In mission-critical applications, reliable RF cable assemblies are the backbone of seamless communication and signal transmission. Whether you’re in engineering, system design, or procurement, selecting the right RF solution directly impacts performance, compliance, and long-term durability.

For over 50 years, STI-CO® has engineered and manufactured high-performance RF cable assemblies for defense, aerospace, public safety, transportation, and commercial IoT. Our build-to-print and custom-engineered assemblies are designed to perform in the harshest conditions, ensuring durability, flexibility, and uncompromised signal integrity.

This guide covers the fundamentals of RF cable assemblies, including key considerations, common challenges, and how STI-CO®’s advanced capabilities help organizations achieve interference-free, audit-ready communication. Whether you need a standard solution or a fully customized assembly, understanding the right specifications will maximize efficiency and longevity.

Explore our RF cable assembly solutions and get expert guidance on your project here.

Let’s dive in.

1. What Are RF Cable Assemblies?

Definition and Function

RF cable assemblies are pre-configured solutions designed to support radio frequency (RF) signal transmission in demanding applications. These assemblies typically include coaxial cables, connectors, adapters, shielding, and over-molding to ensure compatibility and minimize signal loss.

They are indispensable in industries where secure, uninterrupted communication is critical — from military vehicles to public safety networks to transportation systems. By delivering a complete, pre-tested solution, RF cable assemblies eliminate sourcing complexity while guaranteeing system-wide reliability.

STI-CO® specializes in build-to-print and custom-engineered RF cable assemblies, built to withstand vibration, weather, and electromagnetic interference (EMI). Every assembly is produced under an AS9100D & ISO 9001 Certified QMS, in conformance with IPC/WHMA-A-620, and ITAR registration.

Key Components of an RF Cable Kit

• Coaxial Cables – Flexible or hard-line, engineered for minimal signal loss.
  
  
• Connectors – SMA, N-Type, TNC, BNC, F-Type, UHF, 7/16 DIN, MMCX, Mini UHF, and custom solutions.
  
  
• Adapters – Enable cross-compatibility between connector types.
  
  
• Shielding & Over-Molding – Multi-layer shielding plus rugged over-molds provide EMI/RFI protection, strain relief, and environmental durability.
  
  
• Power & Data Transmission – Integrated options for hybrid cable or wire harness assemblies, complete with lot-level serialization and custom labeling for traceability.
  
  

With project-based kitting services, STI-CO® delivers exactly what your system requires, streamlining installation, reducing risk, and saving time.

Industries That Rely on RF Cable Assemblies

RF cable assemblies power secure communication in industries where failure is not an option:

• Defense & Military - ITAR-compliant assemblies for tactical operations, vehicles, and aircraft.
  
  
• Public Safety – Reliable radio communication for first responders and law enforcement.
  
  
• Transportation - RF connectivity for rail, aviation, and automotive, including EN45545-compliant designs for transit fire safety.
  
  
• Aerospace & IoT - High-frequency cable solutions for avionics, satellites, and connected networks.
  
  
• Commercial & Industrial - Broadcast, IoT, and wireless infrastructure.
  
  

Every STI-CO® cable undergoes rigorous testing, including pull strength, dielectric withstand (DW), insulation resistance (IR), and automated harness verification — to guarantee mission-critical reliability.

Looking for high-performance RF cable assemblies tailored to your industry? Contact us today.

2. Why RF Cable Assemblies Matter for Communication Systems

The Role of RF Cables

RF cables carry signals between antennas, radios, and transceivers. Without proper design, performance can be degraded by EMI, signal attenuation, or environmental stress. STI-CO® addresses these risks with:

• Optimized shielding against EMI/RFI
  
  
• Precision coaxial cables for minimal loss
  
  
• Ruggedized, over-molded connectors for harsh environments
  
  

The result: interference-free communication you can trust in the field.

The Cost of Poor-Quality Cables

Using substandard assemblies introduces major risks:

• Compromised safety – Dropped signals in defense or emergency operations.
  
  
• Downtime & failures – Costly replacements and service delays.
  
  
• Non-compliance – Failure to meet aerospace, defense, or public safety inspection requirements.
  
  

That’s why STI-CO® manufactures under an AS9100D & ISO 9001 Certified QMS, in conformance with IPC/WHMA-A-620, with full lot-level control and documentation retention, ensuring your cables are audit-ready.

