Avstar Fuel Systems
AVStar Fuel Systems designs, manufactures, and overhauls carburetors and fuel injection systems for general aviation air-cooled piston engines, supplying Lycoming Engines as an OEM and serving owner pilots, engine shops, and FBOs globally via direct e-commerce and a service center network.
- Company typePrivate
- Founded1999
- HeadquartersJupiter, United States
- Headcount101–250
- GTM typeB2B
- OfferingHardware or Manufacturing
What Avstar Fuel Systems does
AVStar Fuel Systems, Inc. is a privately held designer, manufacturer, and FAA-certified overhaul provider of carburetors and fuel injection systems for general aviation air-cooled piston engines. Founded in 1999 and headquartered in Jupiter, Florida, with manufacturing operations in Auburn, New York, the company serves owner pilots, engine shops, fixed-base operators (FBOs), distributors, and engine manufacturers. The product portfolio spans PMA carburetors (LVC-3-3PA, LVC-5-4PA), fuel injection servos (RSA-5AD1, RSA-10AD1, RSA-10ED1), AVStar-branded fuel injectors, nozzles, flow dividers, and an extensive parts catalog covering gaskets, diaphragms, springs, valves, shafts, and overhaul kits. AVStar is a recognized OEM fuel system supplier to Lycoming Engines for new, remanufactured, and overhauled factory engines.
The company's technical differentiator is CNC-machining components from solid 6061-T6 aluminum billet rather than castings, with claimed 30% higher yield strength, 15% weight reduction, and improved corrosion resistance via anodization. In-house verification is performed on AVStar's proprietary Lambda Flow Bench testing system, which replicates controlled airflow and fuel flow conditions to validate fuel metering accuracy, flow rates, and atomization prior to shipment. The company operates under FAA Parts Manufacturer Approval (PMA No. PQ4021CE), FAA Repair Station certification (V1RR580Y), EASA Part 145 approval (EASA.145.6579), and AS9100 quality system standards, representing the regulatory foundation of its competitive position.
AVStar earns revenue primarily through hardware sales, with three transaction structures: outright units (new or overhauled, no core return), exchange units (reduced price in exchange for a returnable core), and individual parts and repair kits. Pricing ranges from less than $1 for consumable parts to $8,610 for top-end outright fuel injectors; flagship carburetor exchange units list around $1,238–$1,694 and outright units around $2,094. Distribution combines a direct e-commerce storefront (avstardirect.com), phone-based inside sales, OEM supply to Lycoming, and a global network of authorized sales and service centers. To date AVStar claims 600+ PMAs and 50,000+ fuel controls delivered over 25 years.
Avstar Fuel Systems firmographics
Firmographics- Name
- Avstar Fuel Systems
- Legal name
- AVStar Fuel Systems, Inc.
- Website
- https://avstardirect.com
- Company type
- Private
- Founded year
- 1999
- Operating status
- Operating
- Headcount range
- 101–250 employees
- Short description
- AVStar Fuel Systems designs, manufactures, and overhauls carburetors and fuel injection systems for general aviation air-cooled piston engines, supplying Lycoming Engines as an OEM and serving owner pilots, engine shops, and FBOs globally via direct e-commerce and a service center network.
- Ownership category
- akta.pro rank
Avstar Fuel Systems industry classification
Industry- Product category
- Aircraft Fuel System Components
- NAICS
- Aircraft Engine and Engine Parts Manufacturing (336412)
- SIC
- Aircraft Engines & Engine Parts (3724), Aircraft & Parts (3720)
- akta.pro primary industry
- Aerospace Fuel System Components (Tanks, Lines, Valves) (IMABANAJ)
- akta.pro secondary industries
- Engine Modules & Hot-Section Components (Compressors/Turbines/Combustors) (IMABADAJ), Engine Control, Fuel & Ignition Systems (FADEC/Accessories) (IMABADAK)
Keywords
Where Avstar Fuel Systems is headquartered
LocationHeadquarters
- HQ city
- Jupiter
- HQ country
- United States
- HQ region
- North America
Offices2 records
Markets served
Avstar Fuel Systems business model
Business model- GTM type
- B2B
- Offering type
- Hardware or Manufacturing
- Cost components
- Supply Chain, Operations, Personnel, Technology or R&D, Marketing or Sales, Infrastructure
Revenue model
- Fuel System Component Sales: Sale of new and overhauled carburetors, fuel injection servos, flow dividers, nozzles, and related components for general aviation piston engines. Products sold as outright purchases (new or overhauled units) or exchange units (core return required at reduced price).
