01 · Validate
Validate Product Designs
Evaluate form, function, scale and critical geometry before production.
Custom fabrication in Knoxville, TN
Custom CNC Fabrication, Prototyping & Small-Batch Manufacturing in Knoxville, TN
Turn CAD files, product ideas, signage concepts and display designs into precise, production-ready parts using multiple fabrication processes under one roof.
Prototype through production
Multi-process fabrication
Powell pickup + nationwide shipping
Prototype to production
One-offs, pilot parts,
short runs and repeat manufacturing.
Multiple processes
CNC, knife cutting, foam,
forming and 3D printing.
Material guidance
Plastics, wood, foam,
board, metals and composites.
Local + nationwide
Powell pickup and nationwide
project shipping.
Precision fabrication
One manufacturing partner from concept to finished component.
865FabLab helps businesses, product developers, designers, engineers, agencies, retailers and manufacturers move from concept to physical parts without coordinating a separate vendor for every process.
Projects can begin with CAD, vector artwork, drawings, sketches, reference images, measurements or a physical sample.
Match fabrication methods to geometry, material, quantity and end use.
Prototype important details before committing to production.
Combine cutting, printing, forming, fabrication, finishing and assembly.
Fabrication & prototyping services
Precision processes for prototypes, custom components and production work.
Choose a fabrication process or send your project details and let us help determine a practical manufacturing route.
3D Printing & Prototyping
Functional prototypes, housings, fit-check parts, fixtures and low-volume production components.
Explore 3D printing →
Knife & Foam Cutting
Re-board®, cardboard, PET acoustic panels, packaging foam and flexible materials cut accurately without tooling dies.
Explore knife & foam cutting →
Vacuum Forming
Custom plastic housings, shells, trays, covers, display elements and prototype formed components.
Explore vacuum forming →
Custom Fabrication
Multi-material components, fixtures, housings and specialty builds produced using coordinated fabrication processes.
Explore custom fabrication →
Retail & Display Solutions
Dimensional signage, retail fixtures, branded displays, window features and rollout components.
Explore displays →
CNC Routing & Cutting
Precision-cut plastics, wood, ACM, composites, fixture components and production-ready profiles.
Explore CNC routing →Product prototyping
Test the design before committing to production.
Physical prototypes help verify geometry, fit, material behavior, appearance and assembly before larger manufacturing commitments.
01 · Validate
02 · Test
Test Materials & Fit
Compare material behavior, assembly, clearances, appearance and performance.
03 · Produce
Prepare for Production
Refine fabrication files, tolerances, materials and repeatable process steps.
Custom manufacturing & small-batch production
Flexible manufacturing for custom parts, retail fixtures and repeat production.
Suitable for startups, product developers, agencies, retailers and companies moving from prototype into production.
Custom components
Custom Parts & Components
Multi-material components, housings, fixtures and custom parts for prototype or production.
Explore custom parts →
Displays & fixtures
Retail Displays & Fixtures
Custom display structures, branded fixtures, signage and merchandising components.
Explore display fabrication →
Temporary Furniture
Temporary Furniture
Lightweight flat-pack furniture for trade shows, events, booths, and temporary spaces.
View case studies →Project planning
Send the information that helps us determine the right process and quote faster.
| Geometry | CAD, vector artwork, drawings, sketches or physical samples |
|---|---|
| Dimensions | Overall size, critical dimensions, tolerances and mounting points |
| Material | Preferred material or required performance |
| Quantity | Prototype, one-off, pilot quantity, short run or repeat production |
| Finish | Color, texture, edge condition, coating or assembly |
| Schedule | Required completion, event, installation or shipping date |
- CAD, drawing or vector files
- Overall and critical dimensions
- Required quantity
- Material preference, if known
- Indoor, outdoor, impact or heat requirements
- Finish and appearance expectations
- Assembly or mounting requirements
- Shipping destination
- Required completion date
Not sure which process you need?
Send the part, dimensions, quantity
and intended use. We can review the
manufacturing method around the project
instead of forcing the design into
a specific machine.
Why choose 865FabLab?
Fewer vendor handoffs between concept, prototype and finished part.
