Engineered Polycarbonate Systems for the Future of Robotics
Proven plastics expertise — purpose-built for robotics. Five Star Fabricating delivers high-performance polycarbonate windows, thermoformed enclosures, and advanced composite systems for robotics OEMs, system integrators, and automation equipment manufacturers — engineered for AMRs, cobots, LiDAR domes, machine vision, and industrial automation.
When robotics sensor windows and protective enclosures fail, robot uptime, sensor accuracy, and operator safety are all at risk.
Why Robotics OEMs & Integrators Choose Five Star Fabricating
Five Star Fabricating stands as a premier provider of high-performance polycarbonate and thermoformed plastic solutions for the robotics industry. Our expertise spans autonomous mobile robots (AMRs), collaborative robots (cobots), industrial automation systems, and specialized robotics applications across manufacturing, warehouse automation, and service robotics sectors.
Drawing from our deep roots in high-performance manufacturing — including serving as NASCAR's exclusive polycarbonate window supplier since 1992 — we bring proven reliability and innovation to robotics applications where failure is not an option. With 47+ years of expertise, we deliver lightweight, durable, and precision-engineered polycarbonate windows, thermoformed enclosures, and advanced composites that meet the demanding requirements of modern robotic systems.
What Happens When Robotics Glazing & Enclosures Fail
Without proper optical-grade materials, ESD-safe surface treatments, and precision-engineered tolerances, robotics sensor windows and protective enclosures can scratch, fog, distort, or fail prematurely under the demands of continuous operation — compromising LiDAR accuracy, machine vision performance, cobot safety, and robot uptime across high-mix production environments.
When robotics components fail — in service or under impact — it creates real operational risk:
- Compromised sensor accuracy and reduced LiDAR / machine vision performance from optical degradation
- Cobot safety compliance gaps that block ISO 10218 and UL 94 V-0 certification path
- Reduced AMR / AGV battery range and operating time from excessive body-component weight
- Costly robot fleet downtime, replacement cycles, and missed automation deployment timelines
Robotics Manufacturing Capabilities
Our 350,000 square foot facility combines advanced thermoforming capabilities with precision CNC machining, in-house coating, and full assembly — enabling complex geometries, tight tolerances, and the prototype-through-production volumes essential for robotics applications.
<1% haze and >90% light transmission optical-grade polycarbonate — anti-scratch hardcoat, anti-fog, and anti-reflective coating options for LiDAR, camera, and machine vision optics.
Large-format thermoforming up to 10' × 12' for AMR / AGV chassis covers, robot body panels, battery compartment enclosures, and electronics housings.
5-axis CNC machining to ±0.015" tolerances — precision-machined mounting surfaces, sensor mounting interfaces, and complex geometries essential for robotics applications.
UL 94 V-0 flame-retardant grades and ESD-safe static-dissipative surface treatments — meeting the electrical safety and electronics-protection requirements of robotics OEMs.
Sealed precision optical enclosures meeting IP65 / IP67 ingress protection requirements — vibration-damping composite structures for machine vision and laser measurement systems.
Flexible manufacturing from prototype quantities for robotics development through high-volume production for market deployment — with consistent quality across order sizes.
Robotics Component Performance Requirements
Polycarbonate, thermoformed plastic, and composite components for robotics must meet strict demands across six performance areas:
| Requirement | What It Means in Practice |
|---|---|
| Optical Clarity | <1% haze and >90% light transmission optical-grade polycarbonate with anti-scratch hardcoat for LiDAR domes, camera windows, and machine vision optics |
| Impact Resistance | Up to 250 times more impact-resistant than glass — protecting sensors and electronics through robot lifetime operation and accidental contact |
| Weight Reduction | 40-60% lighter than metal alternatives — extending AMR / AGV battery life, increasing payload capacity, and improving overall robot agility |
| Material Compliance | Optical-grade, flame-retardant (UL 94 V-0), ESD-safe, UV-stable, and impact-modified composite grades — each matched to the application |
| Sealed Assemblies | IP65 / IP67 sealed enclosures with precision-machined mounting surfaces for electronics, sensor, and inspection-system protection |
| Dimensional Tolerance | 5-axis CNC machining to ±0.015" tolerances ensuring repeatable fit across high-volume robotics manufacturing |
Why Robotics OEMs & Integrators Trust Five Star Fabricating
We support robotics OEMs, system integrators, and automation equipment manufacturers from DFM consultation through scalable production — engineered for the optical clarity, sensor protection, safety compliance, and weight reduction modern robotics demands.
