Revolutionize Your Automotive Manufacturing with High-Performance Components
Lightweight polycarbonate windows, carbon fiber composite panels, and Fusionite™-coated components engineered for passenger vehicles, commercial fleets, and specialty vehicles.
When automotive components fail validation, vehicle performance, FMVSS compliance, and program launch timelines are at risk.
High-Performance Components for Critical Automotive Applications
Five Star Fabricating offers American-made polycarbonate windows, carbon fiber composite panels, and Fusionite™-coated components that combine impact resistance, optical clarity, and dramatic weight reduction for the most demanding automotive applications. Whether for passenger vehicles, commercial fleets, motorsports body panels, or specialty platforms, our components deliver safety, fuel efficiency, and long-lasting durability for OEM programs at scale.
What Happens When Automotive Components Fail Validation
Without proper materials and validation, automotive components can degrade, lose impact resistance, and compromise vehicle performance under the extreme stress of automotive environments — vibration, thermal cycling, road debris, UV exposure, and high-cycle fatigue.
When automotive components fail — in validation or in the field — it creates real program risk:
- FMVSS compliance delays that push back vehicle launch and production timelines
- Costly redesign cycles late in the OEM program
- Warranty and liability exposure after vehicle delivery
- Compromised occupant safety and program reputation in critical applications
Automotive Component Manufacturing Capabilities
From prototype validation through high-volume OEM production — Five Star supports the complete automotive component program lifecycle.
Complex curved geometries formed to automotive tolerances for windshields, sunroofs, lighting lenses, and body panel applications.
Precision CNC routing and trimming for exact edge profiles and dimensional accuracy across high-volume production runs.
Proprietary hardcoat systems providing scratch, UV, abrasion, and chemical resistance validated for automotive exposure.
Advanced composite body panels and structural components engineered for motorsports and high-performance vehicle programs.
In-house testing for impact resistance, FMVSS 226 compliance, UV degradation, scratch resistance, and thermal cycling.
From prototype to high-volume OEM programs with repeatable quality and Fusionite™ coating consistency at scale.
Automotive Component Performance Requirements
Polycarbonate and composite components for automotive applications must meet strict demands across six performance areas:
| Requirement | What It Means in Practice |
|---|---|
| Impact Resistance | 10x more impact-resistant than glass — withstands road debris and collision forces without fracture |
| Weight Reduction | Up to 70% lighter than traditional materials — reduces vehicle weight up to 30% for improved fuel economy and EV range |
| FMVSS Compliance | Meets FMVSS 226 ejection mitigation standards and applicable safety requirements |
| Optical Clarity | 90% light transmission for windshields, side windows, sunroofs, and lighting lenses |
| UV & Weather Durability | Maintains clarity and coating adhesion across the full vehicle service life |
| Coating Performance | Scratch, UV, abrasion, and chemical resistance validated for automotive exposure |
Why Automotive OEMs Trust Five Star Fabricating
We support automotive OEMs, Tier 1 suppliers, and motorsports teams from prototype validation through high-volume production — engineered for safety, weight reduction, and manufacturability at scale.
Proudly manufactured in our 300,000-square-foot, ISO 9001:2015-certified facility in Twin Lakes, Wisconsin, ensuring compliance with rigorous automotive industry standards and full supply chain traceability.
As the exclusive supplier of composite body parts for NASCAR's Xfinity Series and NASCAR Cup Series Supplier of the Year for 2024 and 2025, our components are proven in the most demanding high-performance environments.
Specializing in polycarbonate, carbon fiber composites, and advanced plastics with Fusionite™ scratch-resistant coatings, we provide lightweight, durable components that reduce emissions and improve fuel economy.
Our custom fabrication capabilities allow us to meet unique vehicle design requirements — from complex geometries to high-volume production — ensuring seamless integration and optimal performance.
All components meet or exceed automotive safety standards, including FMVSS 226, ensuring reliability and safety for end-users. Learn more about our commitment to quality.
Key Features for Automotive Components
- Significant Weight Savings — Up to 70% lighter than traditional materials, reducing overall vehicle weight by up to 30% and extending hybrid and EV range.
- Enhanced Safety — Polycarbonate windows and lenses are 10x more impact-resistant than glass and meet FMVSS 226 ejection mitigation requirements.
- Exceptional Durability with Fusionite™ — Our proprietary coating system delivers scratch, UV, abrasion, and chemical resistance to maintain clarity and performance over the vehicle's full service life.
- Flexible Design Capabilities — Custom fabrication supports advanced designs from complex curved geometries to high-volume production runs tailored to OEM specifications.
- Cost Efficiency — Lightweight materials and durable designs reduce fuel costs and maintenance expenses, providing long-term program value.
- Multi-Material Expertise — Polycarbonate, carbon fiber composites, and advanced plastics from one supplier — eliminating supply chain complexity for OEM programs.
Automotive & Motorsports Component Applications
From hybrid passenger vehicles to NASCAR Cup Series race cars — Five Star polycarbonate and composite components are engineered for the most demanding automotive environments on and off the track.