Multi-process fabrication makes it easier to choose the production method around the project instead of around a single machine.
Process flexibility: CNC routing, knife cutting, foam fabrication, 3D printing, vacuum forming and fabrication.
Prototype support: validate fit, form and appearance before repeat production.
Material knowledge: plastics, wood, board, foam, metals and composites.
Local fabrication: Powell shop serving Knoxville and East Tennessee.
Nationwide support: suitable projects can be prepared for shipment across the United States.
Fabrication workflow
A clear path from project information to finished parts.
Send details
Submit files, dimensions, quantities and references.
Review scope
Confirm process, material, finish and schedule.
Quote
Define the approved fabrication scope.
Prototype
Validate critical details when required.
Fabricate
Cut, print, form, machine, finish and assemble.
Pickup or ship
Collect in Powell or prepare for delivery.
Customer feedback
Detailed fabrication work backed by customer proof.
★★★★★
“865FabLab was amazing! They cut a 10 foot Eiffel Tower for our Girl Scout Troop that I thought would be impossible.”Elizabeth Shelton
★★★★★
“They took me in the same day and stayed late to make sure everything was done.”Xfodude
★★★★★
“They designed and laser cut everything I needed to the exact sizes.”Andrew D
★★★★★
“Great working with them on very detailed projects.”Roe Palermo
Materials
Match material performance with the fabrication process and end use.
Material selection can account for appearance, durability, stiffness, weight, fabrication behavior, environment and finish.
Acrylic / PMMA
Clear, colored, mirrored
and illuminated components.
Polycarbonate
Guards, covers and
durable fabricated panels.
ACM
Signage, panels and
routed display structures.
Wood & Plywood
Fixtures, prototypes,
furniture and CNC parts.
Foam
Props, packaging,
molds and large-format forms.
PET Acoustic Material
Acoustic and decorative
interior components.
Re-board® / Structural Board
Displays and lightweight
temporary structures.
Metals & Specialty Materials
Custom structural and
production components.
Knoxville-area fabrication shop
Local project support from Powell, Tennessee.
Shop location
865FabLab7661 Clinton Hwy
Powell, TN 37849
Monday–Friday
8:00 AM–5:00 PM EST
Areas commonly served
Local pickup is convenient for Knoxville-area and East Tennessee customers, while suitable projects can be prepared for nationwide shipping.
Powell
Knoxville
Farragut
Oak Ridge
Maryville
East Tennessee
Nationwide
Ready to start?
Send your files, dimensions, quantity and project goal.
We can review materials, manufacturing processes, prototype needs, finishing, production quantity and delivery.
File and manufacturability review
Material and process guidance
Prototype or production quantities
Fabrication FAQs
Common questions before requesting a fabrication quote.
The right process depends on geometry, material, size, quantity, finish and what the finished part needs to do.
Discuss Your ProjectWhat types of projects does 865FabLab handle?
Projects may include CNC-routed
components, knife-cut materials,
foam fabrication, 3D printed parts,
vacuum-formed components,
custom displays, prototypes and
short-run production.
Do I need a finished CAD file?
Not always. CAD is useful,
but drawings, sketches,
vector artwork, dimensions,
reference photographs and physical
samples may support an initial review.
Can you help select a material?
Yes. Material choices can be
reviewed around fabrication method,
appearance, strength, weight,
environment, quantity and finish.
Can you make only one prototype?
Yes. One-off prototypes,
custom builds, first articles,
pilot quantities and repeat
production may be reviewed.
Can several fabrication methods be combined in one project?
Yes. Suitable projects may combine
CNC routing, knife cutting,
foam fabrication, 3D printing,
vacuum forming, signage fabrication,
finishing and assembly.
What information helps you quote faster?
Send available files, dimensions,
quantity, material requirements,
finish expectations, deadline,
shipping destination and references
that clarify the desired result.
Do you support projects outside Knoxville?
Yes. 865FabLab is based in Powell
near Knoxville, Tennessee and
supports suitable projects across
the United States.
Contact 865FabLab
Custom fabrication and prototyping near Knoxville, Tennessee.
Send your fabrication question, CAD file, drawing, prototype request or production requirement to the Powell team.