Contour cutting
Outside profiles, internal openings, curves, lettering, custom shapes and repeat parts.
Large-format digital cutting near Knoxville, Tennessee
Clean, heat-free CNC knife cutting for packaging, displays, foam and specialty sheet materials.
Turn vector files, printed sheets and structural-board concepts into precise contour-cut parts, folded displays, inserts, prototypes and short-run production components without laser charring or conventional cutting dies.
Prototype and production quantities
Print-to-cut registration
Powell pickup or nationwide shipping
Digital cutting without a cutting die
Contour cutting, V-grooving, creasing, scoring,
perforation and registered finishing in one workflow.
Heat-free edges
No laser charring, scorching or heat distortion.
±0.1 mm
Stated system repeatability for compatible workflows.
No cutting die
Faster design changes and lower setup for short runs.
1 to 200+
Support for samples, prototypes and repeat batches.
Digital knife-cutting service
A flexible process for materials that should not be burned, melted or heavily machined.
CNC knife cutting uses digitally controlled blades, creasing tools and specialty heads to convert flat sheet materials directly from vector files. It is well suited to display board, cardboard, foam-based products, felt, gasket materials, printed graphics and adhesive-backed media.
Because there is no conventional steel-rule die, designs can be changed quickly between prototypes and short production runs. Multiple operations can also be combined in one setup.
Produce finished outlines, internal cutouts, fold lines, bevels, perforations and registration-aligned parts.
Test packaging, displays and structures before committing to larger production tooling.
Combine knife cutting with printing, routing, fabrication, lighting, 3D printing and assembly.
Cutting and finishing capabilities
Multiple operations for flat, printed, folded and dimensional projects.
V-grooving and beveling
Angled cuts for folded corners, dimensional structures, display forms and edge details.
Creasing and scoring
Controlled fold lines for packaging, paperboard, cardboard and compatible structural materials.
Camera registration
Align compatible cut paths with printed graphics, artwork, logos and registration marks.
Kiss-cutting
Cut selected layers while leaving liners or backing materials intact where the material allows.
Perforation
Create tear lines, removable sections, fold aids and project-specific perforated patterns.
Oscillating knife cutting
Powered blade motion for compatible foam, board, rubber, felt and flexible sheet materials.
Drag-knife cutting
Precise cutting of thinner flexible materials, films, paper, vinyl and selected laminates.
Production kitting
Part numbering, grouping, assembly preparation, protective packing and shipment-ready kits.
Machine and project specifications
Information that helps us qualify your material and quote accurately.
| Cutting methods | Oscillating knife, drag knife, V-cut, creasing and compatible specialty-tool workflows |
|---|---|
| Maximum thickness | Material- and tool-dependent; selected materials may be supported up to approximately 1.5 inches |
| Registration | Camera-assisted cut-to-print alignment for compatible artwork and registration systems |
| Hold-down | Zoned high-flow vacuum hold-down |
| Repeatability | Stated system repeatability of approximately ±0.1 mm |
| Common file types | DXF, SVG, AI, EPS and production-ready PDF |
| Quantities | One-off samples, prototypes, short runs and repeat production batches |
- Vector cut file or dimensional drawing
- Finished dimensions and required quantity
- Material name, manufacturer and thickness
- Whether material is customer supplied
- Printed artwork and registration-mark details
- Cut-through, crease, V-groove or kiss-cut layers
- Edge-quality and tolerance requirements
- Assembly, labeling, packing and shipping needs
- Requested completion date
Maximum cutting depth and edge quality vary with material
density, construction, adhesive layers, grain direction,
blade access and geometry. A sample cut may be recommended
for unfamiliar or customer-supplied materials.
Common materials
Digital cutting for paper-based, foam-based, textile and specialty sheet products.
Re-board®, Swedboard®, Falconboard®, Xanita and similar paper-based structural panels.
Corrugated board, folding carton stock, chipboard, kraft board and presentation materials.
Foam board, PVC-free foam sheets, Gatorfoam® and selected laminated foam products.
Selected rubber foam, gasket media, sealing materials and industrial sheet products.
PET felt, craft felt, compatible fabrics and flexible textile materials.
Magnetic media, vinyl sheets, adhesive-backed laminates and selected film products.
Why choose knife cutting?
The right process when heat, tooling cost or rapid iteration matters.
No heat-affected edge
Knife cutting avoids the burns, discoloration and heat distortion that lasers can cause on foam, adhesives and paper-based materials.