- FAA Repair Station Services: Overhaul, inspection, and return-to-service of fuel system components under FAA-certified Repair Station (Certificate No. V1RR580Y) and EASA Part 145 approval.
- Parts and Kits Sales: Extensive catalog of individual parts including gaskets, diaphragms, springs, valves, shafts, screws, seals, and repair kits for maintaining and overhauling fuel systems.
Pricing tiers
| Model | Billing | Price |
|---|---|---|
| Transaction based/ take rate | Pay-as-you-go | Exchange Units - Core return required at reduced price |
| One time/ perpetual license | Pay-as-you-go | Outright Units - New or overhauled, no core return required |
| Unit Pricing | Pay-as-you-go | Individual Parts and Components |
Go-to-market motion2 records
Distribution channels4 records
Marketing channels5 records
Avstar Fuel Systems product offering
Product offeringCore offering
AVStar Fuel Systems designs, manufactures, and overhauls fuel system components for general aviation air-cooled piston engines. The portfolio includes carburetors, fuel injection servos, fuel injection nozzles, fuel manifold flow dividers, and comprehensive parts/repair kits. Products are sold under FAA Parts Manufacturer Approval (PMA), with exchange, new outright, and overhaul exchange service models backed by an FAA-certified Repair Station.
Product overview
AVStar Fuel Systems designs, manufactures, and overhauls fuel system components for general aviation air-cooled piston engines. The product portfolio centers on carburetors (LVC-3-3PA, LVC-5-4PA), fuel injection servos (AVStar injectors, RSA-5AD1, RSA-10AD1, RSA-10ED1), fuel injector nozzles, and flow dividers (fuel manifold valves). These products support continuous-flow fuel injection systems and carbureted applications for Lycoming and Continental engines. The company offers products as new outright purchases, exchange units (requiring core return), or overhauled units, along with comprehensive repair kits, value kits, float kits, and individual precision parts including venturi assemblies, valves, springs, gaskets, and diaphragms. AVStar's manufacturing differentiates through CNC-machined 6061-T6 billet aluminum components versus legacy castings, achieving 30% higher yield strength, improved corrosion resistance via anodization, and 15% weight reduction. All products are produced under FAA Parts Manufacturer Approval (PMA) and backed by AS9100 quality standards.
Differentiator
Problem solved
Functional benefit
Products and services
- LVC-3-3PA Carburetor AVStar-manufactured FAA PMA carburetor for general aviation air-cooled piston engines, featuring 6061-T6 aluminum billet-machined components with improved gasket materials to address body-to-bowl fuel leak issues. Available in exchange and outright configurations.
- LVC-5-4PA Carburetor AVStar-manufactured FAA PMA carburetor for larger general aviation piston engines, featuring billet-machined throttle body and bowl with 30% increase in yield strength over legacy cast materials. Available in exchange and outright configurations.
- AVStar Fuel Injector (AV2581500-F) New outright AVStar fuel injector servo featuring AL 6061-T6 billet machined throttle body with 30% yield strength increase, fully anodized for corrosion resistance, and optimized air-fuel metering validated by Lycoming Engines.
- AVStar Fuel Injector (AV2576536-2-E) New exchange AVStar fuel injection servo with Precision Airmotive compatibility, featuring 90 oz weight and core return program for cost savings.
- RSA-5AD1 Fuel Injection Servo Precision Airmotive RSA-5AD1 fuel injection servo available as overhaul exchange, built to latest Lycoming flow curves with AVStar's fuel control technology expertise.
