In industries where communication failure isn’t an option, the phrase “close enough” doesn’t apply. Rail systems and military programs demand 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 rugged 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 reliability in harsh 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 customer requirements:

Build-to-Print (BTP)

• Definition: Customer provides complete design package — drawings, BOMs, specifications, and test procedures.
  
  
• Our Role: Manufacture exactly to the specification with no design changes.
  
  
• Flexibility: Limited; modifications require customer approval.
  
  
• Value Add: Precision execution, process control, documentation, and traceability.
  
  
• Typical Customers: Defense primes, Tier 1 integrators, rail operators, and 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) and manufactures to spec.
  
  
• Flexibility: High; STI-CO® manages the design process to ensure spec compliance.
  
  
• Value Add: Engineering collaboration, prototyping, innovation, and turnkey delivery.
  
  
• Typical Customers: Agencies, integrators, or OEMs needing high-performance assemblies without in-house design teams.
  
  

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

1. System Compatibility
   Equipment in both rail infrastructure and military platforms is designed to precise interface and routing requirements. Assemblies must match those specs exactly to ensure safe installation, performance, and signal reliability.
   
   
2. Compliance & Documentation
   Military and rail procurement processes demand traceability. STI-CO® provides serialization, lot control, inspection records, and test reports with every build to meet regulatory and quality assurance requirements.
   
   
3. Environmental and Operational Stress
   Rail and defense systems endure vibration, EMI, weather exposure, and mechanical stress. Built-to-print assemblies ensure the right shielding, materials, and construction methods are specified and delivered.
   
   
4. Repeatability at Scale
   Programs often require hundreds or thousands of assemblies. Built-to-print production guarantees every unit matches the original drawing — every time.
   
   

The Role of Over-Molded Cable Assemblies

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

Key Benefits of Over-Molded Construction:

• Environmental Sealing – Protects against 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 costs.
  
  

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 assemblies — we deliver mission assurance at scale.

What We Provide:

• Engineering Review – Verification of design documentation with optional DFM guidance.
  
  
• RF, Power, and Data Capabilities – High-performance assemblies across multiple transmission types.
  
  
• Over-Molding Expertise – In-house tooling and rugged construction materials.
  
  
• Precision Fabrication – Tight-tolerance cutting, crimping, soldering, and shielding techniques.
  
  
• Testing & Inspection – 100% verification against drawings, with documentation included.
  
  
• Certifications – AS9100D & ISO 9001:2015 Certified QMS, ITAR registered, IPC/WHMA-A-620 compliant.
  
  

Use Cases in Rail and Military Projects

Rail Applications:

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

Military Applications:

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

Ready to Partner on Your Next Program?

If your team has a spec, STI-CO® can build it — 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

Call us at 866-307-8426 or email sales@sti-co.com to submit your requirements.

Want more details? Request our Cable Capabilities Statement at sales@sti-co.com.

Build smarter. Build stronger. Build with STI-CO®.