In industries where communication failure isn’t an option, the phrase "close enough" doesn’t apply. Rail systems and military programs require exact specifications, trusted partners, and proven cable assembly performance under real-world conditions.

That’s why STI-CO® specializes in built-to-print RF, power, and data cable assemblies with options for over-molded construction engineered for mission-critical deployment.

In this article, we’ll break down what "built-to-print" means, how it differs from "design-to-print," and how over-molded assemblies can enhance durability and performance in harsh operating environments.

Built-to-Print vs. Design-to-Print: What’s the Difference?

STI-CO® supports both Build-to-Print (BTP) and Design-to-Print (DTP) projects depending on the customer’s needs:

Build-to-Print (BTP)

• Definition: The customer provides a complete design package, including drawings, BOMs, specifications, and test procedures.
• Our Role: Manufacture exactly to the customer's provided specification, with no changes or design input.
• Flexibility: Limited - no modifications without customer approval.
• Value Add: Precision execution, process control, compliance with documentation and traceability.
• Typical Customers: Defense primes, Tier 1 integrators, rail operators, telecom clients with validated designs.

Design-to-Print (DTP) / Design-to-Spec

• Definition: Customer provides performance or environmental requirements but not detailed drawings.
• Our Role: STI-CO® engineering develops the design (mechanical, electrical, RF), then manufactures to spec.
• Flexibility: High - our team owns the design process and ensures spec compliance.
• Value Add: Engineering collaboration, prototyping, innovation, and end-to-end solution delivery.
• Typical Customers: Agencies, systems integrators, or OEMs who need performance but lack in-house design.

Why Built-to-Print Assemblies Matter for Rail & Military Programs

1. System Compatibility

In both rail infrastructure and military platforms, equipment is designed to specific interface and routing requirements. A cable assembly must match those specs exactly to ensure safe installation, performance, and signal reliability.

2. Compliance & Documentation

Military and rail procurement processes require full documentation. STI-CO provides serialization, lot control, inspection records, and test reports with every build to support regulatory and quality assurance processes.

3. Environmental and Operational Stress

Rail and defense systems face intense vibration, weather exposure, EMI, and mechanical stress. Built-to-print assemblies ensure the right materials, shielding, and construction methods are used for each application.

4. Repeatability at Scale

For programs that deploy hundreds or thousands of cable assemblies, consistency matters. Built-to-print production ensures that every unit matches the original drawing — every time.

The Role of Over-Molded Cable Assemblies in Harsh Environments

STI-CO® offers over-molded options for both build-to-print and design-to-spec assemblies. Over-molding enhances the durability, sealing, and long-term reliability of cable assemblies operating in extreme environments.

Key Benefits of Over-Molded Construction:

• Environmental Sealing: Protects connectors from water, dust, and contaminants.
• Strain Relief: Prevents conductor damage from vibration, tension, and movement.
• Vibration Resistance: Critical for rail and defense platforms.
• Extended Service Life: Reduces field failures and long-term maintenance.

Whether specified on the print or recommended during design consultation, over-molded assemblies are a powerful upgrade for mission-critical use cases.

STI-CO®’s Approach to Cable Assembly Manufacturing

With decades of experience supporting U.S. military programs and transit agencies, STI-CO delivers more than just assembly work — we deliver reliability at scale.

What We Provide:

• Engineering Review: We verify design documentation for manufacturability and offer DFM guidance if requested.
• RF, Power, and Data Capabilities: STI-CO manufactures high-performance assemblies across RF, power, and data applications.
• Over-Molding Expertise: In-house tooling, material selection, and rugged construction.
• Precision Fabrication: Tight-tolerance cable cutting, stripping, crimping, soldering, and shielding techniques.
• Testing & Inspection: 100% verification to drawing requirements, with inspection documentation included.
• Certifications: ISO 9001:2015, AS9100D certified, ITAR registered, and compliant with IPC/WHMA-A-620 workmanship standards.

Use Cases in Rail and Military Projects

Rail:

• Trackside RF systems
• Onboard train communication and telemetry
• Control room-to-platform connectivity
• Kitted cable assemblies for vehicle integration

Military:

• Ground vehicle comms (tactical radio, SATCOM, GPS)
• Ruggedized field communication kits
• Aircraft and shipboard cable runs
• MIL-STD-810, MIL-DTL-17, or customer-specified test standards

Ready to Partner on Your Next Program?

If your team has a spec, STI-CO can bring it to life accurately, consistently, and to the highest quality standards. We speak your language and support your mission.

Request a quote for your build-to-print cable assembly today. Call Us at 866-307-8426 or email us at sales@sti-co.com

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