Our 47+ year track record includes supplying safety-critical components to NASCAR, where failure is not an option. This same commitment to quality and reliability extends to every robotics application we serve.
Complete in-house capabilities from design through finished assembly — thermoforming, CNC machining, coating, and integration — eliminating coordination challenges and ensuring consistent quality control throughout the manufacturing process.
Whether you need prototype quantities for development or production volumes for market deployment, our flexible manufacturing approach adapts to your requirements without compromising quality.
Diverse application experience across automotive OEM glazing, mass transit passenger protection, material handling guards, aerospace lightweight components, and industrial equipment safety systems — transferable engineering know-how robotics OEMs benefit from on every project.
All products are manufactured in our 350,000 square foot Twin Lakes, Wisconsin facility — ISO 9001:2015 certified, UL Listed, ITAR-registered, and supporting American manufacturing initiatives with full commitment to quality.
Sensor Protection, Cobot Guards, Robot Bodies & Vision Enclosures
Four robotics application categories engineered for the optical clarity, safety compliance, weight reduction, and precision protection modern robotics demands.
- Sensor Protection Systems — LiDAR domes and camera enclosures with optical-grade polycarbonate, anti-scratch hardcoats, >90% light transmission, and custom geometries for various sensor mounting configurations.
- Collaborative Robot Systems — Safety-compliant covers and guards supporting ISO 10218 compliance, with smooth rounded geometries eliminating pinch points, impact-absorbing materials, and UL 94 V-0 flame-retardant grades.
- Robot Body Components — Lightweight thermoformed polycarbonate and composite body panels reducing robot weight by 40-60% — including AMR / AGV chassis covers, battery compartment enclosures, electronic housing covers, and custom-molded bumper assemblies.
- Machine Vision & Inspection Systems — Custom thermoformed housings with integrated polycarbonate windows, precision-machined mounting surfaces, ESD-safe material options, and IP65 / IP67 sealed assemblies for cameras, laser measurement systems, and quality inspection equipment.
Polycarbonate, Thermoformed & Composite Systems for Modern Robotics
Our high-performance polycarbonate windows, thermoformed enclosures, and advanced composites are engineered for the full range of robotics applications — from LiDAR domes and machine vision optics through AMR / AGV body panels, cobot safety guards, and industrial automation enclosures.
Typical programs include robotics OEM production runs and system integrator partnerships — with optical-grade polycarbonate sensor protection, ISO 10218 cobot compliance support, UL 94 V-0 flame-retardant materials, 40-60% weight-reduction body components, IP65 / IP67 sealed assemblies, and scalable manufacturing from prototype through production volumes.
-
LiDAR Domes
Optically clear polycarbonate domes with >90% light transmission and <1% haze protecting critical LiDAR sensors throughout the robot's operational life.
-
Camera Enclosures
Custom thermoformed enclosures with integrated polycarbonate windows for robot vision cameras — anti-scratch hardcoat and anti-fog coating options.
-
Collaborative Robot Guards
Safety-compliant covers supporting ISO 10218 compliance — smooth rounded geometries eliminating pinch points and UL 94 V-0 flame-retardant materials.
-
AMR / AGV Chassis Covers
Thermoformed polycarbonate body panels reducing robot weight 40-60% vs metal — extending battery life and improving overall AMR / AGV agility.
