In rail, defense, and public safety applications, cable assemblies must operate flawlessly under demanding conditions. A single point of failure, whether due to a weak crimp, poor shielding, or a mislabeled connector, can compromise system performance, mission outcomes, or even safety.

At STI-CO®, quality assurance is not an afterthought. It is embedded in every step of our cable assembly process. In this article, we outline the testing procedures, certifications, and documentation standards that define high-reliability cable assemblies, as well as what procurement teams should expect from their suppliers.

Why Testing and Inspection Are Critical

Cable assemblies are foundational to system performance across RF, power, and data applications. While their role is often silent, failure in the field can lead to costly downtime or compromised safety, especially in harsh environments.

Common failure risks include:

• Incomplete crimps or cold solder joints
  
  
• Faulty pinout configurations or reversed polarity
  
  
• Inconsistent shielding or grounding
  
  
• Environmental damage during installation or field use
  
  

Comprehensive testing and inspection mitigate these risks, ensuring every unit performs as intended before it reaches your site or fleet.

Common Types of Cable Assembly Testing

STI-CO® uses a wide range of testing protocols designed to catch electrical, mechanical, and workmanship defects before deployment.

Continuity Testing

Verifies correct electrical connection between endpoints. Detects shorts, opens, and miswires.

Hi-Pot (High Potential) Testing

Applies elevated voltage to validate insulation integrity and dielectric strength. Crucial for high-voltage or RF applications.

Pull Testing

Applies measured force to confirm the mechanical strength of crimped or soldered terminations. Critical for mobile, vibration-prone platforms.

Visual Inspection

Ensures workmanship conformance to IPC/WHMA-A-620 standards, checking strip lengths, crimps, terminations, insulation, and shielding placement.

Custom Test Fixtures

Used for complex builds or multi-circuit harnesses to validate pinouts, shielding continuity, and end-to-end system compatibility.

STI-CO® Quality Assurance Standards

Certified quality protocols and decades of industry experience across critical sectors guide our process.

Certified Workmanship

• In conformance with IPC/WHMA-A-620, the recognized global standard for cable and wire harness assembly workmanship.
  
  
• All cable assemblies are built and inspected in accordance with IPC/WHMA-A-620 guidelines, the industry standard for cable and wire harness workmanship.
  
  

Full Lot Traceability

• Each cable assembly is serialized and logged, with detailed lot-level documentation.
  
  
• Enables easy identification, maintenance, and field replacement.
  
  

AS9100D & ISO 9001Certified

• Our quality management system meets aerospace and defense-grade requirements.
  
  
• Audited annually for full compliance and continuous improvement.
  
  

ITAR Registered

• STI-CO® is registered under the International Traffic in Arms Regulations for compliant manufacturing of defense-related assemblies.
  
  

Optional Custom Test Plans

• For complex builds, STI-CO® can implement project-specific test requirements, including printed reports, visual logs, and tailored QA protocols.
  
  

What to Ask Your Cable Supplier

Procurement and engineering teams should ask the following when evaluating a cable assembly partner:

• Do you test 100% of assemblies or just a sample?
  
  
• Does your supplier build cable assemblies in conformance with IPC/WHMA-A-620 workmanship requirements?
  
  
• Can you provide serialized documentation and inspection logs?
  
  
• Are your quality systems AS9100D and ISO 9001 certified?
  
  
• Do you support lot traceability for fleet-wide maintenance?
  
  

If the answer is “no” to any of these, you may be exposing your systems to unacceptable risk.

Why It Matters in the Field

Traceable, fully tested cable assemblies allow for:

• Faster and more accurate field replacement
  
  
• Reduced operational downtime
  
  
• Audit and program compliance
  
  
• System-wide confidence in performance and reliability
  
  

Whether managing a fleet of tactical vehicles or maintaining mission-critical rail communications, tested cable assemblies streamline support and enhance system longevity.

Choose STI-CO® for Mission-Critical Cable Assurance

For more than 50 years, STI-CO® has delivered rugged, reliable cable solutions backed by engineering, testing, and documentation at every level.

We serve:

• Defense & aerospace platforms
  
  
• Rail and transportation systems
  
  
• Public safety and covert vehicle integrations
  
  

Explore our cable assembly capabilities at:
https://sti-co.com/cable-assemblies

For RFQs, consultation, or capability documentation, contact our team:
sales@sti-co.com