Revolutionize Your Automotive Manufacturing with Five Star Fabricating

Your Partner in Automotive Innovation

For over 47 years, Five Star Fabricating has been a trusted partner for automotive OEMs, delivering high-performance components that enhance vehicle efficiency, safety, and design. Based in Twin Lakes, Wisconsin, our 300,000-square-foot, ISO 9001:2015-certified facility produces lightweight polycarbonate windows, carbon fiber composite panels, and custom solutions tailored to meet the unique needs of passenger vehicles, commercial fleets, and specialty vehicles like motorcycles and RVs. 

Our motorsports heritage, including being named NASCAR Cup Series Supplier of the Year for 2024 and 2025, ensures that our components are proven in the most demanding conditions. From hybrid cars to heavy-duty trucks, our solutions, like those used in our collaboration with Stellantis, reduce weight, improve fuel economy, and meet stringent safety standards such as FMVSS 226, empowering OEMs to build the vehicles of tomorrow.

Why Choose Five Star Fabricating?

Our polycarbonate windows outperform traditional materials, offering unmatched strength and clarity while reducing equipment weight. They’re engineered for forestry’s most punishing conditions—providing long-term value with minimal maintenance.

At Five Star Fabricating, we are committed to delivering high-performance, lightweight automotive components that help our partners in the automotive industry excel in performance, safety, and design. 

• Made in USA Excellence: Proudly manufactured in our ISO 9001:2015-certified facility in Twin Lakes, Wisconsin, ensuring compliance with rigorous automotive industry standards.
• Motorsports Leadership: 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 high-performance environments.
• Advanced Materials Expertise: Specializing in polycarbonate, carbon fiber composites, and advanced plastics with Fusionite™ scratch-resistant coatings, we provide lightweight, durable solutions that reduce emissions and improve fuel economy.
• Tailored Solutions for OEMs: Our custom fabrication capabilities allow us to meet unique vehicle design requirements, ensuring seamless integration and optimal performance.
• Safety and Compliance: All components meet or exceed automotive safety standards, including FMVSS 226, ensuring reliability and safety for end-users.

Benefits of Our Automotive Solutions

Our automotive components are engineered to meet the demands of modern vehicle manufacturing, offering a wide range of benefits that set us apart from the competition:

• Significant Weight Savings: Up to 70% lighter than traditional materials, our components reduce overall vehicle weight by up to 30%, improving fuel efficiency and extending electric vehicle range.
• Enhanced Safety: Polycarbonate windows and lenses, 10x more impact-resistant than glass, meet FMVSS 226, ensuring safety during accidents and harsh conditions.
• Exceptional Durability: Designed to resist scratches, impacts, and UV exposure, our components maintain clarity and performance over time, thanks to our Fusionite™ coatings.
• Flexible Design Capabilities: Our custom fabrication allows for innovative designs, from complex geometries to high-volume production, tailored to meet OEM specifications.
• Cost Efficiency: Lightweight materials and durable designs reduce fuel costs and maintenance expenses, providing long-term value for OEMs.

Customization for Automotive Applications

At Five Star Fabricating, we offer a comprehensive range of components tailored for automotive OEMs, enhancing performance, safety, and aesthetics across various vehicle types.

• Polycarbonate Windows and Sunroofs: Lightweight, impact-resistant windows with 90% light transmission, perfect for front windshields, side windows, and sunroofs in passenger and commercial vehicles.
• Lighting Lenses: High-clarity lenses for headlights, taillights, directional lights, and instrument panels, ensuring optimal visibility and safety compliance.
• Motorcycle Wind Deflectors and Fairings: Custom-designed for motorsports, improving aerodynamics and rider comfort in high-performance applications.
• Composite Body Panels: Lightweight panels for performance vehicles, offering strength, flexibility, and design versatility for OEMs.

Applications:

• Passenger Vehicles: Lightweight components for hybrids, sedans, and SUVs to boost efficiency and extend electric vehicle range.
• Commercial Vehicles: Durable parts for trucks, buses, and fleets, ensuring reliability under heavy use.
• Specialty Vehicles: High-performance components for motorcycles and RVs, enhancing both aesthetics and functionality.