-
Battery Compartment Enclosures
Lightweight thermoformed enclosures protecting AMR / AGV battery systems — impact-resistant with ESD-safe surface treatment options.
-
Electronic Housing Covers
ESD-safe polycarbonate housings for robotics control electronics — UL 94 V-0 flame retardancy and IP-rated sealed assemblies.
-
Custom Bumper Assemblies
Impact-modified composite bumpers absorbing accidental contact between mobile robots and warehouse, manufacturing, or service environment infrastructure.
-
Machine Vision Housings
Precision optical enclosures with IP65 / IP67 sealed assemblies and vibration-damping composite structures for quality inspection equipment.
-
Laser Measurement Enclosures
Precision-machined housings with temperature-stable polycarbonate materials for consistent laser measurement and metrology system performance.
Is This the Right Fit for Your Robotics Program?
Not every fabricator understands the demands of modern robotics — optical clarity for LiDAR and machine vision systems, flame-rated materials for collaborative robotics, lightweight components for AMR/AGV battery life, and the dimensional precision required across high-volume robot production. Five Star partners with robotics OEMs, system integrators, and automation equipment manufacturers on long-term production programs — with optical-grade polycarbonate, thermoformed enclosures, and advanced composite systems. Here's where we fit best — and where another partner may serve you better.
- Robotics OEMs, system integrators, and automation equipment manufacturers with ongoing production programs in manufacturing, warehouse, and service robotics
- Sensor protection — LiDAR domes, camera enclosures, and machine vision windows requiring optical-grade light transmission and low haze
- Collaborative robot guarding and covers that support your ISO 10218 safety requirements, with UL 94 V-0 flame-rated material options
- AMR / AGV chassis covers, battery compartments, electronic housings, and bumper assemblies requiring significant weight reduction vs metal
- Machine vision and inspection systems requiring IP65 / IP67 sealed assemblies and ESD-safe material options
- Programs requiring ISO 9001:2015 quality systems and UL-recognized material options
- Hobbyist robotics or standalone, one-off fabrication outside of an OEM program
- Projects where lowest unit cost outweighs optical clarity, sensor protection, and material performance
- Applications requiring metal-only enclosures where polycarbonate or composites are unsuitable
- Programs that don't require custom engineering, DFM consultation, or precision manufacturing tolerances
Not sure if your robotics program is a fit? Talk with an engineer first.
Schedule an Engineering Consultation Learn About Polycarbonate WindowsHow We Move Your Robotics Program Forward
From DFM consultation through scalable production — our robotics polycarbonate, thermoformed plastic, and composite program process is built to reduce design risk, eliminate redesign cycles, and deliver optical clarity, weight reduction, and compliance certification across the full robot service life.
- Align polycarbonate, thermoformed, and composite component performance with robotics OEM specifications early
- Reduce costly redesign risk before production tooling and material commitment
- Validate optical clarity, ISO 10218 / UL 94 V-0 compliance, weight reduction, and dimensional accuracy before scale
- Create a clear path from prototype validation to scalable production with consistent quality across order sizes
Ready to start a DFM consultation? Talk with a Five Star engineer about your robotics program requirements, sensor protection geometry, ISO 10218 / UL 94 V-0 compliance path, and production timeline.
Schedule an Engineering Consultation-
01 DFM Consultation
We evaluate your robotics program requirements, sensor geometry, operating environment, compliance targets (ISO 10218, UL 94 V-0, IP65/IP67, ITAR), and production volume timeline before any tooling commitment.
-
02 Custom Design & Material Selection
Our engineering team works directly with your robotics OEM or integrator team to optimize geometry, material grade (optical, flame-retardant, ESD-safe, UV-stable, impact-modified), coating selection, and dimensional tolerances before production tooling begins.
