Engineered Manufactured Tested Under One Roof
American-made engineered components built for demanding applications where strength, weight, optical performance, and durability matter.
Engineered for OEM applications requiring impact resistance, optical clarity, and long-term durability at scale.
Advanced composite structures built for programs where strength, weight, and precision matter. From prepreg layup to autoclave cure — all under one roof.
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Custom-formed polycarbonate windows engineered for optical clarity, impact resistance, and long service life across heavy equipment, defense, and transit applications.
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High-precision thermoforming for complex plastic components across a range of materials. Engineered for tight tolerances, surface quality, and repeatable production.
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Proprietary FUSIONITE™ hard-coat and optical coatings engineered for abrasion resistance, UV stability, and long-life optical performance on polycarbonate surfaces.
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Precision CNC machining for plastics, composites, and metals. Tight tolerances, clean finishes, and fast turnaround for OEM development and production programs.
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Custom metal fabrication for brackets, frames, enclosures, and structural assemblies. Engineered to spec and built for production-level repeatability.
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In-house testing and qualification services to verify performance before parts leave the facility. ISO 9001:2015 certified with full documentation and traceability.
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From early development and prototyping through validation and full-scale manufacturing, Five Star partners with OEMs to bring engineered components to market and keep them in production.
Our focus is long-term manufacturing programs, not standalone, one-off fabrication projects.
Since 1978, Five Star has engineered high-performance polycarbonate and composite capabilities for demanding OEM applications where failure is not an option.
As the only North American manufacturer that forms, coats, and certifies polycarbonate in-house, we deliver unmatched control over performance, quality, and repeatability across your OEM program—from prototype through full-scale production.
Our certifications
Our quality system and glazing products meet the standards that automotive, motorsport and rail programs specify.
Member of
SAE International
Association of Equipment Manufacturers (AEM)
ISO 9001:2015
Certified quality management system.
ECE R43
UN regulation for vehicle safety glazing, recognized in Europe and internationally.
ANSI Z26.1
US standard for safety glazing materials in motor vehicles.
FRA 49 CFR 238.421
Federal Railroad Administration glazing requirements for passenger rail equipment.
A structured process that reduces risk, accelerates development, and ensures consistent performance at scale. From prototype through full-scale OEM production.
All forming, coating, and certification performed in-house — giving you total control over performance, quality, and repeatability.
The NASCAR Cup Series required lightweight, impact-resistant polycarbonate body panels capable of withstanding extreme race conditions while meeting its strict technical specifications.
Stellantis needed to reduce vehicle weight to improve fuel efficiency and performance. Five Star's lightweight ejection mitigation polycarbonate glazing replaced traditional glass without compromising occupant safety.
Standard polycarbonate windshields scratch under repeated wiper use, shortening service life and raising costs. Five Star's Fuisonate™ coated polycarbonate was put to the test against standard polycarbonate.
Where tight tolerances, fast timelines, and constant innovation turn our premium materials into race-ready performance. Get a behind-the-scenes look at the all-new Sprint Car Body, the '69 Camaro Pro Mod, Northeast Modified bodies, and more.
Talk to EngineeringOur engineers work directly with OEM programs from material selection through full-scale production. No sales intermediary — just engineers solving real application problems.
Ready to discuss your program? Reach our engineering team at +1 (262) 877-2171 or Contact Us
Schedule a ConsultationOEM engineers complete most of their research before first contact. These guides answer the critical questions around cost, performance, and failure risk.
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Work directly with our engineering team to develop high-performance plastic and composite components — from engineering development through full-scale production.
Trusted by OEM programs across EV, heavy equipment, defense, and motorsports.