Typical programs include OEM production volumes, FMVSS 226 compliance requirements, ISO 9001:2015 quality systems, and engineering-led development from prototype through high-volume production scale.
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Polycarbonate Windows & Sunroofs
Lightweight, impact-resistant windows with 90% light transmission — engineered for front windshields, side windows, and sunroofs in passenger vehicles, hybrids, EVs, and commercial fleets.
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Lighting Lenses
High-clarity polycarbonate lenses for headlights, taillights, directional lights, and instrument panels — ensuring optimal visibility, safety compliance, and long-term UV durability.
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Composite Body Panels
Lightweight carbon fiber composite panels for performance vehicles and motorsports — proven in NASCAR Cup Series competition with the strength, flexibility, and design versatility OEMs require.
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Motorcycle Wind Deflectors & Fairings
Custom-designed deflectors and fairings for motorsports and powersports applications, improving aerodynamics and rider comfort in high-performance environments.
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Commercial Vehicle Components
Durable polycarbonate and composite parts for trucks, buses, vans, and fleet vehicles — engineered for reliability under heavy use, long service life, and demanding duty cycles.
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Specialty & EV Vehicle Components
High-performance lightweight components for hybrids, electric vehicles, RVs, and specialty platforms — reducing vehicle weight to extend range, improve efficiency, and enhance both aesthetics and functionality.
Is This the Right Fit for Your Automotive Program?
Not every component supplier is built for production-volume automotive programs. Five Star partners with automotive OEMs, Tier 1 suppliers, and motorsports programs on long-term production programs that demand engineering support, FMVSS-validated performance, and high-volume production repeatability. Here's where we fit best — and where another partner may serve you better.
- OEM automotive programs requiring lightweight polycarbonate windows and composite body panels
- Passenger vehicles, hybrids, and EVs targeting weight reduction and extended range
- Commercial fleets and specialty vehicles requiring durable, custom-fabricated components
- Motorsports teams needing high-performance composite body parts and wind deflectors
- Applications requiring FMVSS 226 ejection-mitigation performance and high impact resistance
- Programs that benefit from polycarbonate, carbon fiber composites, and Fusionite™ hard coatings from a single supplier
- Single-unit replacement parts or standalone, one-off fabrication outside of an OEM program
- Projects without defined OEM specifications or validation requirements
- Programs where lowest unit cost outweighs durability and weight savings
- Applications that don't need engineering support or design-for-manufacture review
Not sure if your program is a fit? Talk with an engineer first.
Discuss Your Application View Fabricating CapabilitiesHow We Move Your Automotive Program Forward
From concept review through high-volume launch and beyond — our automotive component program process is built to reduce FMVSS compliance risk, eliminate redesign cycles, and deliver production-ready polycarbonate and composite components on time.
- Align component performance with FMVSS 226 and OEM specification requirements early
- Reduce costly redesign risk before tooling and production investment
- Validate impact resistance, weight reduction, and Fusionite™ coating durability before scale
- Create a clear path from prototype validation to high-volume OEM production
Ready to start an engineering review? Talk with a Five Star automotive engineer about your program requirements, timeline, and FMVSS compliance path.
Start an Engineering Review-
01 Concept Review
We evaluate your vehicle program requirements, FMVSS 226 compliance constraints, weight reduction targets, environmental exposure conditions, and production timeline before any tooling commitment.
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02 DFM Collaboration
Our automotive engineers work directly with your OEM team to optimize component geometry, thermoform complexity, coating selection, dimensional tolerances, and unit cost before production tooling begins.
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03 Prototype & Validation
Rapid prototyping and in-house lab testing validate impact resistance, Fusionite™ coating performance, FMVSS 226 compliance, UV durability, and thermal stability before production release.
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04 Production & Scale
Full-scale American manufacturing delivers repeatable dimensional accuracy, Fusionite™ coating consistency, and production-ready automotive components for OEM programs at high-volume scale.
What a Properly Engineered Automotive Component System Delivers:
Automotive OEMs and Tier 1 suppliers who partner with Five Star Fabricating from concept through high-volume production consistently achieve these program outcomes — from first article validation through certified production at scale.
Talk with a Five Star automotive engineer about your program requirements, FMVSS compliance path, and production timeline.
What Automotive Leaders Say About Five Star
"Five Star Fabricating has been instrumental in supporting our high-volume automotive programs. Their ability to deliver cost-effective, high-quality components has been invaluable."
Automotive Component Engineering FAQs
Answers to the questions automotive OEMs, Tier 1 suppliers, and motorsports teams ask most about polycarbonate windows, composite components, coatings, and OEM program fit.
Ready to Enhance Your Vehicles with High-Performance Components?
Partner with Five Star Fabricating to transform your automotive manufacturing with capabilities that prioritize safety, efficiency, and innovation. From hybrid passenger vehicles to NASCAR Cup Series race cars — we deliver American-made components engineered for performance.
Built for OEM programs where component performance, FMVSS compliance, coating durability, and high-volume supply continuity matter — from prototype through certified production.
Call us at +1 (262) 877-2171
Supporting Tier 1 and OEM programs across automotive, EV, motorsports, and advanced mobility.