Introduction

Star Composites is a trade name of Flight Star Devices, Inc.

Mission:

The mission of Star Composites is to be a preferred supplier of quality custom molded and proprietary composite products to industry.

History:

Star Composites is a trade name of Flight Star Devices, Inc., a Connecticut corporation founded in 1984 by Bill Jensen originally to develop and market general aviation pilot accessories.

Bill Jensen has much experience in the composites field, having been an employee of Airshield Corp. for 27 years, serving early as Quality Manager, then for 19 years as Engineering Manager.

Airshield Corp. (first known as Rudkin-Wiley Corp.) was the original developer of truck add-on aerodynamic devices including the wind deflector, roof fairing, and cab extenders. These well known and revolutionary fiberglass devices cut fuel consumption drastically and have influenced truck design markedly over the years.

Production processes used were mainly Spray-up, Hand Lay-up, and RTM. The company also produced custom parts for Aerospace and other industries using Prepregs, Vacuum bagging, Autoclaving, and Press Molding with Bulk and Sheet Molding Compound. In 1995, Bill Jensen left Airshield to run Flight Star full time.

Two current Star Composites product lines are the proprietary fiberglass roof-mounted truck signs, called AeroSign ^TM, and the custom molded fiberglass satellite antenna mounts for trucks.

Capabilities:

Current processes include Spray-up and Hand Lay-up, with RTM soon to be available. Other process capabilities are being developed, also.

Complete tooling capability includes patterns, masters, production molds, drill and trim fixtures. Low shrink materials are used where appropriate.

Fast prototyping of new products is done using temporary tooling.

For fast and accurate cost estimating and price quoting, a custom computer program is used.

A wide range of composites related services is also available including product and process, design and development.

Facilities:

Star Composites operates an office in Beacon Falls, CT, and currently contracts with an excellent nearby production fiberglass shop. This experienced shop is owned and operated by a long time close associate and is renowned for quality, on-time production.

In conclusion, Star Composites offers extensive experience in a wide range of composite products and processes, a flexible attitude, and a history of working very closely with customers to ensure satisfaction.

Please feel free to contact us anytime for more information, and thank you for your time and consideration.

Best Regards,

Star Composites