree or trade school preferred, but not required.

The hiring range for this position in Glendale, CA is $87,100.00 to $116,800.00 per year based on a 40-hour work week. The amount of hours scheduled per week may vary based on business needs. The base pay offered will take into account internal equity and also may vary depending on the candidate’s geographic region, job-related knowledge, skills, and experience among other factors. A bonus and/or long-term incentive units may be provided as part of the compensation package, in addition to the full range of medical, financial, and/or other benefits, dependent on the level and position offered.