No conventional cutting die
Digital files drive the process directly, making revisions, prototypes and low-volume runs more practical.
Multiple operations in one setup
Combine cut-through lines, creases, V-grooves, perforations and registration-aligned finishing.
Cleaner display surfaces
Avoid router dust and visible machining marks on many client-facing paper, foam and display substrates.
Faster design iteration
Update the vector file rather than replacing physical tooling when dimensions or graphics change.
Efficient print finishing
Camera registration supports contour cutting of compatible printed displays, signs, prototypes and packaging.
Ideal applications
From one presentation insert to a repeatable national display kit.
Retail displays
Freestanding displays, shelf units, product surrounds, headers, endcaps and branded merchandising structures.
Custom packaging
Folding cartons, presentation boxes, protective inserts, prototypes and short-run packaging components.
Trade-show structures
Lightweight booths, partitions, backdrops, podiums, displays and flat-pack event components.
Printed signage
Registered contour-cut graphics, dimensional letters, point-of-purchase signs and shaped brand elements.
Flat-pack furniture
Slotted stools, counters, tables, shelving, display furniture and temporary fixtures.
Foam inserts and shapes
Presentation inserts, separators, protective components, templates and custom foam profiles.
Gaskets and templates
Prototype gaskets, masks, patterns, assembly aids and project-specific industrial shapes.
Acoustic PET features
Wall panels, room dividers, baffles, folded forms and custom acoustic components.
Production kits
Numbered parts, grouped components, packing instructions and multi-location deployment kits.
Project workflow
A clear route from file review to finished parts.
Share the project
Send files, drawings, quantities, material details and deadline.
Confirm material
Review thickness, density, finish, layers and tooling compatibility.
Plan operations
Define cut, crease, V-groove, registration and perforation layers.
Sample if needed
Validate edge quality, fold behavior, fit and printed alignment.
Cut and inspect
Produce the parts and verify key dimensions and finishing details.
Pack and deliver
Label, group and prepare the project for pickup or shipment.
Ready to price your project?
Send your vector file, material, dimensions and quantity.
We will review tooling compatibility, nesting, cut operations, registration, production quantity, finishing and delivery needs.
Material and file review
Prototype or repeat production
Pickup or nationwide shipment
CNC knife-cutting FAQs
Common questions before requesting a quote.
Material behavior varies, so unfamiliar products may require a sample cut before production.
Ask About Your MaterialCan you contour cut printed sheets?
Yes. Camera registration can align compatible cut paths
with printed graphics, logos and registration marks.
Artwork, bleed, print scale and mark placement should
be reviewed before production.
How thick can the CNC knife cutter cut?
Maximum thickness depends on material density,
construction, blade access, required edge quality and
geometry. Selected materials may be supported up to
approximately 1.5 inches, but the exact limit should
be confirmed for each project.
Can you V-groove and crease folding materials?
Yes. Compatible boards can receive V-grooves, bevels,
score lines and crease lines for boxes, displays,
furniture, partitions and dimensional structures.
Do you offer kiss-cutting and perforation?
Yes, where the selected material and layer construction
allow it. These processes can support peel-away layers,
tear lines, templates and packaging features.
What file types should I send?
Production-ready vector files such as DXF, SVG, AI,
EPS or PDF are preferred. Clearly separate
cut-through, crease, V-groove, perforation and
print-registration layers.
Can you help prepare my cut file?
File preparation, nesting and production-layout
support may be available. Send the best drawing, sketch
or artwork you have along with finished dimensions.
Is knife cutting better than laser cutting?
It depends on the material and desired result. Knife
cutting is often preferred for paperboard, foam, felt
and adhesive-backed materials because it introduces no
heat. Laser cutting may be better for other materials
or very small details.
Do I need to order a large quantity?
No. Digital knife cutting can support single
prototypes, samples, mockups, short runs and repeat
production without a conventional cutting die.
Can I supply my own material?
Customer-supplied material may be accepted after
reviewing its composition, thickness, flatness,
surface finish and cutting compatibility. A sample may
be required.
Do you offer pickup and shipping?
Yes. Projects can be picked up at the Powell,
Tennessee shop or packaged for shipment within the
United States.
Contact 865FabLab
CNC knife cutting near Knoxville, Tennessee.
Discuss packaging, printed display finishing, structural board, foam, felt, gasket material, prototype parts or production kits with the Powell fabrication team.