- RSA-10AD1 Fuel Injection Servo Overhaul exchange RSA-10AD1 fuel injection servo for larger piston engine applications, weighing 128 oz.
- RSA-10ED1 Fuel Injection Servo Overhaul exchange RSA-10ED1 fuel injection servo for precision fuel metering in piston engines.
- Fuel Injection Nozzle (AV2524864-2) Fuel injection nozzle for delivering atomized fuel into intake ports in continuous-flow fuel injection systems for Lycoming and Continental piston engines.
- Fuel Manifold Flow Divider (2524232-2-E) Overhaul exchange precision fuel manifold flow divider that distributes fuel evenly to each cylinder in continuous-flow fuel injection systems, weighing 17 oz.
- MA-4SPA Carburetor Overhaul Marvel-Schebler MA-4SPA carburetor overhaul exchange service rebuilt to factory specifications.
- MA-3SPA Carburetor Overhaul Marvel-Schebler MA-3SPA carburetor overhaul exchange service for smaller piston engine applications.
- Carburetor Major Repair Kits (AV286 Series) Comprehensive overhaul kits containing gaskets, springs, valves, shafts, and precision components for carburetor repair and rebuild.
- Fuel Injection Value Kits (AVK Series) Comprehensive service kits including diaphragms, packings, strainers, bellows, and precision parts for fuel injection servo overhaul, FAA/PMA approved.
- Carburetor Float Kits Brass float replacement kits for carburetors including gaskets, clips, shafts and hardware for various Marvel-Schebler carburetor models.
- Venturi Assemblies Precision-machined venturi assemblies and finished venturi components for fuel metering in carburetors, CNC-machined from billet aluminum.
- Lambda Flow Bench Testing AVStar's proprietary in-house testing and verification system that replicates controlled airflow and fuel flow conditions to verify fuel metering accuracy, measure flow rates, and observe fuel atomization characteristics prior to shipment.
Quantifiable outcome
- 30% increase in yield strength over legacy cast material through 6061-T6 aluminum billet machining
- +3 more outcomes
Companies that use Avstar Fuel Systems
Customer profileNamed customers1 record
Segments5 records
Ideal customer profiles3 records
Avstar Fuel Systems technology and API
TechnologyTechnology focussed No
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Feature4 records
Avstar Fuel Systems partnerships and signals
Strategic signalPartnerships
One partnership is on record.
- Lycoming EnginescoreAVStar is a recognized fuel system supplier to Lycoming Engines for both new, remanufactured, and overhauled factory engines. Products are designed and validated to meet Lycoming's latest flow curves using advanced fluid dynamic analysis. This partnership positions AVStar as a trusted OEM supplier in the piston engine ecosystem.
Scale indicators4 records
Recent moves6 records
Expansion highlights5 records
Avstar Fuel Systems competitors and assessment
Company assessmentOthers
- Lycoming Engines: AVStar's named OEM customer and the dominant general aviation piston engine OEM. While not a direct fuel-system competitor, Lycoming sets the flow-curve specifications and validation standards that AVStar must meet, making it the most consequential entity in AVStar's ecosystem.
Broad incumbents
- Continental Aerospace Technologies: Major general aviation piston engine OEM alongside Lycoming. AVStar supports Continental engines via nozzles and flow dividers, making Continental both a strategic ecosystem participant and a potential OEM customer/competitor.
- Honeywell Aerospace: Diversified aerospace supplier with fuel system, engine control, and propulsion components across commercial and business aviation. Comparable product category but at significantly greater scale and platform breadth.
- Parker Hannifin (Aerospace division): Large aerospace systems integrator with fuel system components and related fluid handling products across commercial, military, and business aviation. A broad incumbent in the same fuel-system category at a much larger scale.
Direct peers
- Marvel-Schebler (Turbine Controls / Precision Aviation Group): Manufacturer of the legacy MA-3SPA and MA-4SPA carburetors that AVStar overhauls and PMA-equivalents. Directly comparable on carburetor product line, overhaul services, and FAA-PMA distribution channels.
