CNC-cut foam inserts
Product cavities, finger pulls, accessory pockets, layered inserts and protective supports for compatible foam materials.
Custom protective packaging near Knoxville, Tennessee
Packaging engineered around your product, handling risks and delivery workflow.
Protect technical, fragile and high-value products with CNC-cut foam inserts, structural-board boxes, reusable transit kits, branded presentation packaging and short-run production built to fit the item—not the other way around.
Prototype and short-run quantities
Custom-fit foam and board structures
Powell pickup or nationwide shipping
Designed to protect, organize and present
Foam cavities, dividers, boxes, trays, labels and
branded surfaces developed as one coordinated package.
Product-specific fit
Cavities, supports and clearances designed around your item.
Prototype first
Test fit, access and handling before repeat production.
Multi-process shop
Foam cutting, knife cutting, routing, printing and assembly.
1 to 200+
Support for one-offs, samples, kits and repeat short runs.
Custom packaging fabrication
More than a box: a coordinated protection, handling and presentation system.
Custom packaging should protect the product during shipping, simplify packing and unpacking, organize accessories, reduce movement, and support the way the customer stores, presents or installs the item.
865FabLab can combine fitted foam, structural cardboard, Re-board®, printed surfaces, dividers, trays, labels and fabricated enclosures into a single packaging solution.
Reduce movement, surface contact and impact risk during shipping and repeated handling.
Organize parts, accessories, installation hardware and documentation in a repeatable layout.
Improve presentation with cleaner packing, branded surfaces and a more intentional unboxing experience.
Packaging solutions
Protection, organization and presentation for products that standard packaging cannot handle well.
Reusable transit kits
Durable trays, dividers and replaceable inserts for repeated shipping, service calls, demonstrations and installations.
Structural-board boxes
Lightweight boxes, sleeves, crates, dividers and folding structures made from Re-board®, Swedboard® and similar boards.
Presentation packaging
Branded product kits, sample cases, sales demonstration packages, launch boxes and presentation inserts.
Protective shipping systems
Support blocks, edge protection, separators and fitted internal structures for delicate or high-value products.
Flat-pack packaging
Digitally cut boxes and enclosures designed to ship or store flat before rapid assembly.
Component and tool organization
Clearly arranged pockets, labels and part positions for tools, fixtures, electronics and service equipment.
Short-run branded packaging
Small production quantities for launches, sales kits, limited products, events and pilot programs.
Multi-location deployment kits
Numbered parts, grouped components and store-ready kits prepared for repeatable delivery to multiple destinations.
Project and quote requirements
The details that help us design the right level of protection.
| Product information | Dimensions, weight, material, finish, fragile areas and orientation requirements |
|---|---|
| Handling conditions | Shipping frequency, storage, repeated use, installation, return shipment and expected handling |
| Protection goals | Scratch prevention, movement control, impact absorption, part separation and presentation |
| Available files | STEP, STL, DXF, SVG, AI, EPS, PDF, dimensioned drawings, photos or physical samples |
| Production quantity | One prototype, small batch, repeat kit or multi-location rollout |
| Branding | Printed graphics, labels, color coding, logos, instructions and product identification |
| Delivery | Local pickup, bulk shipment, individual kit shipment or direct-to-location distribution |
- Product dimensions and approximate weight
- CAD file, drawing, photos or physical sample
- Quantity for prototype and production
- Known fragile areas or protected surfaces
- Shipping carrier and expected handling conditions
- Reusable or single-use requirement
- Outer-box or case dimensions, if already selected
- Accessories, cables, tools or documents to include
- Printing, branding and labeling requirements
- Required completion or delivery date
Packaging performance depends on product weight, fragility,
drop exposure, shipping method, foam density, cavity
clearances and outer-container construction. A prototype or
physical test may be recommended before production.
Packaging materials and processes
Combine cushioning, structure and branding in one coordinated build.
Selected foam rubber, polyethylene-style foam, layered
foam and compatible cushioning materials for fitted
inserts.
Re-board®, Swedboard®, Falconboard®, Xanita and similar
rigid, lightweight display and packaging panels.
Corrugated cardboard, folding carton stock, chipboard,
kraft board, dividers and sleeves.
Lightweight boards for partitions, covers,
presentation layers and protective internal structures.
Soft-contact layers, dividers and presentation surfaces
for compatible products.
Branded graphic layers, labels, identification panels,
instructions and protective laminates.
