High-Performance Carbon Fiber Composite Components
Custom-Engineered for Strength, Precision & Versatility — American-made from Twin Lakes, Wisconsin since 1978.
Industry-Leading Advanced Composite Manufacturing
Five Star Fabricating, Inc. is a leading provider of advanced composite body panels and structural components, delivering high-strength, lightweight components tailored for high-performance industries. Our custom carbon fiber composites are engineered for superior strength-to-weight and stiffness-to-weight ratios, making them an ideal choice for demanding applications across automotive, heavy equipment, transportation, and industrial sectors.
With an in-house tooling department and advanced CNC machining capabilities, we provide precise, high-quality composite components while ensuring rapid production cycles and strict quality control. Whether you need custom composite fabrication, carbon fiber tooling, or large-scale manufacturing, Five Star Fabricating delivers engineered components to meet your exact specifications.
Why Engineers Choose Five Star Composites
Our carbon fiber composites provide up to 70% weight reduction compared to traditional materials like steel, without compromising durability or structural integrity.
Tailored components to fit specific industry needs — from automotive body panels to composite structural parts for industrial applications.
Utilizing 3, 5, and 6-axis CNC machining, advanced bonding techniques, and high-precision mold tooling for superior quality and performance.
Strong relationships with leading material suppliers to ensure consistent quality, availability, and on-time delivery across all program volumes.
Whether you need a single prototype or full-scale OEM production, our flexible manufacturing process ensures efficiency and precision at every volume.
Motorsports-Grade Composites Built for Industry
Our composite manufacturing process was perfected in the unforgiving world of professional motorsports — where failure isn't an option and weight is everything. For over 47 years, Five Star has pushed the limits of what lightweight materials can do.
That same process discipline, material knowledge, and quality culture now drives our OEM composite programs across automotive, aerospace, heavy equipment, and industrial sectors.
Advanced Composites for Every High-Performance Sector
Our advanced composite capabilities are designed for industries requiring durability, lightweight performance, and precision manufacturing.
- Carbon fiber body panels for reduced weight & improved aerodynamics
- High-performance carbon fiber chassis components
- Custom composite components for race cars & performance vehicles
- Lightweight, impact-resistant materials for buses, rail, and commercial vehicles
- High-strength composite components for structural reinforcements
- Durability-focused applications for public transportation safety
- Structural reinforcement components for industrial machinery
- Wear-resistant composite parts for heavy-duty applications
- Custom-molded components for enhanced performance & longevity
- High-strength composite components for protective gear & industrial safety
- Impact-resistant materials for handling & processing applications
- Custom-fabricated safety equipment components
Looking for a prototype? Learn more about our engineering & design services here.
Advanced Composite Manufacturing Capabilities
Precision tooling, multi-axis machining, and proprietary bonding systems — all under one American-made roof.
Our carbon fiber tooling solutions ensure high-quality molds with dimensional stability, heat resistance, and long service life — for prototypes through full production runs.
3, 5, and 6-axis CNC machining for intricate, high-tolerance composite parts with unmatched precision and consistency across large-scale production runs.
Proprietary bonding methods integrate metal fasteners, tethers, hinges, and custom reinforcements directly into composite components for enhanced durability and function.
Carbon Fiber Composites Built at Five Star
Frequently Asked Questions
Common questions about advanced composite and carbon fiber manufacturing.
Looking for High-Quality Carbon Fiber Components?
We're happy to learn more about your requirements. Whether you need a single prototype or a full OEM production program — our team is ready to help.