- Precision Airmotive: Original designer and manufacturer of RSA-series fuel injection servos for general aviation piston engines — AVStar's RSA-5AD1/10AD1/10ED1 products are PMA-equivalents to Precision Airmotive designs, making it a direct product-level competitor and IP counterpart.
Emerging players
- SureFly Partners: STC'd electronic ignition system for general aviation piston engines. Tangentially comparable as an emerging powerplant technology player addressing the same installed base of legacy Continental/Lycoming engines that AVStar services.
- Air Repair & Overhaul: FAA Part 145 repair station focused on general aviation engine accessories and fuel system overhauls. Comparable as a competing MRO/overhaul provider for the same fuel system components AVStar supports.
- GAMI (General Aviation Modifications Inc.): STC developer of fuel system and engine performance modifications (including injectors and fuel metering) for legacy GA piston engines. Comparable as a niche aftermarket technology provider competing for fuel-system upgrade spend in the same customer base.
Regional players
- Eclipse Aerospace (Eclipse 550 avionics and safety): Very light jet OEM with fuel system integration needs and an active general aviation customer base. Indirectly comparable as a fuel-system-consuming OEM in the GA/light jet ecosystem adjacent to AVStar's piston engine focus.
Market position
Strengths4 records
Weaknesses4 records
Competitive moat4 records
Key risks5 records
Key highlights6 records
Customer concentration
Avstar Fuel Systems social profiles
Digital presenceAvstar Fuel Systems compliance and trust
Trust signalCompliance4 records
Avstar Fuel Systems financial estimates
Financial estimateRevenue estimate
Valuation estimate
Avstar Fuel Systems leadership team
Management profileNumber of profiles
Avstar Fuel Systems funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Avstar Fuel Systems M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Avstar Fuel Systems
What does Avstar Fuel Systems do?
AVStar Fuel Systems designs, manufactures, and overhauls fuel system components for general aviation air-cooled piston engines. The portfolio includes carburetors, fuel injection servos, fuel injection nozzles, fuel manifold flow dividers, and comprehensive parts/repair kits. Products are sold under FAA Parts Manufacturer Approval (PMA), with exchange, new outright, and overhaul exchange service models backed by an FAA-certified Repair Station.
Is Avstar Fuel Systems a public or private company?
Avstar Fuel Systems is a private company. It is classified as founder individual operated bootstrapped and is currently operating.
When was Avstar Fuel Systems founded?
Avstar Fuel Systems was founded in 1999. It employs 101 to 250 people.
Where is Avstar Fuel Systems based?
Avstar Fuel Systems is headquartered in Jupiter, United States, in the North America region.
How does Avstar Fuel Systems make money?
Three revenue lines are on record. Fuel System Component Sales are the primary driver. The others are FAA Repair Station Services and parts and Kits Sales.
Who are Avstar Fuel Systems's main competitors?
Lycoming Engines is listed as an others. Broad incumbents are Continental Aerospace Technologies, Honeywell Aerospace and Parker Hannifin (Aerospace division). Direct peers are Marvel-Schebler (Turbine Controls / Precision Aviation Group) and Precision Airmotive. Emerging players are SureFly Partners, Air Repair & Overhaul and GAMI (General Aviation Modifications Inc.). Eclipse Aerospace (Eclipse 550 avionics and safety) is listed as a regional player.
Does Avstar Fuel Systems have an API?
No public API is recorded for Avstar Fuel Systems.
What industry is Avstar Fuel Systems in?
Avstar Fuel Systems's product category is Aircraft Fuel System Components. Its primary akta.pro industry code is IMABANAJ, Aerospace Fuel System Components (Tanks, Lines, Valves), with a secondary code of IMABADAJ, Engine Modules & Hot-Section Components (Compressors/Turbines/Combustors). Its NAICS code is 336412 and its SIC code is 3724.