Why custom packaging?
Standard packing materials often leave protection, labor and presentation problems unresolved.
Less product movement
Fitted cavities and supports reduce shifting compared with loose fill or generic padding.
Faster packing
Defined product and accessory positions make packing more repeatable and reduce guesswork.
Cleaner presentation
Organized inserts and branded surfaces create a more professional delivery or demonstration experience.
Reusable protection
Durable trays and inserts can support recurring shipments, demonstrations, servicing and installations.
Better part control
Dedicated pockets help identify missing accessories, hardware or components before shipment.
Scalable production
Digital fabrication supports design revisions, prototypes, short runs and repeat kits without conventional die tooling.
Industries and applications
Packaging for technical products, valuable components and branded experiences.
Aerospace components
Protective inserts and organized kits for parts, tools, instruments and sensitive components.
Electronics and sensors
Fitted support for devices, cables, chargers, controls, instruments and accessories.
Drones and technical equipment
Reusable transport layouts for equipment, batteries, controls, tools and replacement components.
Signs and fabricated letters
Surface protection, separators and transit structures for finished signage and display elements.
Sales and demonstration kits
Presentation packaging for product samples, launch kits, showrooms, sales teams and customer demonstrations.
Retail rollout kits
Numbered and grouped components prepared for repeat installations across stores or locations.
Industrial tools and fixtures
Organized inserts for gauges, tools, templates, service parts and specialized fixtures.
Fragile prototypes
Protection for one-off models, formed parts, 3D prints, acrylic components and development samples.
Architectural samples
Presentation and shipping kits for material samples, finishes, lighting components and design mockups.
Packaging development process
From product information to a repeatable packing system.
Share the product
Send CAD, dimensions, photos, weight, quantity and handling requirements.
Define the risks
Identify fragile surfaces, impact concerns, movement and access requirements.
Plan the package
Select foam, board, dividers, clearances, branding and outer structure.
Prototype and test
Review product fit, removal, organization and packing workflow.
Produce the run
Cut, print, assemble, label and inspect the approved packaging.
Pack and distribute
Prepare for shop pickup, bulk shipping or direct-to-location delivery.
Ready to develop your packaging?
Send product dimensions, photos, quantity and handling details.
We will review protection requirements, materials, cavity design, prototype needs, branding, production quantity and delivery.
Product and risk review
Prototype and test-fit options
Pickup or nationwide shipment
Custom packaging FAQs
Common questions before requesting a packaging quote.
Product fit, foam performance and shipping requirements vary, so a prototype may be recommended for unfamiliar or high-risk items.
Discuss Your ProductCan you create foam inserts for irregular shapes?
Yes. CNC routing, oscillating knife cutting and other
fabrication methods can produce fitted cavities for
compatible irregular, curved and technical products. A
CAD file, drawing or physical sample can help establish
the geometry.
Can you design reusable packaging?
Yes. Reusable trays, inserts, dividers and transit kits
can be developed for repeated shipping, storage,
installations, servicing, demonstrations and return
transport.
Can the packaging include printed branding?
Yes. Compatible projects can include printed graphics,
labels, logos, color coding, product identification,
instructions and mounted branding layers.
Do you make prototypes and short production runs?
Yes. Packaging projects can begin with one prototype or
test-fit unit and move into short-run or repeat
production after approval.
What files should I send?
STEP, STL, DXF, SVG, AI, EPS and production-ready PDF
files are useful. Dimensioned drawings, photos and
physical samples can also be reviewed when CAD is
unavailable.
Can you help design the insert if I only have the product?
Design support may be available. The team can review
product dimensions, physical samples, handling needs
and protection goals to develop a workable insert and
packaging layout.
Can accessories and documentation be included?
Yes. Packaging can include dedicated spaces for cables,
tools, mounting hardware, manuals, labels and other
related components.
Can you work with an existing case or shipping box?
Often, yes. Inserts and dividers can be designed around
selected case or box dimensions when the internal
space, construction and access requirements are
suitable.
How do you choose the right foam?
Foam selection depends on product weight, fragility,
surface finish, cavity depth, expected impacts, reuse
requirements and shipping conditions. A test fit or
sample may be recommended.
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
Custom packaging and foam inserts near Knoxville, Tennessee.
Discuss protective packaging, presentation kits, foam cavities, reusable transit systems, structural-board boxes or short-run production with the Powell fabrication team.