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Custom Packaging Services

At 865FabLab, we engineer and fabricate custom protective packaging solutions that are functional, lightweight, and production-ready.


Start a Custom Packaging Project

At 865FabLab, we engineer and fabricate custom protective packaging solutions that are functional, lightweight, and production-ready. 

From aerospace parts to signage and electronics, our team builds packaging that protects what matters most — whether it's for shipping, storage, or presentation.

What We Offer

  • Protective packaging for fragile, valuable, or technical items

  • Cut-to-fit foam inserts and cavity blocks

  • Flat-pack boxes and enclosures

  • Branded packaging components

  • Reusable packaging kits and inserts

  • Short-run and prototype production

Specialty Packaging Applications

Our packaging solutions are ideal for:

  • Aerospace components – tools, parts, and avionics

  • Military & drone equipment – secure, lightweight enclosures

  • Electronics & sensors – shock-absorbing, custom-cut packaging

  • Architectural signage & letters – scratch-free delivery

  • Fragile or composite materials – safe, organized storage

Materials & Capabilities

We combine material knowledge and advanced cutting tools for scalable, repeatable solutions.

  • Foam Rubber Sheets – shock-absorbing and CNC-cut

  • Re-board® / Hexacomb board – lightweight and structural

  • Swedboard® / Structural Cardboard – foldable and rigid

  • PET Acoustic Panels / Foam Core Boards – protective layering

Fabrication Methods:

  • CNC Routing

  • Oscillating/drag knife cutting

  • V-Cutting and Creasing

  • Laser cutting and engraving

  • Adhesive bonding and lamination

  • Optional printed branding layers

From CAD to Cut

  1. Send us your part dimensions or sample

  2. We develop the layout and protection strategy

  3. Test-fit prototyping (if needed)

  4. We cut, crease, assemble, and pack

Custom Packaging FAQ's

Yes. We use CNC and oscillating knife technology to produce precise cavity fits for complex shapes.

Yes. We can design inserts and trays for long-term use and repeat handling.

Absolutely. We can add printed layers or mount graphics to reinforce your brand identity.

We regularly support clients in aerospace, defense, electronics, signage, manufacturing, and retail.

We offer both. Orders can be picked up at our Powell, TN facility or shipped anywhere in the USA.