What Is Build-to-Print Test System Manufacturing and When Is It the Right Choice?

Testing…testing…is this thing on? All joking aside, manufacturing test systems are critical to product quality and the long-term success of a program. However, many OEMs are gun-shy about designing and building those systems internally because of potential issues with capacity constraints, schedule risks, and hidden costs.

Luckily, there is a solution, in the form of build-to-print test system manufacturing. Build-to-print companies allow engineering teams to keep ownership of their designs while relying on a seasoned partner to manufacture, replicate, and deliver production-ready test systems.

Wouldn’t it be nice to have a test system delivered on time, on budget, and to your exact specifications?

What Is Build-to-Print Test System Manufacturing?

Build-to-print test system manufacturing is an execution-focused model where the customer provides a defined design package, including drawings, schematics, bills of materials (BOMs), software baselines, and specifications to a manufacturing partner which executes the build.

Unlike design-led or platform-driven integrators, a build-to-print test system manufacturer focuses on execution, replication, quality, repeatability, and product readiness.

The goal is not to reinvent the wheel so to speak. Rather, the objective is to build the tester exactly as intended.

This model is commonly used for:

• Manufacturing and production test systems
• Validation and verification testers
• Ground support equipment (GSE) for aerospace
• Low-volume, high-mix programs

How Build-to-Print Test System Manufacturing Works

A true build-to-print partnership extends well beyond basic assembly. It encompasses the full manufacturing lifecycle required to deliver production-ready test equipment:

• Interpreting customer-owned documentation
• Planning and scheduling builds
• Procuring components through an established supply base
• Assembling electrical, mechanical, and electronic subsystems
• Integrating and verifying system performance

Discipline in execution is what differentiates build-to-print manufacturing from ad-hoc contract assembly.

When Is Build-to-Print the Right Choice for You?

It’s simple: build-to-print is the best choice when engineering capability exists, but internal manufacturing capacity is constrained.

Common scenarios include:

• Engineering teams focused on new product development
• Production ramps requiring multiple identical testers
• Programs where schedule certainty outweighs design iteration
• OEMs seeking AVL-qualified, production-ready suppliers

In these cases, outsourcing execution reduces risk while preserving engineering design control.

What Does a Build-to-Print Test System Manufacturer Actually Do?

A build-to-print test system manufacturer manages the entire manufacturing execution lifecycle. At Ball Systems, that includes:

• Quoting and program planning: We help define the scope, a realistic schedule for your needs, and predictable, reliable delivery
• Procurement and supply chain management: We leverage a mature, compliant supplier network
• System assembly and integration: Ball Systems specializes in creating custom
  panels, cabinets, racks, cable assemblies, PCBA, and mechanical-electrical subassemblies
• System-level testing and verification: Ensuring your functional and production requirements are met
• Quality assurance and documentation: Repeatability, traceability, and audit readiness
• Delivery, installation, and handoff: Production-ready test systems integrated into the customer’s environment
• Follow-up: Don’t worry, Ball Systems is at the ready if anything happens once your build to print system arrives.

This end-to-end execution focus is what repeatable success looks like.

Why Test System Replication Matters in Production Environments

The truth of the matter is that most OEMs don’t need just one test system. They need multiple identical systems across programs, facilities, or production lines. Build-to-print enables this through:

• Consistent replication across builds
• Controlled revisions and configuration management
• Predictable performance across production environments

How OEMs Evaluate Build-to-Print Test System Manufacturing Partners

OEMs evaluating build-to-print partners should focus on execution maturity. In Ball Systems’ case, we bring decades of experience in the build to print space to the table.

• Proven experience with manufacturing test systems
• Capability to support low-volume, high-mix builds
• Mature project management and communication practices
• Quality systems that support AVL qualification
• Comfort executing from customer-owned designs

Strong partners demonstrate reliability, not reinvention. To that end, Ball Systems intentionally operates in an execution-first space to support customers who already know what they need built.

Ball Systems specializes in build-to-print manufacturing and replication of custom test systems across aerospace, defense, automotive, and industrial markets.

Our role is simple:

Build exactly what you’ve designed reliably, repeatedly, and ready for production.