Star Aviation provides an array of manufacturing services that include sheet metal fabrication, medium complexity 3-Axis machining, cable and harness fabrication, testing, heat treat, chemical conversion (Type 1 & II alodine) and painting.  Our manufacturing team has comprehensive knowledge of integration and modification experience covering business jets to commercial aircraft.

As a leading wire harness manufacturer Star has experience ranging from solder and crimp terminals and pins, to fully integrated equipment rack wiring. We use a state of the art laser wire marking system that does not damage the mechanical or electrical properties of the wire.  In addition, we perform 100% inspection on all assemblies built that cover continuity testing, insulation/resistance, hipot and functional testing.

Star has recently acquired a large Milltronics 3-Axis Mill (150" x 80" x 20") to further enhance our manufacturing capabilities with the ability to produce SATCOM Radome adapter plates from a single piece of aluminum billet. This new piece of equipment coupled with our design team will allow us to further optimize our designs and milling process with an emphasis on maximizing strength, minimizing weight, and reducing assembly and installation time. There are a limited number of suppliers with this capability and even fewer that are as accomplished as we are in serving the IFEC industry with connectivity integration and manufacturing support. 

Star Aviation’s Manufacturing Services include:

  • Metal Fabrication
  • CNC Water Jet Machining 
  • CNC Fadal 3-Axis
  • Equipment Racks & Panels
  • Structural Components
  • Mechanical Assemblies
  • Structural Repair & Modification
  • Interior Component Kits



Parts Kitting

  • IFE Equipment Installations
  • Avionics Systems
  • Fleet Standardization

DAR Services

  • First Article Conformity
  • Installation Conformity

Simple Wire Processing

  • Electro Mechanical Assembly
  • Box Builds
  • Panel Builds
  • Sub-Assemblies
  • Kitting

Parts Manufacturing Authority (PMA)

  • Wire Bundle Assembly
  • Cable Assembly
  • Electrical Subassembly
  • Equipment Rack Wiring
  • Testing and Validation
  • Laser Wire Marking

Wire Harness Manufacturing

  • Electronic Cables
  • RF/Video Coax Cables
  • Wire Harnesses
  • Overbraided Harnesses
  • Shielded Harnesses