Proven Plastics Expertise. Purpose-Built for Robotics

Five Star Fabricating delivers high-performance polycarbonate windows, thermoformed enclosures, and advanced composite solutions for robotics OEMs, system integrators, and automation equipment manufacturers.

With over 46 years of expertise in advanced manufacturing, we provide lightweight, durable, and precision-engineered components that meet the demanding requirements of modern robotic systems.

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.


robotics polycarbonate windows

Robotics Applications & Solutions

Sensor Protection Systems

LiDAR Domes & Camera Enclosures Our optically clear polycarbonate domes and windows protect critical sensors while maintaining exceptional light transmission (>90%) and optical clarity. Hard-coated surfaces resist scratches and environmental degradation, ensuring consistent sensor performance throughout the robot's operational life.

Key Benefits:

  • Optical-grade polycarbonate with minimal distortion
  • Anti-scratch hardcoat technology extending service life
  • Impact resistance exceeding glass by 250×
  • Custom geometries for various sensor mounting configurations
  • Anti-fog and anti-reflective coating options available

Collaborative Robot Solutions

Safety-Compliant Covers & Guards Our polycarbonate components support ISO 10218 compliance requirements for collaborative robotics applications, providing the necessary safety features while maintaining operational visibility and access.

Features:

  • 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 applications

Robot Body Components

Lightweight Enclosures & Panels Thermoformed polycarbonate and composite body panels reduce overall robot weight by 40-60% compared to metal alternatives while providing superior impact resistance and design flexibility.

Applications Include:

  • AMR/AGV chassis covers and side panels
  • Battery compartment enclosures
  • Electronic housing covers
  • Decorative and protective shrouds
  • Custom-molded bumper assemblies

 

Machine Vision & Inspection Systems

Precision Optical Enclosures Custom thermoformed housings with integrated polycarbonate windows provide protected environments for machine vision cameras, laser measurement systems, and quality inspection equipment.

Specifications:

  • Precision-machined mounting surfaces
  • ESD-safe material options for electronics protection
  • Sealed assemblies meeting IP65/IP67 requirements
  • Vibration-damping composite structures
  • Temperature-stable materials for consistent performance

 

Robotics Materials & Manufacturing Capabilities

Advanced Materials

  • Optical-Grade Polycarbonate: <1% haze, >90% light transmission
  • Flame-Retardant Grades: UL 94 V-0 certified materials
  • ESD-Safe Options: Static-dissipative surface treatments
  • UV-Stable Formulations: Long-term outdoor durability
  • Impact-Modified Composites: Enhanced toughness for demanding applications

Precision Manufacturing

Our 350,000 square foot facility combines advanced thermoforming capabilities with precision CNC machining, enabling complex geometries and tight tolerances essential for robotics applications.

Manufacturing Capabilities:

  • Large-format thermoforming up to 10' × 12'
  • 5-axis CNC machining to ±0.015" tolerances
  • In-house coating and finishing operations
  • Assembly and integration services
  • Prototype through production volumes

Quality & Compliance

Certifications & Standards

  • ISO 9001:2015 Quality Management System
  • UL Listed Materials for electrical safety compliance
  • Automotive OEM Approved processes and materials
  • ITAR Registration for defense and aerospace applications

Testing & Validation

All robotics components undergo comprehensive testing to ensure they meet performance requirements:

  • Impact resistance testing per ASTM standards
  • Optical quality verification (ASTM D1003)
  • Environmental aging and UV exposure testing
  • Dimensional inspection and tolerance verification
  • Material traceability and certification

Five Star Industry Expertise

Diverse Application Experience

Five Star Fabricating serves multiple industries with overlapping requirements to robotics:

  • Automotive: OEM glazing and body components
  • Mass Transit: Passenger protection systems
  • Material Handling: Equipment guards and enclosures
  • Aerospace: Lightweight structural components
  • Industrial Equipment: Safety systems and operator interfaces

Engineering Support

Our technical team works closely with robotics OEMs and integrators to optimize designs for manufacturability, cost-effectiveness, and performance. Services include:

  • Design for Manufacturing (DFM) consultation
  • Material selection guidance
  • Prototype development and testing
  • Production scaling and optimization
  • Ongoing technical support

Why Choose Five Star Fabricating

Proven Performance Heritage

Our 46+ 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.

Vertical Integration Advantage

Complete in-house capabilities from design through finished assembly eliminate coordination challenges and ensure consistent quality control throughout the manufacturing process.

Scalable Production

Whether you need prototype quantities for development or production volumes for market deployment, our flexible manufacturing approach adapts to your requirements without compromising quality.

American Manufacturing

All products are manufactured in our Twin Lakes, Wisconsin facility, ensuring quality control, supply chain reliability, and support for American manufacturing initiatives.

Get Started

Ready to discuss your robotics application requirements? Our engineering team is available to review your specifications and recommend optimal solutions.




    For specific project requirements, please provide:

    • Application description and operating environment
    • Performance requirements (optical, mechanical, environmental)
    • Quantity requirements and timeline
    • Any relevant drawings or specifications
    • Compliance or certification requirements