-
03 Prototype & Compliance Validation
Rapid prototyping and rigorous in-house testing validate optical clarity (ASTM D1003), impact resistance (ASTM), environmental aging, UV exposure durability, and dimensional inspection before production release.
-
04 Scalable Production
American manufacturing in our 350,000 sq ft Twin Lakes, Wisconsin facility delivers repeatable dimensional accuracy, consistent coating performance, and the scalable production robotics OEMs and integrators need — from prototype runs through high-volume market deployment.
What a Properly Engineered Robotics Component Program Delivers:
Robotics OEMs, system integrators, and automation equipment manufacturers who partner with Five Star Fabricating from DFM consultation through scalable production consistently achieve these program outcomes — from first article validation through certified production at scale.
Talk with a Five Star engineer about your robotics program requirements, sensor protection geometry, compliance certification path, and scalable production timeline.
What Robotics Engineering Leaders Say About Five Star
"Five Star's optical-grade polycarbonate sensor enclosures, thermoformed AMR chassis components, and ISO 10218-compliant cobot guards transformed our robotics program. Their >90% light transmission LiDAR domes, 40-60% weight reduction body panels, and IP65 / IP67 sealed assemblies have improved sensor accuracy, extended robot battery life, and supported our compliance certification path across manufacturing and warehouse automation deployments."
Robotics Polycarbonate, Thermoformed & Composite Component FAQs
Answers to the questions robotics OEMs, system integrators, and automation equipment manufacturers ask most about Five Star's optical-grade polycarbonate, thermoformed enclosures, cobot compliance, AMR weight reduction, and our robotics manufacturing capabilities.
- Optical-Grade Polycarbonate — <1% haze and >90% light transmission for LiDAR domes, camera enclosures, and machine vision windows.
- Flame-Retardant Grades — Materials meeting UL 94 V-0 requirements, supporting cobot safety and electrical compliance.
- ESD-Safe Options — Static-dissipative surface treatments for protecting sensitive electronics in robotics control housings.
- UV-Stable Formulations — Long-term outdoor durability for outdoor service robotics and warehouse-yard automation deployments.
- Impact-Modified Composites — Enhanced toughness for AMR / AGV chassis, bumper assemblies, and demanding robot body components.
- Smooth, rounded geometries eliminating pinch points
- Impact-absorbing materials reducing injury risk
- Flame-retardant grades meeting UL 94 V-0 requirements
- Transparent panels enabling operation monitoring
- Easy-clean surfaces for hygienic manufacturing and service robotics applications
- Large-Format Thermoforming — Up to 10' × 12' for AMR/AGV chassis covers, robot body panels, and large enclosures.
- 5-Axis CNC Machining — Precision tolerances of ±0.015" for sensor mounting surfaces and complex geometries.
- In-House Coating & Finishing — Anti-scratch hardcoats, anti-fog, anti-reflective, and ESD-safe surface treatments.
- Assembly & Integration Services — Vertical integration eliminating coordination challenges across the manufacturing chain.
- Prototype Through Production Volumes — Flexible manufacturing adapting from development quantities through high-volume market deployment.
Improve Sensor Accuracy, Battery Life & Compliance with Five Star Robotics Components
Whether you're a robotics OEM, system integrator, or automation equipment manufacturer — Five Star Fabricating delivers American-made optical-grade polycarbonate windows, thermoformed enclosures, and advanced composite systems engineered for LiDAR clarity, ISO 10218 cobot compliance, AMR weight reduction, and IP-rated sensor protection.
Built for robotics programs where optical clarity for sensor accuracy, ISO 10218 and UL 94 V-0 compliance, 40-60% weight reduction vs metal, IP65 / IP67 sealed assemblies, and scalable American manufacturing matter — from DFM consultation through scalable production.
Or call us at +1 (262) 877-2171 to discuss your project needs
Supporting robotics OEMs, system integrators, and automation equipment manufacturers across manufacturing automation, warehouse automation, and service robotics nationwide.