Benefits of Pre-Configured Assemblies

Compared to sourcing components separately, STI-CO®’s assemblies offer:

• Guaranteed compatibility
  
  
• Faster installation
  
  
• Reduced signal loss
  
  
• Customizability
  
  
• Simplified procurement and secure supply chain
  
  

Ensure your system’s reliability with custom RF cable solutions. Get in touch here.

3. Types of RF Cable Assemblies and Their Applications

STI-CO® provides a full spectrum of RF solutions, standard, custom, ruggedized, and high-frequency engineered to match exact requirements.

1. Standard RF Assemblies – Pre-tested, cost-effective, and ideal for rapid deployment in commercial, IoT, and transportation networks.
   
   
2. Custom RF Assemblies – Build-to-print and custom-engineered for defense, aerospace, and public safety. Backed by CNC prototyping and rapid engineering support.
   
   
3. Ruggedized RF Assemblies – MIL-SPEC and ITAR-compliant, over-molded for durability against vibration, weather, and mechanical stress.
   
   
4. High-Frequency RF Assemblies – Low-loss, precision-engineered cables for aerospace, satellite, and 5G.
   
   

Looking for expert guidance on RF cable solutions? Contact STI-CO® here.

4. Key Factors to Consider When Choosing an RF Cable Kit

When selecting a cable kit, evaluate:

1. Frequency Range – Match VHF/UHF or high-frequency applications with the right cable type.
   
   
2. Durability & Shielding – Ensure EMI/RFI protection with multi-layer shielding and over-molds.
   
   
3. Connector Types – Choose precision-matched connectors to avoid impedance mismatches.
   
   
4. Cable Length & Flexibility – Balance attenuation with installation ease.
   
   
5. Environmental Conditions – Use ruggedized, weatherproof assemblies for extreme applications.
   
   

Beyond technical fit, STI-CO® provides the added security of a U.S.-based supply chain and audit-ready documentation.

Find the right RF cable kit for your system. Start your order here.

5. STI-CO’s Approach to RF Cable Kit Engineering

Our engineering philosophy is built on three pillars:

• Advanced Design – Custom and build-to-print assemblies tailored to exact requirements.
  
  
• High-Quality Materials – Multi-layer shielding, precision coax, and rugged over-molds.
  
  
• Rigorous Testing & Compliance – AS9100D & ISO 9001 Certified QMS, IPC/WHMA-A-620 conformance, ITAR registration, and MIL-SPEC builds.
  
  

With expanded U.S. manufacturing capacity and CNC prototyping support, STI-CO® accelerates lead times while maintaining aerospace-grade quality.

Talk to our engineering team about your RF cable requirements here.

6. Common Issues and How to Avoid Them

Typical pitfalls include:

• Signal Loss & Interference – Mitigated with low-loss coax and STI-CO®’s multi-layer shielding.
  
  
• Incorrect Connector Selection – Prevented by precise impedance matching and rugged connector designs.
  
  
• Improper Installation – Avoided through pre-assembled kits and best-practice routing.
  
  
• Environmental Wear – Addressed with ruggedized, over-molded, MIL-SPEC solutions.
  
  

By proactively addressing these challenges, STI-CO® helps ensure long-term, mission-critical reliability.

7. Future Trends in RF Cable Assemblies

As 5G, satellite, and IoT expand, demand is rising for lighter, higher-frequency, low-loss assemblies. STI-CO® is investing in:

• Next-gen shielding and dielectric materials
  
  
• Compact, flexible RF solutions for aerospace and defense
  
  
• Expanded R&D in high-frequency (5G & satellite) applications
  
  
• Doubling manufacturing investment to meet future demand
  
  

STI-CO® remains dedicated to building future-ready RF assemblies that support next-generation networks.

8. How to Get the Right RF Cable Kit for Your Needs

Standard vs. Custom Solutions

• Standard Kits – Cost-effective, ready-to-deploy.
  
  
• Custom Assemblies – Engineered for specific frequencies, shielding, and environmental demands.
  
  

How STI-CO® Helps Clients Choose

• Expert Consulting & Engineering
  
  
• Build-to-Print Manufacturing
  
  
• Rapid Prototyping
  
  
• Audit-Ready, Industry-Compliant Solutions, backed by an AS9100D & ISO 9001 Certified QMS.
  
  

From defense to transportation to IoT, STI-CO® delivers traceable, compliant, U.S.-manufactured cable assemblies that perform where it counts.

Get in touch today to find the perfect RF cable kit for your needs! Request a Quote here.