Custom Defense Parts
with Mastars
Cut risk, speed up launch, and streamline your supply chain
with rapid prototyping and on-demand production
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Certifications:
ISO 9001:2015
AS9100D
ITAR
Defense Products Manufacturing
Mastars provides end‑to‑end manufacturing for the defense and military sector, from DFM and rapid prototyping through tooling, pilot runs, and high‑volume production, covering plastics, metals, electronics, and testing. Supported by an integrated supply chain and rigorous quality and cost‑control systems, we help customers turn concepts into shippable products and sustain consistent, cross‑batch performance from validation to scaled delivery.
Our stack uses GD&T/CMM + preload for tolerance control; optimizes lead-screw/motor matching via lead compensation and end-point calibration to reduce backlash; suppresses resonance and ensures microstepping linearity for stable trajectories; and applies wear management, thermal drift compensation and SPC for durability. With mature, cost-effective solutions (e.g., roll-forming lead screws), standardized suppliers and full-process control (machining-injection-assembly-EOL), we achieve ~10% cost reduction, 10,000 units/year output, cross-batch consistency, faster time-to-market and maximized yield from NPI to volume production.
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Defense Parts Mastars Services
Manufacturing Services for Defense Products
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Additive Manufacturing
Learn MoreAdditive manufacturing with DMLS produces high‑performance, lightweight metal parts for aerospace and defense, while Mastars also delivers rugged plastic parts via FDM, SLS, and MJF; these methods support prototyping for fit, finish, and function, and in some cases enable bridge and limited‑run production, with multiple finishing options such as post‑machining, painting, and advanced coatings.
High performance and lightweight: DMLS enables complex, topology‑optimized, lightweight structures for aerospace and other high‑demand applications, delivering an excellent strength‑to‑weight ratio.
Rapid iteration and multi‑process coverage: From prototyping to low‑volume production, it supports plastics via FDM/SLS/MJF and metals via DMLS, shortening development and reducing tooling costs.
Manufacturability and surface quality integration: A full path from design optimization to finished parts, including post‑machining, painting, and advanced coatings, ensures performance and appearance.
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Injection Molding
Learn MoreAcross today’s aircraft, injection molded parts are standard, and high‑performance thermoplastics enable lightweight, robust interior components such as overhead bins and cabin lighting.
High efficiency and scalability: fast, automated cycles with multi‑cavity molds enable high‑volume production and low per‑unit cost at scale.
Precision and consistency: produces parts with tight tolerances and excellent repeatability, ensuring uniform quality across large runs.
Design flexibility and material versatility: supports complex geometries and features like threads and undercuts, with a wide choice of thermoplastics, thermosets, and elastomers
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Sheet Metal Fabrication
Learn MoreStreamline your project from quote to shipment with fast, flexible production and multiple finishing choices.
Instant quotes with interactive DFM feedback
6 sheet metal materials: aluminum, stainless steel, steel, brass, copper
Finishing from welding and hardware insertion to powder coating and silk screening
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CNC Machining
Learn MoreOur facilities do some of the most advanced, precise CNC machining work all over the world, including tough materials like aluminum, titanium and Inconel.
High precision and consistency: tight tolerances to ±0.00025 in with excellent repeatability across large runs.
Efficiency and automation: 24/7 unmanned operation, minimal setup, and fast reprogramming for rapid prototyping and scaling.
Complex shapes and material versatility: 3D contours, 5‑axis capability, and support for aluminum, steel, titanium, plastics, composites.
Materials for Defense Applications
✔️ Titanium
Lightweight yet strong, this material is available via machining and metal 3D printing services, offering excellent corrosion and temperature resistance.
✔️ Stainless Steel
Widely used in robotics, stainless steel combines strength and corrosion resistance to keep robotic components reliable through repeatable cycles and tough operating conditions.
✔️ Aluminum
High strength‑to‑weight makes this metal ideal for load‑bearing housings and brackets; available as CNC‑machined and 3D‑printed parts.
✔️ Inconel
Nickel‑chromium superalloy parts made by 3D printing offer outstanding high‑temperature resistance, making them ideal for rocket engine components and other extreme‑heat applications.
✔️ Liquid Silicone Rubber
Fuel‑ and oil‑resistant elastic fluorosilicone is tailored for demanding sealing; our optical silicone rubber offers a high‑clarity alternative to PC/PMMA.
Top Precision Defense Applications
✔️ Aircraft interiors
✔️ Spacecraft and satellite components
✔️Telecommunications components
✔️ Optical system components
✔️ Military rifle components
✔️ Military vehicle components
✔️ Military UAV and drone components
✔️ High-performance tools and fixtures
Why Choose Mastars?
✔️ We know the challenges your parts face—whether on the ground, in the air, or in space. Backed by certifications and deep technical expertise, we deliver high‑performance, cost‑effective components that hit your specs.
✔️ From early prototypes for design validation to late‑stage ones for fit, finish, and function—plus bridge and full production—we support you through the entire product lifecycle.
✔️ Our unmatched range of manufacturing tech—additive manufacturing, injection molding, sheet metal forming, precision CNC machining—covers every need.
✔️ We have a proven record delivering top‑quality parts to aerospace firms, military agencies, and other leaders in these cutting‑edge fields.
✔️ And we’re problem solvers. Got complex geometries, short‑run/high‑mix parts, or “impossible” projects? Bring them to us—we’ll get it done.
Defense Industry Post-Processing Capabilities
✔️ Anodizing
✔️ Passivization
✔️ Electroplating
✔️ Powder Coating
✔️ Insert Installation
✔️ Heat Treatment
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Manufacturing on Demand
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