He began his career with small roles on television and in films such as Spy Kids 3-D: Game Over (2003) and Fast Food Nation (2006).

Powell attained wider prominence for starring in the action film Top Gun: Maverick (2022) and the romantic comedy Anyone but You (2023).

He initially expected to complete the requirements in spring 2024, but after his career limited his time commitments, he moved his goal to 2025.

[9][10] Powell's acting career began while working with Antonio Banderas and Sylvester Stallone in Spy Kids 3-D: Game Over.

After moving to the city, Powell stayed with a friend of the family, and he later described struggling during this period to get roles, including failed auditions for Friday Night Lights, Cowboys & Aliens, and The Longest Ride.

[10][15] However, he saw some success with small credits in television series, including Into the West, Jack & Bobby, CSI: Miami, NCIS, Without a Trace, Rizzoli & Isles, and The Lying Game.

[25] Powell next worked as a voice actor in the animated film Apollo 10 1⁄2: A Space Age Childhood, which premiered in March 2022.

[31][32] Around its release in December 2023, the film generated buzz because of speculation about a potential off-screen romance between Powell and Sweeney, although the two stars later admitted that the appearance of a real-life relationship was part of a marketing strategy.

[17] Powell produced and co-wrote the script of the romantic black comedy Hit Man with director Richard Linklater.

Alissa Wilkinson of The New York Times called it a "genuine star-clinching turn" for Powell,[37] while Sophie Butcher of Empire wrote that he "announces himself as a movie star and a filmmaking force to be reckoned with".

[42] His performance in Hit Man earned him a nomination for the Golden Globe Award for Best Actor in a Motion Picture – Musical or Comedy.

[43] Powell will next star in the thriller Huntington,[44][45] as well as the Hulu comedy series Chad Powers, in which he will also serve as co-creator, writer and executive producer.