This paper presents optimised design, analysis and fabrication of a 500 W, 2.5 m/s, 4-pole tubular linear induction motor (TLIM) prototype with a modified stator core structure. An exhaustive design procedure, involving conventional hand calculation, multi-objective design optimisation, followed by analysis usingstandard FEM packages is presented here. Development of the modified motor structure (such as stamping geometry, armature core structure etc.) are also discussed in details. Since, the motor is a special variant of linear motors, due emphasis has been laid on the optimisation of air-gap dimensions, efficiency-p.f. product and magnetic loading to improve the goodness factor, space factor and thrust. Normal force due to longitudinal end effects has also been considered. Fabrication challenges and innovative approaches to circumvent those hurdleshave been also been mentioned to address the interests of upcoming engineers/researcher trying to develop such machines from scratch. Devising a low cost ingenious loading arrangement in the lab for the specified prototypeis another highlight of the work. Preliminary tests have been conducted. There is good agreement between the calculated and experimentally obtained results.